1995 JEEP XJ tow

The stop lamp and turn signal plug-in relays are
located behind left quarter trim panel (Fig. 3).
HITCH REMOVALÐXJ VEHICLES
An XJ class III, weight-distributing/equalizer type
hitch (Fig. 4)is comprised of:
²Towing tube with a ball mount receptacle.
²Various reinforcement/support brackets that are
attached to the vehicle frame sills and rear cross-
member with bolts.(1) If necessary, remove the trailer tow wire har-
ness connector from the hitch (Fig. 5).
(2) Support the hitch.
(3) Remove the bolts that attach the towing tube to
the frame sills and reinforcement bracket. If
equipped, remove the fuel tank skid plate.
The reinforcement brackets are held on the
frame sills with two blind rivets.
(4) Remove the bolts from the plate bracket and
rear crossmember and lower the support and hitch.
Fig. 4 Equalizer Type HitchÐXJ Vehicles
Fig. 2 Class III Trailer Tow Wire Harness and
ConnectorsFig. 3 Class III Trailer Tow Wire Harness Plug-In
Relays
23 - 78 TRAILER HITCHJ

INSTALLATIONÐXJ VEHICLES
(1) Install frame reinforcement brackets, if re-
moved. Slide the brackets through the vehicle rear
sill openings and hold in position on the frame sills
with blind rivets (Fig. 6).(2) Place hitch on a lifting device. Raise, position
hitch at the proper location for installation on vehicle
and support it.
(3) If equipped, position fuel tank skid plate on ve-
hicle frame sills.
(4) Loosely install the bolts to attach the towing
tube (and the skid plate) to frame sills and reinforce-
ment brackets.
(5) Position the plate bracket and install the at-
taching bolts through the vehicle rear crossmember.
(6) Tighten all bolts/nuts to the specified torque:
²Towing tube-to-reinforcement bracket bolt, 50 Nzm
(37 ft. lbs.).
²Plate bracket-to-rear crossmember nut, 52 Nzm (40
ft. lbs.).
(7) Remove the lift/support and, if removed, attach
the trailer wire harness connector to the hitch.
Fig. 6 Reinforcement Bracket and Hitch Installation
Fig. 5 Trailer Tow Wire Harness Connector
JTRAILER HITCH 23 - 79

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 body stripe/decal removal and installation:
²Commercial tape stripe/decal removal solution.
²Commercial adhesive removal solution.
²Liquid dish detergent (for the wetting solution).
²Mixture of wetting solution.
²Commercial wax and silicone removal solution.
²Isopropyl (rubbing) alcohol.
²Small squeegee (plastic or hard rubber).
²Water bucket and sponge.
²Clean wiping rags or paper towels.
²Heat gun (or infra-red heat bulb).
²Wax pencil.
²Sharp knife, single edge razor blade or X-acto
knife.
²Pair of scissors.
²Needle or pin.
A wetting solution assures a better bond between
the painted surface of the body and the tape stripe/
decal. Prepare a supply of wetting solution by mixing
two or three teaspoons of dish detergent with 1 gal-
lon of water.Do not use soap.
Too much detergent will reduce the effective-
ness of the mixture.
REMOVAL
The key to successful tape stripe/decal re-
moval is to apply heat to area and slowly peel
stripe/decal from panel.
(1) Clean the repaired surface, adjacent panels and
door 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 the panel.
WARNING: USE THE TAPE STRIPE/DECAL RE-
MOVAL SOLUTION IN A WELL-VENTILATED AREA
ONLY.
(3) A commercial tape stripe/decal removal solution
can be used for stripe/decal removal at areas where a
heat gun is ineffective:
²mask-off the body panel area surrounding the tape
stripe/decal (Fig. 1).
²Move the removal solution spray back and forth
across the complete length of the stripe/decal with a
smooth, steady motion.
²Ensure that the complete stripe/decal is covered
with the solution.
²Allow the stripe/decal removal solution to remain
on the stripe/decal for 20 minutes.²After 20 minutes, peel stripe/decal away from the
flange and, starting at a corner, peel the stripe/decal
from the body (Fig. 2).
²If there is difficulty with peeling stripe/decal away
from body use a squeegee for stripe/decal removal
(Fig. 3).
²With the stripe/decal removed, scrape all the
stripe/decal removal solution from the panel surface
before proceeding.
WARNING: USE THE ADHESIVE REMOVAL SOLU-
TION IN A WELL-VENTILATED AREA ONLY.
(4) After the stripe/decal is removed, remove any
adhesive remaining on body with a removal solution.
(5) After 3 to 5 minutes, use a squeegee to remove
adhesive (Fig. 4).
(6) Remove the masking tape and mask from the
panel.
(7) Wipe the panel with a cloth with a general pur-
pose cleaning solution.
Fig. 1 Stripe/Decal Removal Solution Application
Fig. 2 Body Stripe/Decal Removal
JEXTERIOR COMPONENTSÐYJ 23 - 117

(15) Slide the center bow legs out of the lower side
retainers and remove the top cover from the vehicle.
Fig. 10 Releasing Spreader Bar Tension
Fig. 11 Rear Curtain Stowed
Fig. 12 Detaching Rear Corner Side (Lower)
Retainer
Fig. 13 Top Cover Snap-On Retainers At Upper Side
Retainers
Fig. 14 Folding Top Cover
Fig. 15 Sliding Top Cover Rearward
23 - 130 EXTERIOR COMPONENTSÐYJJ

INSTALLATION
(1) If stowed at the rear of the vehicle, detach the
elastic straps that retain the top cover (Fig. 16).
(2) If not stowed, position the center bow legs an-
chor pins in the lower side retainer receptacles (Fig.
17).
(3) Grasp the cover at the upper side snap retain-
ers and pull the top cover upward and forward.
(4) Position front of the upper side snap retainers
at the door flanges and lock pin at each side of the
vehicle (Fig. 18). Engage the locks with the pins and
then slide the locks rearward.
(5) Insert the front edge of the top cover into the
retainer channel on the windshield frame (Fig. 19).
(6) Ensure that the center bow leg is positioned all
the way forward in the receptacle.
(7) Ensure that the rear corners of the top cover
are inserted in the retainer channels (Fig. 19).
(8) Pull the rear bow legs rearward until they en-
gage with the notch in the lower side retainers. En-
sure that the side curtain rear zippers are not
entrapped or folded behind the rear bow.(9) Force the spreader bars (Fig. 20) upward until
the lock engages.
(10) Slide the front edge of each side curtain up-
ward into the retainer channel on the center bow.
(11) Close top zipper on each side curtain5-8cm
(2 - 3 in). Next, close the rear zipper at the bottom
corner of the curtain5-8cm(2-3in).
(12) Attach the side curtain front and rear tab
snap-on retainers to the lower side retainer.
(13) Completely close both side curtain zippers.
(14) Pull downward firmly on the side curtains.
Start at one end and move toward the opposite end.
The bottom edge of the curtains must be completely
inserted in the lower side retainer channels.
(15) Release the rear window curtain straps and
insert the bottom edge into the tailgate retainer
Fig. 16 Stowed Top Cover
Fig. 17 Bow Leg and Anchor Pin
Fig. 18 Upper Side Retainer Lock Engagement
Fig. 19 Soft Top Installation
JEXTERIOR COMPONENTSÐYJ 23 - 131

(3) Close the jaws on the latch.
(4) Push the lock-to-latch rod forward toward the
inside release handle. Check to ensure the lock lever
on the latch is in the unlocked position.
(5) Position the threaded end of the lock rod over
the lever clip on the latch and push the rod into the
lock lever clip (Fig. 9). The lock lever should have a
full sweep of travel when activated by the inside con-
trol button. It should not bind or be stiff.
(7) Position the threaded end of the release lever
rod over the release lever clip on the latch and push
the rod into the release lever clip. The release lever
on the latch should be resting against the stop with
no preload after the rod is engaged in the retaining
clip. Visual observation will reveal any preload. If
preload is noted, disconnect the release lever rod and
install it again to eliminate the preload.
(8) Pull up on the outside handle release rod to po-
sition it as far up as possible and push the rod into
the release lever clip on the latch. The release lever
on the latch should be resting against stop with no
preload after the rod is engaged in the retaining clip.
(9) Close the latch jaws.
(10) Activate the inside lock control button. It
should not bind or be stiff, if either condition exists,
the latch should replaced.
(11) With the inside lock control button in the un-
lock position, pull the inside door handle to open the
jaws on the latch and close the door.
FULL-METAL DOOR LATCH INSIDE RELEASE AND
LOCK HANDLEÐYJ
REMOVAL
(1) Remove the retaining screw (Fig. 8).
(2) Pull the handle outward and detach the lock
and release rods from handle (Fig. 9).
(3) Remove the handle from the upper trim panel
(Fig. 8).
INSTALLATION
(1) Position the handle adjacent to the rods in the
upper trim panel opening and attach the rods to the
handle (Fig. 9).
(2) Position the handle in the upper trim cover and
install the retaining screw Fig. 8).
FULL-METAL DOOR TRIM PANELÐYJ
The door interior trim panels are covered with a vi-
nyl material (Fig. 8). They are attached to the door
inner panel rail retainer and with plastic clips in-
serted into holes in the door inner panel.
REMOVAL
(1) Remove the door assist handle (Fig. 8).
(2) Remove the window glass regulator handle
(Fig. 8).
(3) Remove the door latch release handle and the
upper trim panel (Figs. 8 and 9).
(4) Pry the lower trim panel-to-door retainers (lo-
cated around the perimeter of the panel) outward
and remove the panel (Fig. 8).
INSTALLATION
(1) Position the lower trim panel on the door inner
panel and insert the retainers in the holes in the
door inner panel.
To prevent creasing the trim panel vinyl
cover, do not hammer or exert excessive force
on the retainers.
(2) Install the upper trim panel and the door han-
dle.
(3) Install the window glass regulator handle (Fig.
8).
(4) Install the door assist handle.
FULL-METAL DOOR WATERDAMÐYJ
The waterdam is attached to the door inner panel
with adhesive and tape (Fig. 10).
REMOVAL/INSTALLATION
(1) To remove a waterdam, insert a putty knife be-
tween it and the door inner panel.
(2) When installing a waterdam, ensure that lower
portion of
waterdam is tucked inside the door panel at the ac-
cess opening.
FULL-METAL DOOR VENT WINDOW GLASSÐYJ
REMOVAL
(1) Remove the door trim panel and the waterdam
(Fig. 8 and 9).
(2) Lower the door window glass to the down-stop
position.
(3) Remove the division channel upper attaching
screw and the lower adjustment screw (Fig. 11).
Fig. 9 Inside Door Handle and Rods
JDOORSÐYJ 23 - 137

(4) Detach the front three inches of weatherstrip
seal from the door upper frame. Lower the division
channel and tilt it toward the rear of the door.
(5) Remove the vent window glass from the door
frame.
INSTALLATION
(1) Position the vent window glass in the door
frame.
(2) Install the division channel in the door and po-
sition the channel on the window glass.(3) Install the upper attaching screw and the lower
adjustment screw.
(4) Attach the weatherstrip seal to the door upper
frame.
(5) Water test the window and inspect for leaks.
(6) If water leakage is evident, apply windshield
sealant to seal the area or re-align the weatherstrip
seal.
(7) Test the operation and adjustment of the door
window glass.
(8) Install the door waterdam and the trim panel
(Fig. 8 and 10).
FULL-METAL DOOR WINDOW GLASS
REGULATORÐYJ
REMOVAL
(1) Remove the door trim panel and the waterdam
(Fig. 8 and 10).
(2) Lower the door window glass to expose the reg-
ulator arm guide retainer screws (Fig. 11 and 12).
Remove the bushings, the nuts and the guide chan-
nel (Fig. 12).
(3) Lift the window glass to the fully closed posi-
tion and apply masking tape to the window glass and
over the top of the window frame to retain it.
(4) Remove the division channel lower adjustment
screw.
(5) Remove the window glass regulator attaching
screws (Fig. 11).
(6) Push the division channel outward and remove
the window glass regulator through the access hole
in the door inner panel.
INSTALLATION
(1) Position the window glass regulator within the
door panels and install the screws. Tighten screws to
10 Nzm (96 in. lbs.) torque.
(2) Remove the masking tape from the window
glass and lower it.
Fig. 10 Door Waterdam
Fig. 11 Door Internal Components
Fig. 12 Regulator Arm Guide
23 - 138 DOORSÐYJJ

(3) Slide the regulator arm guide onto the regula-
tor arm and position the guide on the window glass
(Fig. 12). Install the nuts, bushings and screws.
(4) Install the division channel lower adjustment
screw.
(5) Test the window glass for proper operation.
(6) Install the door waterdam and the trim panel
(Fig. 8 and 10).
FULL-METAL DOOR WINDOW GLASSÐYJ
ADJUSTMENT
One adjustment location provides amount of effort
required to raise and lower the door window glass.
The door window glass division channel is adjustable
fore and aft at the lower attaching location.
(1) Remove the door trim panel and the waterdam
(Fig. 8 and 10).
(2) Loosen channel lower adjustment screw and
move the division channel fore or aft to obtain the
desired door window glass operation.
Movement of the division channel fore or aft
will decrease or increase the free-play between
the channels.
(3) Tighten the division channel lower adjustment
screw.
(4) Install the door waterdam and the trim panel
(Fig. 8 and 10).
REMOVAL
(1) Remove the door trim panel and the waterdam
(Fig. 8 and 10).
(2) Remove the window glass down-stop bumper
(Fig. 11).
(3) Remove the screws that attach the regulator
arm guide to the window glass. Remove the screws,
bushings, nuts and the guide from the glass (Fig. 11).
(4) Lower the window glass to the bottom of the
door.
(5) Remove the division channel upper attaching
screw and the lower adjustment screw. Detach the
front 3 inches of window glass weatherstrip seal from
the door upper frame.
(6) Separate the division channel from the front
window glass rubber seal. Pull the division channel
up and in toward the inside of vehicle.
(7) Raise and tilt the window glass toward the
hinge side of the door and disengage it from the rear
channel.
(8) Pull the window glass up and out of the door
panel.
INSTALLATION
(1) Lower the window glass into the door, while in-
serting the window glass into the front and rear
channels.
(2) Slide the window glass downward to the bottom
of the door panel.(3) Lower the division channel into the door and
position the window glass securely in the channel.
(4) Install the weatherstrip seal in the upper door
frame and install the upper attaching screw and the
lower adjustment screw.
(5) Slide the guide onto the regulator arm and po-
sition the guide on the window glass. Install the re-
taining nuts, bushings and screws (Fig. 12).
(6) Install the window glass down-stop bumper
(Fig. 11).
(7) Test the window operation for proper adjust-
ment.
(8) Install the door waterdam and the trim panel
(Fig. 8 and 10).
FULL-METAL DOOR KEY LOCK CYLINDERÐYJ
REMOVAL
(1) Remove the door trim panel and the waterdam
(Fig. 8 and 10).
(2) Remove the door latch cover screws and remove
the cover (Fig. 11).
(3) Remove the retaining clip and remove lock cyl-
inder-to-latch rod (Fig. 13).
(4) Remove the lock cylinder retainer and the lock
cylinder from the door panel (Fig. 13 and 14).
INSTALLATION
(1) Install the lock cylinder in the door panel (Fig.
14).
(2) Install the lock cylinder retainer, the lock cylin-
der-to-latch rod and the retaining clip.
(3) Install the door latch cover and the cover
screws (Fig. 11).
(4) Install the door waterdam and the trim panel
(Fig. 8 and 10).
Fig. 13 Key Lock Cylinder and Door Handle
JDOORSÐYJ 23 - 139