1995 JEEP XJ oil change

If the transmission is warm, lube oil could
drip out of the fill hole. This is acceptable but
the lube oil should not gush out of the fill hole.
(2) If not acceptable, raise the lube oil level to the
bottom edge of the transmission fill hole.
Add lube oil in small amounts to raise the
level.
(3) Install the fill-hole plug in the transmission.
Tighten the plug with 37 Nzm (27 ft. lbs.) torque.
LUBE OIL CHANGE
When it becomes necessary to change manual
transmission lube oil, use the following procedure.
(1) Raise and support the vehicle.
(2) Remove the fill-hole plug from the transmis-
sion.
(3) Place a container to collect the lube oil under
the transmission drain-hole plug.
(4) Remove the drain-hole plug and drain the lube
oil from the transmission into the container.
Care should be exercised when disposing
used lube oil after it has been drained from a
transmission.
(5) Install the drain-hole plug in the transmission.
Tighten the plug with 37 Nzm (27 ft. lbs.) torque.
(6) Fill the transmission until the lube oil begins to
drip out of the fill hole.
(7) Install the fill-hole plug in the transmission.
Tighten the plug with 37 Nzm (27 ft. lbs.) torque.
(8) Remove the support and lower the vehicle.
AUTOMATIC TRANSMISSION
The automatic transmission fluid should be
changed and bands adjusted at the intervals de-
scribed in the Maintenance Schedules section of this
Group. The automatic transmission should be in-
spected for fluid leaks and proper fluid level whenother under hood service is performed. Refer to
Group 21, Transmission for proper service proce-
dures.
CAUTION: To minimize fluid contamination, verify
that dipstick is seated in the fill tube after fluid level
reading is taken.
TO INSPECT THE TRANSMISSION FLUID
LEVEL
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT PUT YOUR
HANDS NEAR THE DRIVE BELT, PULLEYS OR FAN
BLADE. DO NOT STAND IN A DIRECT LINE WITH
THE FAN BLADE.
(1) Be sure transmission fluid is at normal operat-
ing temperature. Normal operating temperature is
reached after approximately 15 miles (25km) of oper-
ation.
(2) Position the vehicle on a level surface. This is
important for an accurate fluid level check.
(3) While sitting in driver seat, apply brakes and
place gear selector in each position, then move the
selector to:
²XJ vehicles-P (Park).
²YJ vehicles-N (Neutral).
(4) Apply parking brake.
(5) Raise hood and wipe off dipstick handle to pre-
vent dirt from entering fill tube. Then remove trans-
mission fluid level indicator (dipstick) and wipe clean
with a wiping cloth.
(6) Install dipstick and verify it is seated in fill
hole or tube.
(7) Remove dipstick, with handle above tip, take
fluid level reading. If the vehicle has been driven for
at least 15 minutes before inspecting fluid level,
transmission can be considered hot and reading
should be in the OK area. If vehicle has run for less
than 15 minutes and more than 60 seconds transmis-
sion can be considered warm and reading should be
above MIN mark. Add fluid only if level is below
MIN mark on dipstick when transmission is warm
(Fig. 4).
CAUTION: Do not overfill automatic transmission,
leakage or damage can result.
AUTOMATIC TRANSMISSION FLUID
SPECIFICATION
When it becomes necessary to add fluid or when
the ATF is replaced, use:
²MOPAR Dexron IIE/Mercon ATFonlyfor AW-4
automatic transmissions (XJ vehicles).
²MOPAR ATF PLUS type 7176 (YJ vehicles).
Fig. 3 Manual Transmission Fill- & Drain-Hole
PlugsÐTypical
JLUBRICATION AND MAINTENANCE 0 - 23

LUBRICANT LEVEL
Determine the axle differential housing lubricant
level according to the following procedure.
(1) Raise and support the vehicle.
(2) Remove the fill-hole plug (Fig. 6 and 7) from
the axle differential housing cover. The gear lubri-
cant should be 13 mm (1/2 inch) below the bottom
edge of the fill hole.
(3) If not acceptable, raise the lubricant level to 13
mm (1/2 inch) below the bottom edge of the fill hole.
Add lubricant in small amounts to raise the
level.
(4) Install the fill-hole plug in the differential
housing cover. Tighten the plug with 34 NÉm (25 ft.
lbs.) torque.
(5) Remove the support and lower the vehicle.
LUBRICANT CHANGE
When it becomes necessary to change the axle lu-
bricant in a Jeep front or rear axle, use the following
procedure.
(1) Raise and support the vehicle.(2) Place a container under the axle differential
housing.
(3) Remove the axle differential housing cover
bolts. Remove the housing cover.
(4) Allow the axle gear lubricant to completely
drain into the container.
CAUTION: Do not flush a rear axle Trac-Lok differ-
ential. Trac-Lok differentials may be cleaned only by
disassembling the unit and wiping the components
with clean, lint-free cloth.
(5) Flush the inside of the differential housing
with a flushing oil.Do not use water, steam, ker-
osene or gasoline for flushing.
(6) Remove any residual RTV sealant/gasket mate-
rial from the differential housing and cover. Thor-
oughly clean the contact surfaces with mineral spirits
and dry the surfaces completely.
(7) Apply a bead of MOPAR RTV Sealant, or an
equivalent sealant, around the bolt circle on the
housing and on the cover (Fig. 8).
If differential housing cover is not installed
within 20 minutes after applying sealant, the
sealant must be removed and another bead ap-
plied.
(8) Install the cover on the differential housing
with the attaching bolts (Fig. 9). Tighten the cover
bolts with 47 Nzm (35 ft. lbs.) torque.
(9) Remove the fill-hole plug and add the replace-
ment gear lubricant to the differential housing. Refer
to Specifications above.
(10) Install the fill-hole plug. Tighten the plug
with 34 NÉm (25 ft. lbs.) torque.
Fig. 6 Rear AxleÐTypical
Fig. 7 Front Axle (4WD)ÐTypical
Fig. 8 RTV Sealant ApplicationÐTypical
JLUBRICATION AND MAINTENANCE 0 - 25

FLUID LEVEL
The fluid level indicator (dipstick) is attached to
the reservoir cap (Fig. 6). The fluid level in the res-
ervoir can be determined with the fluid either hot or
cold.
(1) Remove the cap from the reservoir.
(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.CAUTION: Do not over fill power steering reservoir
when adding fluid, seal damage and leakage can re-
sult.
MANUAL STEERING GEAR
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. Refer to Group
19, Steering for additional information and service
procedures.
POWER BRAKE SYSTEM
RECOMMENDED MAINTENANCE
The brake fluid level (Fig. 8) should be inspected
when other underhood service is done. With disc-
brakes, the fluid level can be expected to fall as the
brake pads wear. However, a low fluid level can also
be caused by a leak, and repair will then be neces-
sary. Refer to Group 5, Brakes for proper service pro-
cedures.
In addition, the brake system should be operation-
ally tested periodically to ensure that it is function-
ing normally.
FLUID SPECIFICATION
Jeep power 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.
Use brake fluid from properly sealed container
when adding fluid to the reservoir. Never use re-
claimed fluid or fluid that does not conform to the
DOT/SAE Standards.
CAUTION: Use of a brake fluid that has a lower ini-
tial boiling point then specified by FMVSS No. 116,
DOT 3 and SAE J-1703 could result in sudden brake
failure during hard, prolonged braking.
Do not allow petroleum base fluids to contaminate
the brake fluid. Seal damage will result.
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 and 8). If not, add brake fluid as nec-
essary.
(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. 5 Power Steering SystemÐYJ Vehicles
Fig. 6 Power Steering Fluid Reservoir DipstickÐ
Typical
0 - 30 LUBRICATION AND MAINTENANCEJ

(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, 5 Brakes 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 at
the intervals described in the Maintenance Schedules
section of this group.
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
22, Tires And Wheels.
ROTATION
Refer to Group 22, Tires And Wheels for the recom-
mended method of tire/wheel rotation for a Jeep ve-
hicle.
BODY COMPONENTS
LUBRICATION REQUIREMENTS
All Jeep operating mechanisms and linkages
should be lubricated when necessary. The door
weatherstrip seals should be lubricated to prolong
their life as well as to improve door sealing.
LUBRICANT SPECIFICATIONS
All applicable exterior and interior vehicle operat-
ing mechanisms should be:
²Inspected
²Cleaned
²Pivot/sliding contact areas on the mechanisms
should then be lubricated.
Multi-purpose NLGI GC-LB MOPAR Multi-Mileage
Lubricant or an equivalent, should be used to lubri-
cate the mechanisms. The door weatherstrip seals
should be lubricated with silicone lubricant spray.
Refer to the Body Lubricant Specifications chart be-
low for additional lubricant applications.
LUBRICATION
All pivoting and sliding contact areas, should be lu-
bricated periodically to ensure quiet, easy operation
and to protect against wear and corrosion. Areas in-
clude:
²Seat tracks.
²Door hinges/latches/strikers.
²Liftgate/tailgate/hood hinges (Fig. 11).
(1) As required, lubricate the body components
with the specified lubricants.
(2) Apply silicone lubricant to a cloth and wipe it
on door seals to avoid over-spray that can soil pas-
senger clothing.
(3) Before applying lubricant, the component
should be wiped clean. After lubrication, any excess
lubricant should be removed.
(4) The door lock cylinders should be lubricated 2
times each year (preferably autumn and spring):
²Spray a small amount of lock cylinder lubricant di-
rectly into the lock cylinder.
²Apply a small amount to the key and insert it into
the lock cylinder.
²Rotate it to the locked position and then back to
the unlocked position several times.
²Remove the key. Wipe the lubricant from it with a
clean cloth to avoid soiling of clothing.
Fig. 9 Park Brake Equalizer (XJ)ÐTypical
Fig. 10 Park Brake Equalizer (YJ)ÐTypical
0 - 32 LUBRICATION AND MAINTENANCEJ

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
axle assembly to the body. The lower arms uses
shims at the body mount to allow for adjustment of
caster and drive shaft pinion angle. The suspension
arm travel is limited through the use of jounce
bumpers in compression and shocks absorbers in re-
bound.
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 body. The bot-
tom of the shocks are bolted to the axle spring
bracket.
The stabilizer bar is used to minimize vehicle body
roll 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 body 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 the four-wheel
drive axle.
The steering knuckles and hub bearing 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 has semi-elliptic multi-leaf
springs mounted to the axle assembly. The rearward
end of the springs are mounted to the frame rail
hangers. The forward end of the springs are attached
to the frame with shackles. The springs and shackles
use rubber bushings to isolate road noise. The shack-
les allow the springs to change their length as the
vehicle moves over various road conditions. The
Fig. 2 Front AxleÐ2WD Vehicles
Fig. 3 YJ Front Suspension
2 - 2 FRONT SUSPENSION AND AXLEJ

MODEL 30 AXLE AND TUBE AXLE (2WD)
INDEX
page page
Axle Bushing Replacement.................. 34
Axle ShaftÐCardan U-Joint.................. 26
Backlash and Contact Pattern Analysis......... 45
Cleaning/Inspection........................ 37
Differential and Pinion Measurement........... 40
Differential Assembly....................... 38
Differential Disassembly.................... 35
Differential Installation...................... 44
Differential Removal....................... 34
Differential Shim Pack Measurement and
Adjustment............................ 43
Drive Axle Assembly ReplacementÐXJ Vehicles . . 23
Drive Axle Assembly ReplacementÐYJ Vehicles . . 24Final Assembly........................... 46
Hub Bearing and Axle Shaft................. 25
Information.............................. 22
Inner Axle Shaft Oil Seal Replacement......... 35
Lubricant Change......................... 23
Lubricant Specifications..................... 22
Pinion Gear Assembly/Installation............. 42
Pinion Gear Depth Information............... 39
Pinion Removal/Disassembly................. 36
Pinion Seal Replacement................... 25
Steering Knuckle and Ball Studs.............. 32
Vacuum Disconnect AxleÐYJ Vehicles......... 27
INFORMATION
The Model 30 front axles consists of a cast iron dif-
ferential housing with axle shaft tubes extending
from either side. The tubes are pressed into the dif-
ferential housing and welded.
The integral type housing, hypoid gear design has
the centerline of the pinion set above the centerline
of the ring gear.
The axle has a fitting for a vent hose used to re-
lieve internal pressure caused by lubricant vaporiza-
tion and internal expansion.
The axles are equipped with semi-floating axle
shafts, meaning that loads are supported by the hub
bearings. The axle shafts are retained by nuts at the
hub bearings. The hub bearings are bolted to the
steering knuckle at the outboard end of the axle tube
yoke. The hub bearings are serviced as an assembly.
The axles are equipped with ABS brake sensors.
The sensors are attached to the knuckle assemblies
and tone rings are pressed on the axle shaft.Use
care when removing axle shafts as NOT to dam-
age the tone wheel or the sensor.
The stamped steel cover provides a means for in-
spection and servicing the differential.
The Model 30 axle has the assembly part number
and gear ratio listed on a tag. The tag is attached to
the housing cover. Build date identification codes are
stamped on the axle shaft tube cover side.
The differential case is a one-piece design. The dif-
ferential pinion mate shaft is retained with a roll
pin. Differential bearing preload and ring gear back-
lash is adjusted by the use of shims (select thick-
ness). The shims are located between the differential
bearing cones and case. Pinion bearing preload is set
and maintained by the use of collapsible spacer.
COMMAND-TRACÐYJ VEHICLES
The Command-Trac system is a vacuum disconnect
axle. The system has a two-piece axle shaft coupled
together by a shift collar. For two-wheel drive opera-
tion, the vacuum motor and shift fork disengages the
axle shaft splines. For four-wheel drive operation, the
vacuum motor and shift fork engages the axle
splines.
SELEC-TRACÐXJ VEHICLES
The Selec-Trac system is a non-disconnect axle.
Shifting from two-wheel to four-wheel drive is done
at the transfer case.
For XJ vehicles equipped withSelec-Tracand
ABS brake system, refer to Group 5ÐBrakes for ad-
ditional service information.
LUBRICANT SPECIFICATIONS
Multi-purpose, hypoid gear lubricant should be
used for Model 30 axles. The lubricant should have
MIL-L-2105C and API GL 5 quality specifications.
MOPARtHypoid Gear Lubricant conforms to both of
these specifications.
²The factory fill for the Model 30 axle is SAE Ther-
mally Stable 80W-90 gear lubricant.Do not use
heavier weight lubricant, this will cause axle
engagement difficulties.
²The factory installed lubricant quantity for the
NON-DISCONNECT TYPE AXLE is 1.48 L (3.13
pts.).
²The factory installed lubricant quantity for the
VACUUM-DISCONNECT TYPE AXLE is 1.65 L (3.76
pts.).
Refer to Group 0, Lubrication and Maintenance for
additional information regarding temperature range,
viscosity and fluid level.
2 - 22 FRONT SUSPENSION AND AXLEJ

CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.
LUBRICANT CHANGE
The gear lubricant will drain quicker if the vehicle
has been recently driven.
(1) Raise and support the vehicle.
(2) Remove the lubricant fill hole plug from the dif-
ferential housing cover.
(3) Remove the differential housing cover and
drain the lubricant from the housing.
(4) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.Do not use water,
steam, kerosene or gasoline for cleaning.
(5) Remove the sealant from the housing and cover
surfaces. Use solvent to clean the mating surfaces.
(6) Apply a bead of MOPARtSilicone Rubber Seal-
ant to the housing cover (Fig. 1).Allow the sealant
to cure for a few minutes.
Install the housing cover within 5 minutes af-
ter applying the sealant. If not installed the
sealant must be removed and another bead ap-
plied.
(7) Install the cover and any identification tag.
Tighten the cover bolts in a criss-cross pattern to 41
Nzm (30 ft. lbs.) torque.
(8) Refill the differential with MOPARtHypoid
Gear Lubricant to bottom of the fill plug hole.
(9) Install the fill hole plug and lower the vehicle.
DRIVE AXLE ASSEMBLY REPLACEMENTÐXJ
VEHICLES
REMOVAL
(1) Raise the vehicle and position support stands
under the frame rails behind the lower suspension
arm frame brackets.
(2) Remove the front wheels.
(3) Remove the brake components and ABS brake
sensor (if equipped). Refer to Group 5ÐBrakes.
(4) On 4WD vehicles, disconnect the axle vent
hose.
(5) On 4WD vehicles, mark the drive shaft yoke
and axle pinion yoke for alignment reference. Discon-
nect the drive shaft from the axle.
(6) Disconnect the stabilizer bar link at the axle
bracket.
(7) Disconnect the shock absorbers from axle
bracket.
(8) Disconnect the track bar from the axle bracket.
(9) Disconnect the tie rod and drag link from the
steering knuckle. Disconnect the steering damper
from the axle bracket.
(10) Support the axle with a hydraulic jack under
the differential.
(11) Disconnect the upper and lower suspension
arms from the axle bracket.
(12) Lower the jack enough to remove the axle.
The coil springs will drop with the axle.
(13) Remove the coil springs from the axle bracket.
INSTALLATION
CAUTION: Suspension components with rubber
bushings should be tightened with the vehicle at
normal height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort could be affected
and premature bushing wear may occur. Rubber
bushings must never be lubricated.
(1) Install the springs and retainer clip. Tighten
the retainer bolts to 21 Nzm (16 ft. lbs.) torque.
(2) Support the axle on a hydraulic jack under the
differential. Position the axle under the vehicle.
(3) Raise the axle with a floor jack and align it
with the spring pads.
(4) Position the upper and lower suspension arm at
the axle bracket. Install bolts and nuts finger
tighten.
(5) Connect the track bar to the axle bracket and
install the bolt.Do not tighten at this time.
It is important that the springs support the
weight of the vehicle when the track bar is con-
nected. If springs are not at their usual posi-
tion, vehicle ride comfort could be affected.
Fig. 1 Typical Housing Cover With Sealant
JFRONT SUSPENSION AND AXLE 2 - 23

(5) Lubricate all differential components with hy-
poid gear lubricant.
PINION GEAR DEPTH INFORMATION
Ring and pinion gears are supplied as matched sets
only. The identifying numbers for the ring and pinion
gear are etched into the face of each gear (Fig. 39). A
plus (+) number, minus (-) number or zero (0) is
etched into the face of the pinion gear. This number
is the amount (in thousandths of an inch) the depth
varies from the standard depth setting of a pinion
etched with a (0). The standard setting from the cen-
terline of the ring gear to the back face of the pinion
is 92.1 mm (3.625 inches) for Model 30 axles (Fig.
40). The standard depth provides the best teeth con-
tact pattern.THE BUTTON END ON THE PINION GEAR
HEAD IS NO LONGER A MACHINED-TO-SPECIFI-
CATIONS SURFACE. DO NOT USE THIS SUR-
FACE FOR PINION DEPTH SET-UP OR
CHECKING (Fig. 40).
Compensation for depth variance is achieved by a
selected thickness oil slinger (production) or shims
(service). The slinger is placed between the inner pin-
ion bearing cone and gear head (Fig. 41). The shim
pack is placed under the inner (rear) bearing cup for
service. To change the pinion adjustment, shims are
available in thicknesses of 0.003, 0.005, and 0.010
inch.The oil slinger or baffle must be measured
and the thickness included with the total shim
pack.
Fig. 38 Ring Gear Bolt Installation
Fig. 39 Pinion Gear ID Numbers
Fig. 40 Pinion Gear Head
Fig. 41 Shim Locations
JFRONT SUSPENSION AND AXLE 2 - 39