1995 JEEP YJ power steering

MAINTENANCE SCHEDULES
INTRODUCTION
There are two maintenance schedules that show
proper service intervals for Jeep Cherokee and Jeep
Wrangler vehicles. Use the schedule that best de-
scribes the conditions the vehicle is operated under.
When mileage and time is listed, follow the interval
that occurs first.
ScheduleÐAlists all the scheduled maintenance
to be performed under normal operating conditions.
ScheduleÐBis a schedule for vehicles that are
usually operated under one or more of the following
conditions.
²Frequent short trip driving less than 5 miles (8
km).
²Frequent driving in dusty conditions.
²Trailer towing or heavy load hauling.
²Frequent long periods of engine idling.
²Sustained high speed operation.
²Desert operation.
²Frequent starting and stopping.
²Cold climate operation.
²Off road driving.
²Commercial service.
²Snow plow operation.
²More than half of vehicle operation occurs in
heavy city traffic during hot weather (above 90É F).
AT EACH STOP FOR GASOLINE
²Check engine oil level and add as required.
²Check windshield washer solvent and add as re-
quired.
ONCE A MONTH
²Check tire pressure and look for unusual tire wear
or damage.
²Check fluid levels of coolant reservoir, brake mas-
ter cylinder, power steering and transmission. Add
fluid as required.
²Check all lights and other electrical items for cor-
rect operation.
²Inspect battery and clean and tighten terminals as
required.
²Check rubber seals on each side of the radiator for
proper fit.
AT EACH OIL CHANGE
²Inspect exhaust system.
²Inspect brake hoses.
²Rotate the tires at each oil change interval shown
on ScheduleÐA: (7,500 Miles) or every other interval
shown on ScheduleÐB: (6,000 Miles).
²Check engine coolant level, hoses, and clamps.
²Lubricate 4x4 steering linkage.
²Lubricate propeller shaft universal joints and slip
spline, if equipped.After completion of off-road (4WD) operation, the
underside of the vehicle should be thoroughly in-
spected. Examine threaded fasteners for looseness.
HARSH SURFACE ENVIRONMENTS
After vehicle operation in a harsh surface environ-
ment, the following components should be inspected
and cleaned as soon as possible:
²Brake drums.
²Brake linings.
²Front wheel bearings (2WD vehicles only).
²Axle coupling joints.
This will prevent wear and/or unpredictable brake
action.
EMISSION CONTROL SYSTEM MAINTENANCE
The schedule emission maintenance listed inbold
typeon the following schedules, must be done at the
mileage specified to assure the continued proper
functioning of the emission control system. These,
and all other maintenance services included in this
manual, should be done to provide the best vehicle
performance and reliability. More frequent mainte-
nance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.
SCHEDULEÐA
7,500 MILES (12 000 KM) OR AT 6 MONTHS
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
15,000 MILES (24 000 KM) OR AT 12 MONTHS
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage.
22,500 MILES (36 000 KM) OR AT 18 MONTHS
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
²Inspect brake linings.
30,000 MILES (48 000 KM) OR AT 24 MONTHS
²Replace air cleaner element.
²Replace spark plugs.
²Adjust belt tension on non-automatic tensioning
drive belts.
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage.
²Drain and refill automatic transmission.
²Drain and refill transfer case.
0 - 4 LUBRICATION AND MAINTENANCEJ

CHASSIS AND BODY COMPONENTS
INDEX
page page
Body Components........................ 32
Chassis Component and Wheel Bearing
Lubricants............................. 28
Front Wheel Bearings...................... 28
Headlamps.............................. 33
Manual Steering Gear...................... 30Power Brake System....................... 30
Power Steering System..................... 29
Speedometer Cable....................... 33
Steering Linkage.......................... 28
Tires................................... 32
CHASSIS COMPONENT AND WHEEL BEARING
LUBRICANTS
The chassis component and wheel bearing lubri-
cants that are recommended for Jeep vehicles are
identified by the NLGI Certification Symbol (Fig. 1).
The symbol contains a coded designation that identi-
fies the usage and quality of the lubricant.
The letterGdesignates wheel bearing lubricant.
LetterLdesignates chassis lubricant. When the let-
ters are combined the lubricant can be used for dual
applications. The suffix lettersCandBdesignate the
level of the lubricant for the application. The letterC
represents level available for wheel bearing lubricant
(G) and the letterBrepresents level available for
chassis lubricant (L).
STEERING LINKAGE
The steering linkage (Fig. 2) should be lubricated
and inspected at the intervals described in the Main-
tenance Schedules section of this Group. Refer to
Group 2, Front Suspension and Axles for proper ser-
vice procedures.
LUBRICANT SPECIFICATION
Use Mopar, Multi-purpose Grease or NLGI GC-LB
lubricant equivalent to lubricate the steering linkage.
INSPECTION
(1) Inspect the steering linkage. Examine the tie
rods and the drag link for bending, and the ball
studs for looseness and excessive wear.(2) Replace, as necessary, all torn/ruptured ball-
stud seals and damaged/defective steering linkage
components.
CAUTION: Use care to prevent lubricant from con-
tacting the brake rotors.
FRONT WHEEL BEARINGS
Some 2WD XJ vehicles are equipped with service-
able front wheel bearings. XJ 4WD vehicles have
semi-floating axle shafts and axle shaft bearings that
are lubricated via differential lube oil.
RECOMMENDED MAINTENANCEÐ2WD XJ
VEHICLES
If equipped, the serviceable front wheel bearings
should be lubricated (re-packed) at the same time as
front brake pad/caliper service is conducted.
LUBRICANT SPECIFICATION
Wheel bearings should be lubricated with a lubri-
cant that is identified as NLGI GC-LB lubricant.
INSPECTION/LUBRICATION
(1) Remove the wheel/tire and the disc brake cali-
per.Do not disconnect the caliper brake fluid
Fig. 1 NLGI Lubricant Container Certification/
Identification Symbol
Fig. 2 Steering Components (XJ)ÐTypical
0 - 28 LUBRICATION AND MAINTENANCEJ

hose unless the caliper must also be removed
for maintenance.Support the caliper with a
hanger to prevent brake fluid hose damage.
(2) Remove the dust cap, the cotter pin, the nut re-
tainer, the adjustment nut, and the thrust washer
from the spindle (Fig. 3). Discard the cotter pin.
(3) Remove the wheel outer bearing from the hub.
(4) Remove the wheel hub/disc brake rotor from
the spindle.
(5) Remove the seal and the inner wheel bearing
from the hub cavity.
(6) After removal, inspect both front wheel bearing
races for indications of pitting, brinelling and exces-
sive heat.
(7) Wipe the spindle clean and apply a small
amount of chassis/wheel bearing lubricant (NLGI
GC-LB lubricant) to prevent rust. Wipe the wheel
hub cavity clean.
CAUTION: Do not over-fill the wheel hub cavity with
lubricant. Excessive lubricant can cause overheat-
ing and bearing damage. Also, excessive lubricant
can be forced out of the wheel hub cavity and con-
taminate the brake rotor/pads.
(8) Partially fill the wheel hub cavity with chassis/
wheel bearing lubricant (NLGI GC-LB lubricant).
(9) Pack the wheel bearings with chassis/wheel
bearing lubricant (NLGI GC-LB lubricant). Ensure
that sufficient lubricant is forced between the bear-
ing rollers.
(10) Install the wheel inner bearing in the wheel
hub and install a replacement seal.
(11) Clean the disc brake rotor contact surfaces, if
necessary.
(12) Install the wheel hub/disc brake rotor on the
spindle.
(13) Install the wheel outer bearing, the thrust
washer, and the spindle nut.(14) Tighten the spindle nut with 28 Nzm (21 ft.
lbs.) torque while rotating the disc brake rotor to
seat the bearings.
(15) Loosen the spindle nut 1/2 turn. While rotat-
ing the disc brake rotor, tighten the spindle nut with
2Nzm (19 in. lbs.) torque.
(16) Install the nut retainer and a replacement cot-
ter pin.
(17) Clean the dust cap and apply wheel bearing
lubricant to the inside surface.Do not fill the dust
cap with lubricant.
(18) Install the dust cap.
(19) Install the disc brake caliper.
POWER STEERING SYSTEM
The power steering fluid level should be inspected
when other under hood service is performed. For
proper service procedures, refer to Group 19, Steer-
ing.
Inspect the power steering system (Fig. 4, and 5)
for the sources of fluid leaks, steering gear housing
cracks and ensure that the steering gear is securely
attached to the vehicle frame rail. Inspect the steer-
ing damper for leaks and loose connections.
FLUID SPECIFICATION
Use MOPAR Power Steering Fluid, or an equiva-
lent product.
POWER STEERING FLUID INSPECTION
WARNING: ENGINE MUST NOT BE RUNNING WHEN
INSPECTING POWER STEERING FLUID LEVEL,
PERSONAL INJURY CAN RESULT.
Fig. 3 2WD Front Wheel BearingsÐXJ Vehicles
Fig. 4 Power Steering SystemÐXJ Vehicles
JLUBRICATION AND MAINTENANCE 0 - 29

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

ALIGNMENT MEASUREMENTS AND ADJUSTMENTS
Before each alignment reading, the vehicle should
be jounced (rear first, then front). Grasp each
bumper at the center and jounce the vehicle up and
down several times. Always release the bumper in
the down position.Set the front end alignment to
specifications with the vehicle at its NOR-
MALLY RIDE HEIGHT.
CAMBER
The wheel camber angle is preset. This angle is not
adjustable and cannot be altered.
CASTER
Before checking the caster of the front axle for cor-
rect angle, be sure the axle is not bent or twisted.
Road test the vehicle, make left and right turns. If
the steering wheel returns to the center position un-
assisted, the caster angle is correct. If steering wheeldoes not return toward the center position unas-
sisted, an incorrect caster angle is probable.
Caster can be adjusted by installing the appropri-
ate size shims (Fig. 2, 3).Changing caster angle
will also change the front propeller shaft angle.
The propeller shaft angle has priority over
caster. Refer to Group 16, Propeller Shafts for
additional information.
TOE POSITIONÐXJ VEHICLES
The wheel toe position adjustment should be the fi-
nal adjustment.
(1) Start the engine if equipped with power steer-
ing. Turn wheels both ways before straightening the
Fig. 2 AdjustmentÐYJ Vehicles
Fig. 3 AdjustmentÐXJ Vehicles
Fig. 4 Steering LinkageÐXJ (LHD)
2 - 8 FRONT SUSPENSION AND AXLEJ

TOE POSITIONÐYJ VEHICLES
The wheel toe position should be the final front
wheel alignment adjustment. In all instances follow
the equipment manufacturer's recommended proce-
dure.
(1) Start the engine if equipped with power steer-
ing. Turn wheels both ways before straightening the
wheels. Secure the steering wheel with the front
wheels in the straight-ahead position. Turn off the
engine.
(2) Loosen the adjustment sleeve clamp bolts on
the tie rod (Fig. 7).The tie rod and adjustment sleeve have both
right and left hand threads to provide equal ad-
justment for each wheel.
(3) After the adjustment is completed, position the
tie rod adjustment sleeve clamp bolts as shown.
(4) Tighten the adjustment sleeve clamp bolts to
27 Nzm (20 ft. lbs.) torque.
(5) Complete the adjustment. Position the drag
link clamp bolts as shown. Tighten the bolts to 49
Nzm (36 ft. lbs.) torque.
Fig. 7 Steering Linkage
YJ Vehicles
ALIGNMENT SPECIFICATIONSÐXJ VEHICLESALIGNMENT SPECIFICATIONSÐYJ VEHICLES
2 - 10 FRONT SUSPENSION AND AXLEJ

SERVICE BRAKE DIAGNOSIS
INDEX
page page
Brake Drag............................... 6
Brake Fade.............................. 6
Brake Fluid Contamination................... 7
Brake Noise.............................. 7
Brake Pull............................... 6
Brake Warning Light Operation................ 5
Brakes Do Not Hold After Driving Through Deep
Water Puddles........................... 7
Component Inspection...................... 5
Contaminated Brakelining.................... 7
Diagnosing Parking Brake Malfunctions.......... 8
Diagnosis Procedures....................... 4
General Information........................ 4Hard Pedal or High Pedal Effort............... 6
Low Pedal............................... 5
Master Cylinder/Power Booster Test............ 8
Pedal Falls Away.......................... 5
Pedal Pulsation (Non-ABS Brakes Only)......... 6
Power Booster Check Valve Test............... 9
Power Booster Vacuum Test.................. 9
Preliminary Brake Check..................... 4
Rear Brake Grab.......................... 7
Road Testing............................. 5
Spongy Pedal............................. 5
Wheel and Tire Problems.................... 7
GENERAL INFORMATION
The diagnosis information in this section covers
service brake components which include:
²disc brake calipers
²disc brakeshoes
²drum brake wheel cylinders
²drum brakeshoes and brake drums
²drum brake support plates
²parking brake mechanism
²master cylinder/combination valve
²vacuum power brake booster
²brake pedal and brakelight switch
²brake warning light
DIAGNOSIS PROCEDURES
Service brake diagnosis involves determining if a
problem is related to a mechanical, hydraulic or vac-
uum operated component. A preliminary brake check,
followed by road testing and component inspection
are needed to determine a problem cause.
Road testing will either verify proper brake opera-
tion or confirm the existence of a problem. Compo-
nent inspection will, in most cases, identify the
actual part responsible for a problem.
The first diagnosis step is the preliminary brake
check. This involves inspecting fluid level, parking
brake action, wheel and tire condition, checking for
obvious leaks or component damage and testing
brake pedal response. A road test will confirm or
deny the existence of a problem. The final diagnosis
procedure involves road test analysis and a visual in-
spection of brake components.
PRELIMINARY BRAKE CHECK
(1) If amber ABS light is illuminated, refer to ABS
Brake System Diagnosis. If red warning light is illu-
minated, or if neither warning light is illuminated,
continue with brake check.(2) Inspect condition of tires and wheels. Damaged
wheels and worn, damaged, or underinflated tires
can cause pull, shudder, tramp and a condition simi-
lar to grab.
(3) If complaint was based on noise when braking,
check suspension components. Jounce front and rear
of vehicle and listen for noise that might be caused
by loose, worn, or damaged suspension or steering
components.
(4) Inspect brake fluid level:
(a) If vehicle has one-piece master cylinder, fluid
level should be within 6 mm (1/4 in.) of reservoir
rim.
(b) If vehicle has nylon reservoir with single
filler cap, correct level is to FULL mark on side of
reservoir. Acceptable level is between FULL and
ADD marks.
(c) Remember that fluid level in the reservoir
compartments will decrease in proportion to nor-
mal lining wear. However, if fluid level is abnor-
mally low, look for leaks at calipers, wheel
cylinders, brakelines and master cylinder.
(5) Inspect brake fluid condition:
(a) Fluid should be free of foreign material.Note
that brake fluid tends to darken over time.
This is normal and should not be mistaken for
contamination. If fluid is clear of foreign ma-
terial, it is OK.
(b) If fluid is highly discolored, or appears to con-
tain foreign material, drain out a sample with a
clean suction gun. Pour sample in a glass container
and note condition described in step (c).
(c) If fluid separates into layers, obviously con-
tains oil, or a substance other than brake fluid,
system seals and cups will have to be replaced and
hydraulic system flushed.
(6) Check parking brake operation. Verify free
movement and full release of cables and foot pedal or
5 - 4 SERVICE BRAKE DIAGNOSISJ

(5) Connect vacuum hose to brake booster check
valve.
(6) Install master cylinder and combination valve.
(7) Bleed brakes. Then tighten brakeline fittings to
15-18 Nzm (130-160 in. lbs.) at master cylinder and
18-24 Nzm (160-210 in. lbs.) at combination valve.
BRAKE PEDAL REMOVAL
(1) Remove lower trim panel and A/C duct if nec-
essary.
(2) Remove steering column lower trim panel and
bezel.(3) Remove necessary dash panel-to-instrument
panel brace rods.
(4) Disconnect and remove brakelight switch.
(5) Remove retainer clip securing booster push rod
to pedal (Fig. 16).
(6) Remove nut securing pedal shaft in support
bracket.
(7) Slide pedal shaft outward for clearance and re-
move brake pedal (Figs. 28 and 29).
(8) Remove pedal bushings if they are to be re-
placed.
BRAKE PEDAL INSTALLATION
(1) Install new bushings in pedal. Lubricate bush-
ings and pivot pin with Mopar multi mileage grease.
(2) Position pedal, sleeve and spacer(s) in bracket
and install pivot pin.
(3) Install new nut on pivot pin.Pivot pin nut is
specially formed and should not be reused. Be
sure to install new nut to secure pin.
(4) ) Tighten new pivot pin nut to 27 Nzm (20 ft.
lbs.) on models with manual transmission. Tighten
nut to 35 Nzm (26 ft. lbs.) on models with automatic
transmission.
(5) Install booster push rod on pedal pin (Fig. 16).
Secure push rod with original, or new retainer clip if
necessary.
(6) Install and connect brakelight switch.
(7) Install dash brace rod, if equipped.
(8) Install instrument panel and steering column
trim covers.
Fig. 28 Brake Pedal And Support Bracket (YJ)
Fig. 29 Brake Pedal And Support Bracket (XJ)
JPOWER BRAKE BOOSTERÐBRAKE PEDALÐBRAKELIGHT SWITCH 5 - 31