1995 JEEP YJ mirror

REMOVAL AND INSTALLATION
WINDSHIELD
Windshield glass removal is accomplished by the
use of a razor knife and an electric hot knife to cut
through the urethane adhesive. This removal method
applies in all instances.
Depending on the circumstances, either one of two
windshield glass installation methods can be used:
²The short method.
²The extended method.
The short method is used when the windshield
glass is removed intact, and the body opening and
the pinchweld flanges do not require repair.
The extended method must be used when the body
opening or a flange is damaged. The extended method
must also be used when urethane no longer adheres to
either the windshield glass or the pinchweld flanges.
REMOVAL
NOTE: When using the windshield glass short in-
stallation method, ensure that a bead of urethane
remains on the pinchweld flange.
(1) Cover the interior and exterior body surface ar-
eas with a protective covering.
(2) With doors open, remove the windshield wiper
arms, interior trim moldings and rearview mirror.
(3) Make a cut around theperimeterof the wind-
shield glass along the glass edge with a razor knife.
(4) Clean the blade of the hot knife with solvent
and a cloth. Sharpen the blade with a fine-tooth file.
CAUTION: When cutting through urethane with a
hot knife, do not allow the knife blade to remain
stationary at any location. Excessive heat will per-
manently soften urethane and cause complete re-
placement of the urethane.
Fig. 3 Cutting Glass Urethane Adhesive With Hot Knife
23 - 68 STATIONARY WINDOW GLASSÐXJJ1995 Jeep Cherokee/Wrangler
Publication No. 81-370-5146
TSB 26-05-95 July, 1995

(5) Start the hot knife blade (special tool C-4386)
between the glass and the urethane. Next, cut the
adhesive as close to the glass edge as possible (Fig.
1). Allow as much adhesive to remain on the pinch-
weld flange as possible.For best cutting results,
clean the knife blade frequently with steel wool
while the blade is hot.
(6) Remove the windshield glass from the body
opening.
(7) After the hot knife blade has cooled, clean the
blade with solvent and a clean cloth.
INSTALLATIONÐSHORT METHOD
Normally, after a replacement windshield glass is
installed, the rearview mirror bracket also requires
installation.Do not install the bracket until after
the windshield glass installation is completed.
(1) Inspect the windshield opening pinchweld
flanges. Prime any bare spots with urethane primer.
Allow a minimum of 18 minutes for dry time.
(2) Inspect urethane bead for high spots. Level
bead by shaving off high spots with a razor knife.
(3) Clean the outer edge of windshield glass with
naphtha or an equivalent product.
(4) Prime outer perimeter of interior side of glass 16
mm (5/8 inch) from edge. Use a wipe-off type urethane
primer and wipe glass dry after primer application.
NOTE: The reveal molding has an adhesive applied
to the windshield contact surface to help secure the
molding to the windshield during the installation
procedure.
(5) Apply the molding to the windshield:
²With the molding at room temperature, press the
molding onto the windshield corners.
²From corner to corner, work the molding to the
center of each side. (Some stretching of the mold-
ing may be required during this procedure.)(6) Place the glass on the pinchweld flanges and
inspect for gaps in the urethane. Gaps in excess of 3
mm (1/8 inch) must be filled with urethane.
(7) Adjust windshield glass position until it is
aligned with the flanges and adhesive. Next, make
alignment marks on the glass and body.
(8) Remove the windshield glass and position it on
a flat surface.
CAUTION: Avoid spilling or dripping primer on
painted surfaces. Clean spills or drips immediately.
The primer will damage the paint if it remains on
the surface for any length of time.
(9) If the replacement windshield glass does not
have blackout primer:
²Attach a 25 mm (1 in) wide masking tape band
around the interior side of the glass 16 mm (5/8
in) from the edge of the glass.
²Do not attach tape along the bottom of the glass
andattach it only to the inside of the glass.
Fig. 4 Masking Tape Location For Blackout Primer
JSTATIONARY WINDOW GLASSÐXJ 23 - 691995 Jeep Cherokee/Wrangler
Publication No. 81-370-5146
TSB 26-05-95 July, 1995

²Clean the 16-mm (5/8-in) wide surface area around
the glass with isopropyl alcohol.
²Thoroughly mix and apply glass blackout primer
to the 16 mm (5/8 in) surface area around the in-
terior side of the glass (Fig. 3).
²Allow the primer to dry for at least 10-12 minutes.
(10) Apply a small amount of adhesive to the bot-
tom support spacers and attach the support spacers
to the bottom of the windshield, 170 mm inboard
from the outer windshield edge (Fig. 4).
(11) Cut the urethane adhesive applicator nozzle
(Fig. 7).
CAUTION: Be prepared to install glass immediately
after applying the adhesive, as the adhesive will be-
gin to cure in less than 10 minutes.
(12) Apply a continuous, 6-mm (1/4-in) diameter
bead of urethane adhesive to the surface area.(13) Align the glass with the reference marks and
position the glass on the pinchweld flanges. Ensure
that the windshield glass is correctly seated on the
support spacers.
(14) Force the windshield glass inward just enough
to wet-out and set the urethane. Use care to avoid
excessive squeeze-out of adhesive.
(15) Water test the windshield with a water spray
after installation. Do not direct high pressure
streams of water directly at urethane. If any leaks
are detected, apply urethane as necessary.
(16) If used remove the masking tape from the in-
ner surface of the glass.
(17) Install all components and clean the vehicle.
(18) Open the vehicle windows to prevent interior
pressure while the urethane is curing.If not
vented, pressure in the interior of the vehicle
may interfere with proper glass bonding.
(19) Install the rearview mirror.
Fig. 6 Windshield Bottom Support SpacersFig. 5 Blackout Primer Application
23 - 70 STATIONARY WINDOW GLASSÐXJJ1995 Jeep Cherokee/Wrangler
Publication No. 81-370-5146
TSB 26-05-95 July, 1995

INSTALLATIONÐEXTENDED METHOD
Normally, after a windshield is installed, the rear-
view mirror bracket also requires installation.Do
not install the bracket until after the wind-
shield installation is completed.
(1) Remove all of the urethane from all pinchweld
flanges. Use an electric hot knife and a plow-type
knife blade to remove the adhesive.
(2) Inspect and repair the windshield opening and
pinchweld flanges.
(3) Prime the pinchweld flanges with a urethane
base primer. However, if the flange is color-coated
with paint, prime the flanges with a paint finish
primer.This is important because urethane ad-
hesive will not adhere to all color-coat paints.
Allow primer sufficient time to dry.
NOTE: The reveal molding has an adhesive applied
to the windshield contact surface to help secure the
molding to the windshield during the installation
procedure.
(4) Apply the reveal molding to the windshield:
²With the molding at room temperature, press the
molding onto the windshield corners.
²From corner to corner, work the molding to the
center of each side. (Some stretching of the mold-
ing may be required during this procedure).(5) Install and inspect the fit of the windshield on
the pinchweld flanges as follows:
²Position windshield until it is aligned within wind-
shield opening.
²
Measure the gap between the pinchweld flanges
and glass around perimeter of the glass and flange.
²The reveal molding should equally cover the A-Pil-
lars on both sides.
²The flanges should also extend above the glass
edge equally around the perimeter of the opening.
Fig. 7 Applicator Nozzle Preparation
JSTATIONARY WINDOW GLASSÐXJ 23 - 711995 Jeep Cherokee/Wrangler
Publication No. 81-370-5146
TSB 26-05-95 July, 1995

(6) If the pinchweld flanges require repair, remove
the windshield glass and straighten, align, or repair
the flange(s) as necessary.
(7) Position the windshield in the opening and in-
spect the windshield fit again. Mark the windshield
final position on the glass and body with a wax pen-
cil (or use masking tape). The marks (or masking
tape) will be used for installation alignment refer-
ence.
(8) If the replacement windshield does not have
blackout primer:
²Attach a 25-mm (1-in) wide masking tape band
around the interior side of glass 16 mm (5/8 in)
from edge of glass (Fig. 2).
²Do not attach tape along the bottom of the glass
and attach only to the inside of glass.
²Thoroughly mix and apply blackout primer to the
16 mm (5/8 in) surface area around the interior
side of the glass (Fig. 4).
²Allow the primer to dry for at least 10-12 minutes.
(9) Apply a small amount of adhesive to the bot-
tom support spacers and attach the support spacers
to the bottom of the windshield, 170 mm inboard
from the outer windshield edge (Fig. 6).
(10) Cut the urethane applicator nozzle (Fig. 7).
(11) Apply a continuous bead of urethane to the
surface area with blackout primer on the interior
side of glass. The bead should be 9-mm (3/8-in) wide
by 12.7-mm (1/2-in) deep for best results.CAUTION: Be prepared to install the windshield im-
mediately after applying the adhesive, as the adhe-
sive will begin to cure in less than 10 minutes.
(12) Align the windshield with the wax pencil in-
stallation alignment reference marks (or the tape
strips). Position the windshield on pinchweld flanges
and spacers.
(13) Force the windshield inward just enough to
wet-out and set the urethane. Use care to avoid ex-
cessive squeeze-out of adhesive.
(14) Water test the windshield with a water spray
after installation. Do not direct high pressure
streams of water directly at the urethane. If any
leaks are detected, apply urethane as necessary.
(15) If used, remove the masking tape from the in-
ner surface of glass.
(16) Install all components and clean the vehicle. If
necessary, refer to the installation procedures.
(17) Open the vehicle windows to prevent interior
pressure while the urethane adhesive is curing.If
not vented, pressure in the interior of vehicle
will interfere with glass bonding.
(18) Install the rearview mirror on the bracket.
REAR DOOR STATIONARY WINDOW GLASS
REMOVAL
(1) Lower the window glass.
(2) Pry the window beltline molding away from the
clips and remove the molding from the door.
(3) Remove the window weatherstrip seals from
the door.
23 - 72 STATIONARY WINDOW GLASSÐXJJ1995 Jeep Cherokee/Wrangler
Publication No. 81-370-5146
TSB 26-05-95 July, 1995

TRAILER HITCH
TRAILER HITCHÐXJ
CLASS III HITCH
A class III weight-distributing/equalizer type hitch
can be used to tow a trailer:
²Having a maximum gross weight of 5,000 lbs/2250
kg.
²Having a maximum tongue weight of 750 lbs/332
kg).
The following vehicle basic equipment is required
for class III trailer towing:
²P205/75R15 or larger tires.
²Full size spare tire.
²Trailer sway control.
²Trailer tow wire harness and connector.
²Heavy duty turn signal flasher element.
²Heavy duty axle (with synthetic lubricant).
²Heavy duty cooling system.
²Heavy duty generator/battery.
²Auxiliary automatic transmission fluid cooler.
²I-6, 4.0L engine.
Wide-angle type door mirrors are recommended but
not required.
WIRE HARNESS CONNECTORS
CLASS I HITCH CONNECTOR
The trailer tow wire harness connector for class I
trailer hitches is a 5-terminal, in-line type connector.
Terminal 5 is the source for vehicle ground (Fig. 1)
CLASS III HITCH CONNECTOR
The trailer tow wire harness connector for class III
trailer-tow hitches is a 7-terminal, circular type con-
nector (Fig. 2).
The 12-volt circuit for the trailer is protected
from overloads. A auto-reset type circuit
breaker is located in the trailer tow wire har-
ness near the plug-in relays.
CAUTION: The trailer tow wire harness package
does not include a vehicle battery isolator unit. Be-
cause of this, the trailer battery can totally dis-
charge the vehicle battery if the engine is not
operated for an extended period of time.
A blue wire (without a connector) located under in-
strument panel near fuse panel is available for
trailer electric brake control unit.
Fig. 1 Trailer Tow Wire Harness Connectors
JTRAILER HITCH 23 - 77

(2) Remove the automatic transmission shift indi-
cator bezel (Fig. 4). Remove the transfer case shift in-
dicator bezel (if equipped) or cover plate from the
console (Fig. 5).(3) If equipped, insert a thin-blade tool under the
edge of the outside mirror remote control switch and
pry outward to detach it from the console. Disconnect
the wire harness connector from the switch (Fig. 6).
Fig. 4 Full Console
Fig. 5 Transfer Case Shift Indicator Bezel/Cover
PlateFig. 6 Outside Mirror Remote Control Switch
23 - 96 INTERIOR COMPONENTSÐXJJ

(4) Remove the cover retaining screws and remove
the cover from the console (Fig. 7).
(5) Remove the remainder of the console attaching
screws from the brackets and disconnect the wire
harness connector.
(6) Separate the console floor air duct from the air
outlet duct (Fig. 8).
(7) Remove the console and air duct from the floor.
(8) Separate the floor air duct from the console.
(9) Remove the retaining screws and detach the
floor duct from the heater housing, if necessary.
(10) Remove the console support brackets.
The brackets are attached directly to the
floor panel below the carpet.
INSTALLATION
(1) Install the console support brackets, if re-
moved. Tighten the screws to 1 Nzm (11 In-lbs)
torque.
The brackets are attached directly to the
floor panel below the carpet.(2) Attach the floor duct to the heater housing, if
removed. Tighten the screws to 1 Nzm (11 In-lbs)
torque.
(2) Attach the air duct to the console.
(3) Position the console on the floor, attach the air
duct to the air outlet duct, connect the wire harness
connector and install the console retaining screws in
the brackets. Tighten the screws to 1 Nzm (11 In-lbs)
torque.
(4) Install the console cover and shift indicator be-
zels (or cover plate). Tighten the screws to 1 Nzm(11
In-lbs) torque.
(5) If equipped:
²Connect the wire harness connector to the outside
mirror remote control switch.
²Insert the switch into the console hole.
²Push inward to engage the retaining clips.
(6) Install the shift lever handle/knob.
JACK STORAGEÐXJ
The XJ lift jack and related tools are stored under
the rear seat behind the front passenger's seat. The
jack and tools are attached to the floor panel and
seat cushion crossmember with a retainer and hold-
down bolt (Fig. 1).
When necessary, the jack retainer bracket can be
removed from the crossmember by drilling-out the
rivet heads and then removing the rivet bodies with
a punch. Install the retainer bracket with either riv-
ets or bolts and nuts (Fig. 2).
Fig. 7 Full Console Removal/Installation
Fig. 8 Air Outlet and Console Floor Air Ducts
Fig. 1 Jack and Related Tools
JINTERIOR COMPONENTSÐXJ 23 - 97