1994 JEEP CHEROKEE service

(47) Inspect the low range annulus gear (Fig. 38).
The gear is not a serviceable component. If
damaged, replace the gear and front case as an
assembly.
(48) Remove the oil seals from the rear retainer,
extension housing, oil pump and case halves.
(49) Mark differential case halves for reference.
(50) Remove differential case bolts and separate
top case from bottom case. Use slots in case halves to
pry them apart (Fig. 39).
(51) Remove thrust washers and planet gears from
case pins (Fig. 40).(52) Remove mainshaft and sprocket gears from
bottom case (Fig. 41). Note gear position for reference
before separating them.
CLEANING AND INSPECTION
Clean the transfer case components thoroughly
with solvent. Remove all traces of sealer from the
case and retainer seal surfaces.
Clean the oil pickup screen with solvent and dry it
with compressed air. Also use compressed air to re-
move solvent residue from all oil feed passages and
channels.
Fig. 38 Inspecting Low Range Annulus Gear
Fig. 39 Separating Differential Case Halves
Fig. 40 Removing Planet Gears And Thrust Washers
Fig. 41 Removing Mainshaft And Sprocket Gears
JNP242 TRANSFER CASE 21 - 305

WHEELS
GENERAL INFORMATION
Original equipment wheels are designed for the
specified Maximum Vehicle Capacity.
All models use steel or cast aluminum drop center
wheels. The safety rim wheel (Fig. 1) has raised sec-
tions between the rim flanges and the rim well.
Initial inflation of the tire forces the bead over
these raised sections. In case of tire failure, the
raised sections hold the tire in position on the wheel
until the vehicle can be brought to a safe stop.
Cast aluminum wheels require special balance
weights and alignment equipment.
WHEEL INSTALLATION
The wheel studs and nuts are designed for specific
applications. They must be replaced with equivalent
parts. Do not use replacement parts of lesser quality
or a substitute design. All aluminum and some steel
wheels have wheel stud nuts which feature an en-
larged nose. This enlarged nose is necessary to en-
sure proper retention of the aluminum wheels.
Before installing the wheel, be sure to remove any
build up of corrosion on the wheel mounting surfaces.
Ensure wheels are installed with good metal-to-metal
contact. Improper installation could cause loosening
of wheel nuts. This could affect the safety and han-
dling of your vehicle.
To install the wheel, first position it properly on
the mounting surface. All wheel nuts should then be
tightened just snug. Gradually tighten them in se-
quence to 129 Nzm (95 ft. lbs.) torque (Fig. 2).Never
use oil or grease on studs or nuts.
WHEEL REPLACEMENT
Wheels must be replaced if they have:
²Excessive runout²Bent or dented
²Leak air through welds
²Have damaged bolt holes
Wheel repairs employing hammering, heating, or
welding are not allowed.
Original equipment wheels are available through
your dealer. Replacement wheels from any other
source should be equivalent in:
²Load carrying capacity
²Diameter
²Width
²Offset
²Mounting configuration
Failure to use equivalent replacement wheels may
affect the safety and handling of your vehicle. Re-
placement withusedwheels is not recommended.
Their service history may have included severe treat-
ment.
Refer to the Specifications Chart for informa-
tion regarding above requirements.
WHEEL ORNAMENTATION
WARNING: HANDLE ALL WHEEL ORNAMENTATION
WITH EXTREME CARE DURING REMOVAL AND IN-
STALLATION. SHARP EDGES ON THE COVERS OR
CAPS CAN CAUSE PERSONAL INJURY.
TIRE AND WHEEL BALANCE
It is recommended that a two plane dynamic bal-
ancer be used when a wheel and tire assembly re-
quire balancing. Static should be used only when a
two plane balancer is not available.
For static imbalance, find location of heavy spot
causing imbalance. Counter balance wheel directly
opposite the heavy spot. Determine weight required
to counterbalance the area of imbalance. Place half
of this weight on theinnerrim flange and the other
Fig. 2 Lug Nut Tightening Pattern
Fig. 1 Wheel Safety Rim
22 - 6 WHEELS AND TIRESJ

BODY COMPONENTSÐXJ VEHICLES
CONTENTS
page page
DOORS............................... 34
EXTERIOR COMPONENTS................. 3
FIXED WINDOW GLASS................. 73GENERAL BODY SERVICE INFORMATION.... 1
INTERIOR COMPONENTS................ 91
UNDERBODY COMPONENTS.............. 84
GENERAL BODY SERVICE INFORMATION
RIGHT HAND DRIVE VEHICLES
The XJ Body Components procedures in this sec-
tion were developed on a left hand drive (LHD) vehi-
cle. Unless a component is unique to a right hand
drive vehicle, it will not be specifically covered in
this section, i.e. cargo barrier. In general, compo-
nents on left hand drive vehicles will be located on
the opposite side in right hand drive vehicles.
LABELS/DECALS/PLATES
Most of the labels that are affixed to the vehicles
(Figs. 1 through 5) contain safety or maintenance in-
formation. If a body component or window glass are
replaced, a replacement label should be installed. In
most cases, label location on right hand drive (RHD)
vehicles will be on the opposite side of the vehicle.
Refer to the Introduction of this manual for more
information involving labels and plates.
INSTALLATION
Follow the instructions included with each replace-
ment label.
Fig. 1 XJ Underhood & Window Glass Labels/Decals
Fig. 2 XJ Exterior Labels/Decals
Fig. 3 XJ Interior Labels/Decals
JBODY COMPONENTSÐXJ VEHICLES 23 - 1

KEY LOCK CYLINDERS
The ignition switch, glove box door, front doors and
liftgate all have key lock cylinders (Fig. 6). When
lock cylinder access or replacement is necessary, re-
fer to the applicable service information source:
²Ignition SwitchÐGroup 8D,
²Instrument Panel,
²Front Doors, and
²Liftgate.
Fig. 4 XJ VIN PlateFig. 5 XJ Jack Usage & Storage Instruction Labels
Fig. 6 Ignition Switch & Glove Box Door Key Lock
Cylinders
23 - 2 BODY COMPONENTSÐXJ VEHICLESJ

crossmember at the front of vehicle (Fig. 10). Install
and tighten screws to 9 Nzm (76 in-lbs) torque.
(3) For 2.5L engines, install the power steering
pump reservoir on the left filler panel (Fig. 9).
(4) Install the grille opening panel (GOP).
HOOD
The hood service procedures included in this sec-
tion include:
²hood removal and installation;
²hood adjustment;
²hingeÐlatchÐstriker service; and
²latch release cable service.
Refer to Figures 12Ð16 for the hood component
reference.
Fig. 11 Horns, Baffle Braces & Wire Harnesses
23 - 6 BODY COMPONENTSÐXJ VEHICLESJ

(2) Remove the nuts that attach the liner to the
wheelhouse.
(3) Remove the liner from the wheelhouse.
(4) Remove the push-nuts that attach the flare re-
tainers to the wheelhouse.
(5) Remove the flare and retainers from the wheel-
house.
INSTALLATION
(1) Position the flare and retainers at the wheel-
house.
(2) Install the push-nuts to attach the flare retain-
ers to the wheelhouse.
(3) Position the liner in the wheelhouse.
(4) Install the nuts to attach the liner to the
wheelhouse and flare retainers.
(5) Install the flare and liner lower screws. Tighten
the screws to 1 Nzm (13 in-lbs) torque.
BODY SIDE MOULDING/CLADDING
REMOVAL
(1) Loosen the vinyl body side moulding with a
heat gun.
(2) Lift edge of moulding with a putty knife and
peel moulding from body panel. Apply heat to any lo-
cation where the moulding remains adhered to a
panel.
(3) Remove the adhesive from the body panel with
3M All Purpose Cleaner, or an equivalent cleaner.
(4) If the original moulding will be installed, also
remove all adhesive from it.
INSTALLATION
(1) Install 3M 06379 double-sided tape on the
moulding.
(2) For vertical alignment, use masking tape or a
string as reference.
(3) Remove the backing from the tape, align the
moulding and position it on the body panel.(4) Press the moulding onto the body panel with a
roller or hand pressure.
WOODGRAIN MOULDING
SERVICE INFORMATION
Woodgrain mouldings are attached to the vehicle
outer panels by four types of fasteners (Fig. 58):
Fig. 56 Body Side MouldingÐ2-Door XJ Vehicles
Fig. 57 Body Side Moulding/CladdingÐ4-Door XJ
Vehicles
Fig. 55 Rear Wheel Opening FlareÐXJ Vehicles
JBODY COMPONENTSÐXJ VEHICLES 23 - 19

(2) Carefully pry the applique off the license plate
visor and tailgate (Fig. 62).
INSTALLATION
(1) Align the moulding with the visor and then
press the applique into place.
(2) Install the rivets to attach the outboard tabs on
applique to the tailgate.
WOODGRAIN OVERLAY
SERVICE INFORMATION
Exterior woodgrain overlay is a weather-resistant
vinyl. The adhesive backing is protected by a paper
liner until removed for installation.
OVERLAY REPAIR
Small nicks and scratches on an overlay can be
touched-up with paint.
To eliminate blisters and air bubbles, pierce them
with a needle or pin. Force the trapped air out of the
hole and press firmly on the overlay. Heat also can
be applied to remove small wrinkles.
Whenever an overlay must be stretched, do
not slit or cut it. Instead, apply heat and press
or squeegee the overlay into place.
INSTALLATION REQUIREMENTS
Overlay replacement requires metal repair and
paint refinish to be completed before the overlay is
installed.
The work area temperature should be between
18ÉC (65ÉF) and 32ÉC (90ÉF).A woodgrain overlay
should not be replaced if the work area temper-
ature is less than 18ÉC (65ÉF).
The following equipment and material are neces-
sary for overlay installation:
²a commercial woodgrain overlay removal solution;
²a commercial adhesive removal solution;
²liquid dish detergent (for wetting solution);
²a mixture of wetting solution;
²a commercial wax and silicone removal solution;
²isopropyl alcohol (rubbing alcohol);
²a squeegee (4 to 5 inches wide, plastic or hard rub-
ber);
²a water bucket and sponge;
²sandpaper (no. 360 or no. 400, wet or dry type);
²a heat gun (or infra-red heat bulb);
²clean wiping rags or paper towels;
²a pair of scissors;
²a needle or pin; and
²a wax pencil.
Using a wetting solution helps the installation of
an overlay. Prepare a solution by mixing two or three
teaspoons of dish detergent with 1 gallon of water.
Do not use soap.
Too much detergent will reduce the effective-
ness of the mixture.
OVERLAY REMOVAL
(1) Remove the adjacent moulding from panel.
(2) Start at one corner and apply heat with a heat
gun. Slowly peel the overlay from the panel (Fig. 63).
WARNING: USE THE WOODGRAIN OVERLAY AND
ADHESIVE REMOVAL SOLUTIONS IN A WELL-VEN-
TILATED AREA ONLY.
(3) A commercial solution can be used for overlay
removal where a heat gun is ineffective.
(4) Remove any adhesive remaining with a com-
mercial solution.
(5) Wipe the panel with a cloth saturated with a
cleaning solution.
OVERLAY INSTALLATION
The panel area that will be covered by the
woodgrain overlay must be scuff sanded and then
cleaned with a cleaning solution.
SURFACE PREPARATION
(1) Scuff-sand the painted surface with no. 360 or
400 sandpaper.Freshly painted surfaces must be
dry.
(2) Clean the painted surface with a commercial
wax and silicone removal solution. Wipe the surface
with a clean cloth and allow it to dry.
OVERLAY PREPARATION
(1) If a complete panel overlay is not to be in-
stalled, position the overlay on the panel surface to
be covered:
²mark the approximate outline on the overlay with
a wax pencil;
Fig. 63 Woodgrain Overlay Removal
23 - 22 BODY COMPONENTSÐXJ VEHICLESJ

FUEL FILLER DOOR OVERLAY APPLICATION
(1) Clean the door flange with an appropriate solu-
tion.
(2) Position the top edge of the overlay at the char-
acter line and notches at door edge.
(3) Wipe the adhesive side of fuel filler door over-
lay edges with isopropyl alcohol.
(4) Heat the door overlay edges with a heat gun to
soften and make them more pliable.
CAUTION: Avoid unnecessary pulling and stretch-
ing at the ends.
(5) Fold the overlay edges over onto the door panel
flange areas and press them into place.
LIFTGATE OVERLAY APPLICATION
(1) Position the top edge of the overlay at charac-
ter line and inner edges at the license plate recess.
(2) Wipe the adhesive side of the liftgate overlay
edges with isopropyl alcohol.
(3) Heat the liftgate overlay edges with a heat gun
to soften and make them more pliable.
CAUTION: Avoid unnecessary pulling and stretch-
ing at the ends.
(4) Fold the overlay edges over onto liftgate panel
flange and press them into place.
(6) Install the liftgate moulding.
(7) Install the license plate visor applique.
BODY STRIPES/DECALS
SERVICE INFORMATION
XJ body stripes and decals are weather resistant
tape with a adhesive backing.
REPAIR
Small nicks, scratches and other surface marks in
a body stripe/decal can be touched-up with paint.To eliminate blisters and air bubbles in a body
stripe/decal, pierce them with a needle or pin.
A heat gun can also be used to remove small wrin-
kles in a stripe/decal.
REQUIREMENTS
Body stripe/decal replacement requires that the
metal repair and paint refinish be completed first.
The work area temperature should be between
18ÉC (65ÉF) and 32ÉC (90ÉF).A tape stripe/decal
should not be replaced if the work area temper-
ature is less than 18ÉC (65ÉF).
The following equipment and material are neces-
sary for removal and installation:
²a commercial tape stripe/decal removal solution;
²a commercial adhesive removal solution;
²liquid dish detergent (for the wetting solution);
²a mixture of wetting solution;
²a commercial wax and silicone removal solution;
²isopropyl (rubbing) alcohol;
²a small squeegee (plastic or hard rubber);
²a water bucket and sponge;
²clean wiping rags or paper towels;
²a heat gun (or infra-red heat bulb);
²a wax pencil;
²a sharp knife, single edge razor blade or X-acto
knife;
²a pair of scissors; and
²a needle or pin.
The use of a wetting solution aids the installation
of a tape stripe/decal on a painted panel. Prepare the
wetting solution by mixing two or three teaspoons of
dish detergent with 1 gallon of water.Do not use
soap.
Too much detergent will reduce the effective-
ness of the mixture.
REMOVAL
(1) Clean the repaired surface, adjacent panels and
door the openings as necessary.
(2) Start at one end of the tape stripe/decal and
apply heat with a heat gun. Slowly peel the stripe/
decal from the panel by pulling it back.Do not pull
the tape stripe/decal outward from panel.
WARNING: USE TAPE STRIPE/DECAL REMOVAL
SOLUTION IN A WELL-VENTILATED AREA ONLY.
(3) A tape stripe/decal removal solution can be
used for removal at areas where a heat gun is inef-
fective:
²Mask-off the body panel area surrounding the tape
stripe/decal (Fig. 71);
²move solution spray across the complete length of
stripe/decal with a steady motion;
²ensure that the complete stripe/decal is covered
with solution;
Fig. 70 Liftgate Overlay Side Retainers
JBODY COMPONENTSÐXJ VEHICLES 23 - 25