1994 JEEP CHEROKEE Service Repair Manual

(2) Depending on fluid temperature, if the level is
below the FULL HOT mark or the FULL COLD
mark on the dipstick, add power steering fluid.
(3) Install the cap on the reservoir.
MANUAL STEERING GEARÐYJ VEHICLES
RECOMMENDED MAINTENANCE
The manual steering gear should be inspected for
damage at the same time as the engine oil is
changed and the oil filter is replaced. Repair as nec-essary (refer to Group 19ÐSteering for additional in-
formation and service procedures).
POWER BRAKE SYSTEM
RECOMMENDED MAINTENANCE
The condition of the brake system should be in-
spected and the fluid level in the master cylinder
should be checked each time the brake system is ser-
viced. Add brake fluid and repair as necessary.
In addition, the brake system should be operation-
ally tested periodically to ensure that it is function-
ing normally.
FLUID SPECIFICATION
Jeeptpower brake systems require MOPAR
Heavy-Duty Brake Fluid, or an equivalent product
identified as conforming to FMVSS No. 116, DOT-3
and SAE J-1703 specifications.
Usenew brake fluid onlywhen adding fluid to
the reservoir, to fill the brake system. Never use re-
claimed fluid.
BRAKE FLUID LEVEL
STANDARD POWER BRAKE SYSTEM
(1) Clean the cover and the sides of the brake fluid
reservoir.
(2) Detach the bail retainer from the reservoir
cover and remove the cover from the reservoir.
(3) The brake fluid level should be 6 mm (1/4 in)
below the rim of each reservoir well for XJ and YJ
Vehicles (Fig. 7). If not, add brake fluid as necessary.
(4) Inspect the reservoir cover bail retainer for ten-
sion and the cover for proper fit. The cover should fit
tight and have a good seal.
Fig. 4 Power Steering SystemÐXJ Vehicles
Fig. 5 Power Steering SystemÐYJ Vehicles
Fig. 6 Power Steering Fluid Reservoir
DipstickÐTypical
0 - 32 LUBRICATION AND MAINTENANCEJ

(5) Inspect the reservoir rubber diaphragm seal for
cracks, cuts and distortion.
(6) Inspect the brake fluid tubing fittings and the
master cylinder housing for indications of fluid leak-
age. Repair as necessary.
(7) Install the brake fluid reservoir cover.
ANTI-LOCK BRAKE SYSTEMÐXJ VEHICLES
The anti-lock brake system fluid reservoir for XJ
Vehicles is located in the engine compartment at the
left side of the dash panel.
(1) Turn the ignition switch ON and allow the
pump motor to operate until it automatically de-en-
ergizes.
(2) Clean the cover before removing it.
CAUTION: Over-filling could cause fluid overflow
and possible reservoir damage when the pump mo-
tor energizes.
(3) The brake fluid level should be no lower than
the MIN arrow indicator on the side of the reservoir
(Fig. 8). If not, add brake fluid as necessary. Raise
the fluid level to the MAX arrow indicator only. Do
not over-fill the reservoir.
(4) Turn the ignition switch OFF.
BRAKE SYSTEM INSPECTION
BRAKE FLUID HOSES/TUBING
(1) Inspect all brake fluid rubber hoses (Fig. 9) for
cracks, swelling, kinks, a distorted condition and
fluid leakage.
(2) Inspect the brake fluid hoses and tubing that
are routed along the frame rail.
PADS/LININGS, ADJUSTER, WHEEL CYLINDERS AND
CALIPER
The front disk brake pads can be visually inspected
via the brake caliper inspection ports.(1) Inspect the brake pads and linings for excessive
wear, cracks, charred surfaces and broken rivets.
(2) Inspect the brake pads and linings for contam-
ination with brake fluid, axle lubricant and/or an-
other fluid.
(3) Replace the brake pads and/or linings if they
are worn to within 0.78 mm (1/32 in) of the rivet
head.
(4) Operate the rear brake self-adjuster lever and
pivot. Test the operation of the self-adjuster screw for
ease of movement.
(5) Inspect the self-adjuster components for bent
areas, frayed cables, loose or overheated springs, and
a binding condition.
Fig. 7 Reservoir Fluid LevelÐTypicalFig. 8 Reservoir Fluid LevelÐAnti-Lock Brake
System
Fig. 9 Rubber Brake Fluid HoseÐTypical
JLUBRICATION AND MAINTENANCE 0 - 33

(6) Inspect the disc brake caliper dust boot for cor-
rect installation, damage/tears and indications of
brake fluid leakage. Inspect the bushings and pins
for corrosion, tears and a binding condition.
(7) Pull the rear wheel cylinder dust boot back to
expose the wheel cylinder housing and inspect for
fluid leaks. Inspect the pistons and cylinder bores for
proper appearance.
(8) Inspect the brake differential warning valve
and housing for indications of leakage, kinked hoses
and loose fittings.
PARK BRAKE
(1) As applicable, engage the park brake lever or
pedal and then release it.
(2) If the park brake is functioning normally, test
it for smooth operation and vehicle-holding capabil-
ity.
(3) Inspect the park brake cables for kinks, fraying
and a binding condition.
(4) With the park brake released, the rear wheels
should rotate without restriction. Adjust the park
brake cable tension at the equalizer (Fig. 10), if nec-
essary.
(5) Repair any park brake malfunctions.
BRAKE OPERATIONAL TEST
(1) Drive the vehicle and test for proper brake ac-
tion.
(2) Note any indication of drum/rotor overheating,
wheel dragging or the vehicle pulling to one side
when the brakes are applied.
(3) Evaluate any performance complaints received
from the owner/operator.
(4) Repair the brake system as necessary (refer to
Group 5ÐBrakes for additional information and ser-
vice procedures).
TIRES
RECOMMENDED MAINTENANCE
The general condition of the tires and the inflation
pressures should be inspected at the same time the
engine oil is changed and the oil filter is replaced.
In addition, the tires/wheels should be rotated pe-
riodically to ensure even tread wear and maximum
tread life. The tires/wheels should be rotated initially
after the first 12 000-km (7,500-miles). Thereafter,
after each 24 000-km (15,000-miles) interval of vehi-
cle operation has elapsed.
INSPECTION
Inspect the tires for excessive wear, damage, etc.
Test the tires for the recommended inflation pres-
sure. Refer to the tire inflation pressure decal located
on the inside of the glove box door, and also to Group
22ÐTires And Wheels.
ROTATION
Refer to Group 22ÐTires And Wheels for the rec-
ommended method of tire/wheel rotation for a Jeept
vehicle.
BODY COMPONENTS
RECOMMENDED MAINTENANCE
Body components should be lubricated (as required)
after each 48 000-km (30,000-miles) interval of vehi-
cle operation has elapsed.
LUBRICANT SPECIFICATIONS
All applicable exterior and interior body compo-
nents should be:
²inspected for excessive wear,
²cleaned, and
²all pivot/sliding contact areas of the components
should be lubricated with the specified lubricant.
Refer to the Body Lubricant Specifications chart
below. When excessive wear is apparent, replace/re-
pair as necessary.
LUBRICATION
All pivoting and sliding contact areas, including:
²seat tracks,
²door hinges/latches/strikers, and
²liftgate/tailgate/hood hinges (Fig. 11),
should be lubricated periodically to ensure quiet,
easy operation and to protect against wear and cor-
rosion.
(1) As required, lubricate the body components
with the specified lubricants.
(2) When lubricating door weatherstrip seals, ap-
ply the lubricant to a cloth and wipe it on the seal.
(3) Prior to the application of lubricant, the compo-
nent should be wiped clean to remove dust, grit and
debris. After lubrication, any excess lubricant should
be removed.
Fig. 10 Park Brake Equalizer (XJ)ÐTypical
0 - 34 LUBRICATION AND MAINTENANCEJ

(4) Extra close attention should be given to exter-
nal key lock cylinders during the autumn and winter
months to ensure protection from water and ice.(5) Extra close attention should also be given to
the hood latch components to ensure proper function-
ing.
HEADLAMPS
RECOMMENDED MAINTENANCE
Approximately every six months the headlamps
should be displayed on a vertical test surface. This
will ensure that the headlamps are positioned for
safe night-time driving.
BEAM AIM ADJUSTMENT
(1) Changes in the vehicle front and rear suspen-
sion will alter the headlamp beam patterns and this
can cause unsafe night-time driving conditions.
(2) If a vehicle is loaded the headlamp beam pat-
terns should be displayed on an vertical test surface
and the headlamps re-aimed.
(3) Observe the headlamp beam patterns on an ap-
propriate vertical test surface and, if necessary, ad-
just the headlamp beam aim.
(4) If necessary, refer to Group 8LÐLamps for
headlamp aim adjustment procedures.
BODY LUBRICANT SPECIFICATIONS
Fig. 11 Hood Hinge LubricationÐXJ Vehicles
JLUBRICATION AND MAINTENANCE 0 - 35

FRONT SUSPENSION AND AXLE
CONTENTS
page page
AXLE NOISE/VIBRATION DIAGNOSIS....... 16
FRONT WHEEL ALIGNMENT............... 5
GENERAL INFORMATION.................. 1
MODEL 30 AXLE AND TUBE AXLE (2WD) . . 20TORQUE SPECIFICATIONS................ 47
XJ FRONT SUSPENSION................. 10
YJ FRONT SUSPENSION................. 13
GENERAL INFORMATION
FRONT SUSPENSION
XJ VEHICLES
The Cherokee front suspension is a link/coil design
comprised of (Fig. 1);
²Drive axle (4WD), tube axle (2WD)
²Track bar
²Stabilizer bar
²Upper and lower suspension arms
²Coil springs
²Dual-action shock absorbers²Jounce bumpers (used to limit the travel of the
suspension)
The link/coil suspension allows each wheel to adapt
to different road surfaces without greatly affecting
the opposite wheel. Wheels are attached to a hub/
bearings which bolts to the knuckles. The hub/bear-
ing is not serviceable and is replaced as a unit.
Steering knuckles pivot on replaceable ball studs at-
tached to the axle tube yokes.
The upper and lower suspension arms are different
lengths, with bushings at both ends. They bolt the
Fig. 1 XJ Front Suspension
JFRONT SUSPENSION AND AXLE 2 - 1

axle assembly to the frame. The lower arms uses
shims at the frame mount to allow for adjustment of
caster and pinion angle. The suspension arm travel
(jounce or rebound) is limited through the use of rub-
ber bumpers.
Suspension components which use rubber bushings
should be tightened at vehicle ride height. This will
prevent premature failure of the bushing and main-
tain ride comfort. Bushings must never be lubricated.
The coil springs control ride quality and maintain
proper ride height. The coil springs mount up in the
fender shield which is part of the unitized body
bracket. A rubber isolator is located between the top
of the spring and the frame. The bottom of the spring
seats on a axle pad and is retained with a clip.
The shock absorbers dampen jounce and rebound of
the vehicle over various road conditions. The top of
the shock absorbers are bolted to the frame. The bot-
tom of the shocks are bolted to the axle spring
bracket.
The stabilizer bar is used to minimize vehicle front
sway during turns. The spring steel bar helps to con-
trol the vehicle body in relationship to the suspen-
sion. The bar extends across the front underside of
the chassis and connects to the frame rails. Links are
connected from the bar to the axle brackets. Stabi-
lizer bar mounts are isolated by rubber bushings.
The track bar is used to minimize front axle side-
to-side movement. The bar is attached to a frame rail
bracket with a ball stud and isolated with a bushing
at the axle bracket.
TUBE AXLE (2WD VEHICLES)
The front axle used on two-wheel drive vehicles is
a one-piece, tubular axle (Fig. 2). The tubular axle
mounts in the same bracketry as does the four-wheel
drive front axle. The steering knuckles and hub bear-
ing assemblies are the same as used on the Model 30
drive axle.
YJ VEHICLES
The Wrangler (YJ) front suspension is leaf spring
design comprised of (Fig. 3);
²Drive axle
²Track bar
²Stabilizer bar
²Leaf springs
²Dual-action shock absorbers
²Jounce bumpers (used to limit the travel of the
suspension)
The front suspension uses semi-elliptic multi-leaf
springs mounted on the drive axle. The rearward end
of the springs are mounted to the frame rail hangers
through rubber bushings. The bushings isolate road
noise as the springs move. The forward end of the
springs are attached to the frame with shackles. The
spring and shackles use rubber bushings to isolate
road noise. The shackles allow the springs to changetheir length as the vehicle moves over various road
conditions. The spring and axle travel (jounce or re-
bound) is limited through use of rubber bumpers
mounted on the frame.
Suspension components which use rubber bushings
should be tightened at vehicle ride height. This will
prevent premature failure of the bushing and main-
tain ride comfort. The bushings should never be lu-
bricated.
Fig. 2 Front AxleÐ 2WD Vehicles
Fig. 3 YJ Front Suspension
2 - 2 FRONT SUSPENSION AND AXLEJ

The shocks absorbers dampen jounce and rebound
of the vehicle over various road conditions. The top of
the shock absorbers are bolted to the frame. The bot-
tom of the shocks are bolted to the axle bracket.
The stabilizer bar is used to minimize vehicle front
sway during turns. The spring steel bar helps to con-
trol the vehicle body in relationship to the suspen-
sion. The bar extends across the front underside of
the chassis and connects to the frame rails. Links are
connected from the bar to the axle brackets. Stabi-
lizer bar mounts are isolated by rubber bushings.
The track bar is used to minimize front axle side-
to-side movement. The track bar is attached to a
frame rail bracket and the axle bracket.
The bar uses bushings at both ends.
FRONT DRIVE AXLE
It is not necessary to remove the complete axle
from the vehicle for routine differential service. If
the differential housing or axle shaft tubes are dam-
aged, the complete axle assembly can be removed
and serviced.
For complete drive axle assembly removal and in-
stallation refer to Drive Axle Assembly Replacement
in this Group.
The removable cover provides for servicing without
removing axle from vehicle.
The integral type housing, hypoid gear design has
the centerline of the pinion set above the centerline
of the ring gear.
The Model 30 axle has the assembly part number
and gear ratio listed on a tag. The tag is attached to
the housing cover (Fig. 4). Build date identification
codes are stamped on the axle shaft tube cover side.XJ and YJ axles are equipped with an optional
A.B.S. brake system. The A.B.S. tone rings are
pressed onto the axle shaft near the hub and
knuckle. For additional information on the A.B.S.
system refer to Group 5, Brakes.
²XJ vehicles use a non-disconnect axle.
²YJ vehicles use a vacuum disconnect axle (Fig. 5).
STANDARD DIFFERENTIAL OPERATION
The differential gear system divides the torque be-
tween the axle shafts. It allows the axle shafts to ro-
tate at different speeds when turning corners.
Each differential side gear is splined to an axle
shaft. The pinion gears are mounted on a pinion
mate shaft and are free to rotate on the shaft. The
pinion gear is fitted in a bore in the differential case
and is positioned at a right angle to the axle shafts.
In operation, power flow occurs as follows:
²Pinion gear rotates the ring gear
²Ring gear (bolted to the differential case) rotates
the case
²Differential pinion gears (mounted on the pinion
mate shaft in the case) rotate the side gears
²Side gears (splined to the axle shafts) rotate the
shafts
During straight-ahead driving, the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to gears is di-
vided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 6).
When turning corners, the outside wheel must travel
a greater distance than the inside wheel. This difference
must be compensated for in order to prevent the wheels
from scuffing and skidding through the turn. To accom-
plish this, the differential allows the axle shafts to turn
at unequal speeds (Fig. 7). In this instance, the input
torque applied to the pinion gears is not divided
equally. The pinion gears now rotate around the pinion
mate shaft in opposite directions. This allows the side
gear and axle shaft attached to the outside wheel to ro-
tate at a faster speed.
Fig. 4 Model 30 Differential Cover
Fig. 5 Disconnect Feature
JFRONT SUSPENSION AND AXLE 2 - 3