2002 JEEP GRAND CHEROKEE length

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
LUBRICATION & MAINTENANCE
SPECIFICATIONS - FLUID CAPACITIES.......1
INTERNATIONAL SYMBOLS
DESCRIPTION..........................2
PARTS & LUBRICANT RECOMMENDATION
STANDARD PROCEDURE - PARTS &
LUBRICANT RECOMMENDATIONS.........2
FLUID TYPES
DESCRIPTION
DESCRIPTION - ENGINE COOLANT........2
DESCRIPTION - ENGINE COOLANT........3
ENGINE OIL..........................4
DESCRIPTION - ENGINE OIL.............4
DESCRIPTION........................5
DESCRIPTION - TRANSFER CASE - NV242 . . 5
DESCRIPTION - TRANSFER CASE - NV247 . . 5
DESCRIPTION - AUTOMATIC
TRANSMISSION FLUID..................5
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES............................6OPERATION - AUTOMATIC TRANSMISSION
FLUID...............................6
FLUID FILL/CHECK LOCATIONS
INSPECTION - FLUID FILL/CHECK
LOCATIONS..........................6
MAINTENANCE SCHEDULES
DESCRIPTION..........................6
LIFT POINTS
STANDARD PROCEDURE - HOISTING AND
JACKING RECOMMENDATIONS...........6
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . . 7
EMERGENCY TOW HOOKS
DESCRIPTION..........................8
TOWING
STANDARD PROCEDURE - TOWING
RECOMMENDATIONS...................8
LUBRICATION &
MAINTENANCE
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
FUEL TANK 20 U.S. Gallons (76
Liters)****
Engine Oil - with Filter -
2.7L Diesel6.5L (6.9 qts.)
Engine Oil - with Filter -
4.0L5.7 L (6.0 qts.)
Engine Oil - with Filter -
4.7L5.7 L (6.0 qts.)
Cooling System - 2.7L
Diesel14.2L (15 qts.)***
Cooling System - 4.0L 14.1 L (15 qts.)***
Cooling System - 4.7L 13.7 L (14.5 qts.)***
AUTOMATIC TRANSMISSION
Service Fill - 42RE 3.8 L (4.0 qts.)
Service Fill - 545RFE 2WD - 5.2 L (11 pts.)
4WD - 6.2 L (13 pts.)
O-haul Fill - 42RE 9.1-9.5 L (19-20 pts.)
DESCRIPTION SPECIFICATION
O-haul Fill - 545RFE 13.33 L (28.0 pts.)
Dry fill capacity Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or use
of an auxiliary cooler, these figures may vary. (Refer to
appropriate 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC/FLUID - STANDARD PROCEDURE).
TRANSFER CASE
NV242 1.35L (2.85 pts.)
NV247 1.6L (3.4 pts.)
FRONT AXLE   0.3 L (1 oz.)
186 FBI (Model 30) 1.18 L (2.5 pts.)*
* With Vari-Lok add 0.07 L (2.5 oz.) of Friction Modifier.
REAR AXLE   0.3 L (1 oz.)
198 RBI (Model 35) 1.66 L (3.5 pts.)*
226 RBA (Model 44) 2.24 L (4.75 pts.)**
* With Trac-lok add 0.07 L (2.5 oz.) of Friction Modifier.
** With Trac-lok or Vari-Lok, add 0.07 L (2.5 oz.) of
Friction Modifier.
*** Includes 0.9L (1.0 qts.) for coolant reservoir.
****Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
WJLUBRICATION & MAINTENANCE 0 - 1

(10) Start the engine and re-check for vibration. If
there is little or no change in vibration, move the
clamp to one of the other three positions. Repeat the
vibration test.
(11) If there is no difference in vibration at the
other positions, the source of the vibration may not
be propeller shaft.
(12) If the vibration decreased, install a second
clamp (Fig. 2) and repeat the test.
(13) If the additional clamp causes an additional
vibration, separate the clamps (1/4 inch above and
below the mark). Repeat the vibration test (Fig. 3).
(14) Increase distance between the clamp screws
and repeat the test until the amount of vibration is
at the lowest level. Bend the slack end of the clamps
so the screws will not loosen.
(15) If the vibration remains unacceptable, apply
the same steps to the front end of the propeller shaft.
(16) Install the wheel and tires. Lower the vehicle.RUNOUT
(1) Remove dirt, rust, paint, and undercoating
from the propeller shaft surface where the dial indi-
cator will contact the shaft.
(2) The dial indicator must be installed perpendic-
ular to the shaft surface.
(3) Measure runout at the center and ends of the
shaft sufficiently far away from weld areas to ensure
that the effects of the weld process will not enter into
the measurements.
(4) Refer to Runout Specifications chart.
(5) If the propeller shaft runout is out of specifica-
tion, remove the propeller shaft, index the shaft 180É,
and re-install the propeller shaft. Measure shaft
runout again.
(6) If the propeller shaft runout is now within
specifications, mark the shaft and yokes for proper
orientation.
(7) If the propeller shaft runout is not within spec-
ifications, verify that the runout of the transmission/
transfer case and axle are within specifications.
Correct as necessary and re-measure propeller shaft
runout.
(8) Replace the propeller shaft if the runout still
exceeds the limits.
RUNOUT SPECIFICATIONS
Front of Shaft 0.020 in. (0.50 mm)
Center of Shaft 0.025 in. (0.63 mm)
Rear of Shaft 0.020 in. (0.50 mm)
note:
Measure front/rear runout approximately 3 inches (76
mm) from the weld seam at each end of the shaft
tube for tube lengths over 30 inches. For tube lengths
under 30 inches, the maximum allowed runout is
0.020 in. (0.50 mm) for the full length of the tube.
STANDARD PROCEDURES
This procedure applies to both the front propeller
shafts and the rear propeller shaft. To obtain the
front (output) angle on the C/V front propeller shaft,
the inclinometer is placed on the machined ring of
the pinion flange. To obtain the propeller shaft angle
measurement on the C/V front propeller shaft, the
inclinometer is placed on the propeller shaft tube.
PROPELLER SHAFT ANGLE
(1) Raise and support the vehicle at the axles as
level as possible. Allow the wheels and propeller
shaft to turn.
(2) Remove any external bearing snap rings from
universal joint if equipped, so the inclinometer base
will sits flat.
Fig. 2 TWO CLAMP SCREWS
Fig. 3 CLAMP SCREWS SEPARATED
1 - ó INCH
WJPROPELLER SHAFT 3 - 3
PROPELLER SHAFT (Continued)

PROPELLER SHAFT - FRONT
REMOVAL
NOTE: Different length propeller shafts are used for
different drivetrain applications. Ensure that the
correct propeller shaft is used.
(1) Place vehicle on floor or drive-on hoist with full
weight of vehicle on suspension.
(2) Shift the transmission and transfer case, if nec-
essary, into the Neutral position.
(3) Measure the distance from the face of the C/V
joint cup to the end of the C/V joint boot (Fig. 8).
(4) The correct length is 142.7 mm (5.61 in.).
NOTE: If the measurement is not correct, the wrong
shaft may have been installed or a mating compo-
nent (front axle or transfer case) may be installed
incorrectly. Investigate and correct as necessary.
(5) Mark a line across the companion flange at the
transfer case and C/V joint at the rear of the front
propeller shaft for installation reference.
(6) Mark a line across the C/V joints and the pin-
ion companion flanges for installation reference.
(7) Remove bolts from the front C/V joint to the
pinion companion flange.
(8) Remove bolts from the rear C/V joint to the
transfer case companion flange.
(9) Push the propeller shaft forward to clear trans-
fer case companion flange and remove the shaft.
INSTALLATION
NOTE: Different length propeller shafts are used for
different drivetrain applications. Ensure that the
correct propeller shaft is used.
(1) Install the shaft between companion flanges.
(2) The shaft should rotate freely in the pinion
flange.
(3) Align marks on the companion flanges with the
marks on the C/V joints.
(4) Install bolts to the front C/V joint and tighten
bolts to 32 N´m (24 ft. lbs.).
(5) Install the bolts to the rear C/V joint and
tighten bolts to 32 N´m (24 ft. lbs.).
(6) Verify propeller shaft length.
(7) Lower vehicle.
PROPELLER SHAFT - FRONT
4.7L
REMOVAL
(1) Raise and support vehicle.
(2) Remove crossmember/skid plate as necessary to
gain access to the propeller shaft.
(3) Shift transmission and transfer case, if neces-
sary into Neutral.
(4) Mark a line across the yoke at the transfer
case, link yoke and propeller shaft yoke at the rear of
the front propeller shaft for installation reference
(Fig. 9).
(5) Mark a line across the propeller shaft yoke and
pinion shaft yoke for installation reference.
Fig. 8 MEASUREMENT
1 - C/V JOINT CUP
2 - C/V BOOT END
3 - MEASUREMENT
Fig. 9 REFERENCE MARKS ON YOKES
1 - REFERENCE MARKS
3 - 6 PROPELLER SHAFTWJ

(6) Install propeller shaft with installation refer-
ence marks aligned.
(7) Fill differential with gear lubricant.
(8) Install brake rotors and calipers.
(9) Install wheel and tire assemblies.
(10) Lower the vehicle.
COLLAPSIBLE SPACER
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove brake rotors and calipers. Refer to 5
Brakes for procedures.
(4) Mark the propeller shaft and pinion companion
flange for installation reference.
(5) Remove propeller shaft from the pinion com-
panion flange.
(6) Rotate pinion gear a minimum of ten times and
verify pinion rotates smoothly.
(7) Record pinion gear rotating torque with a
torque wrench for installation reference.
(8) Remove pinion nut and washer. Using a short
piece of pipe and Spanner Wrench 6958 to hold the
pinion companion flange.
(9) Remove pinion companion flange with Remover
C-452 and Flange Wrench C-3281.
(10) Remove pinion shaft seal with Remover
7794-A and slide hammer (Fig. 35).
(11) Remove front pinion bearing using a pair of
pick tools to pull the bearing straight off pinion
shaft.NOTE: If bearing becomes bound on the pinion
shaft, lightly tap the end of the pinion gear with a
rawhide/rubber mallet.
(12) Remove the collapsible spacer.
INSTALLATION
(1) Install anewcollapsible preload spacer on pin-
ion shaft.
(2) Install pinion front bearing.
(3) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with an appropriate
installer (Fig. 36).
(4) Install pinion companion flange with Installer
W-162-D, Cup 8109 and Flange Holder 6958.
(5) Install pinion washer and anewnut on the
pinion gear. Tighten the nut to 298 N´m (220 ft. lbs.)
minimum.Do not overtighten.Maximum torque is
500 N´m (368 ft. lbs.).
CAUTION: Never loosen pinion nut to decrease pin-
ion rotating torque and never exceed specified pre-
load torque. If preload torque is exceeded a new
collapsible spacer must be installed.
(6) Using Spanner Wrench 6958, a length of 1 in.
pipe and a torque wrench set at 500 N´m (368 ft. lbs.)
crush collapsible spacer until bearing end play is
taken up (Fig. 37).
(7) Slowly tighten the nut in 6.8 N´m (5 ft. lbs.)
increments until the required rotating torque is
achieved. Measure the rotating torque frequently to
avoid over crushing the collapsible spacer.
(8) Rotate pinion gear a minimum of ten times and
verify pinion rotates smoothly. Check rotating torque
with an inch pound torque wrench. The rotating
torque should be the amount recorded during
removal plus:
²Original Bearings: 0.56 N´m (5 in. lbs.).
Fig. 35 PINION SEAL PULLER
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
Fig. 36 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
WJFRONT AXLE - 186FBI 3 - 39
PINION SEAL (Continued)

PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring gear and pinion are serviced as a
matched set. Nevar replace one gear without replac-
ing the other matching gear.
(1) Raise and support vehicle
(2) Mark pinion companion flange and propeller
shaft for installation alignment.
(3) Remove propeller shaft from pinion companion
flange and tie propeller shaft to underbody.
(4) Remove differential from axle housing.
(5) Place differential case in a vise with soft metal
jaw (Fig. 51).
(6) Remove bolts holding ring gear to differential
case.
NOTE: On Veri-LokTdifferential the side bearing
and oil feed plenum must be removed before
removing the ring gear bolts.
(7) Driver ring gear off the differential case with a
rawhide hammer (Fig. 51).(8) With Spanner Wrench 6958 and a short length
of 1 in. pipe, hold pinion companion flange and
remove pinion nut and washer (Fig. 52).
(9) Remove pinion companion flange from pinion
shaft with Remover C-452 and Flange Wrench
C-3281.
Fig. 50 DIFFERENTIAL CASE BEARING
1 - INSTALLER
2 - HANDLE
Fig. 51 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 52 Pinion Flange
1 - PINION FLANGE
2 - FRONT AXLE
3 - SPANNER WRENCH
WJFRONT AXLE - 186FBI 3 - 45
DIFFERENTIAL CASE BEARINGS (Continued)

(5) Apply a light coating of gear lubricant on the
lip of pinion seal and install seal with an appropriate
installer (Fig. 60).
(6) Install rear pinion bearing and oil slinger/depth
shim onto the pinion shaft with Installer 6448 and a
press (Fig. 61).
(7) Install anewcollapsible spacer on pinion shaft
and install the pinion into the housing (Fig. 62).
(8) Install pinion companion flange, with Installer
W-162-B, Cup 8109 and Spanner Wrench 6958.(9) Install pinion washer and anewnut onto the
pinion gear and tighten the nut to 298 N´m (220 ft.
lbs.).Do not over-tighten.
CAUTION: Never loosen pinion gear nut to decrease
pinion rotating torque and never exceed specified
preload torque. If preload torque is exceeded a new
collapsible spacer must be installed.
(10) Use Flange Wrench 6958, a length of 1 in.
pipe and a torque wrench set at 500 N´m (368 ft. lbs.)
and crush collapsible spacer until bearing end play is
taken up (Fig. 63).
(11) Slowly tighten the nut in 6.8 N´m (5 ft. lb.)
increments until the required rotating torque is
achieved. Measure the rotating torque frequently to
avoid over crushing the collapsible spacer (Fig. 64).
(12) Rotate the pinion a minimum of ten times.
Verify pinion rotates smoothly and check rotating
torque with an inch pound torque wrench (Fig. 64).
Pinion gear rotating torque is:
²Original Bearings: 1 to 2.25 N´m (10 to 20 in.
lbs.).
²New Bearings: 1.7 to 3.4 N´m (15 to 30 in. lbs.).
(13) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
Fig. 60 PINION SEAL
1 - HANDLE
2 - INSTALLER
Fig. 61 REAR PINION BEARING
1 - INSTALLER
2 - OIL SLINGER
3 - PINION GEAR
4 - REAR PINION BEARING
5 - PRESS
Fig. 62 COLLAPSIBLE PRELOAD SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - DEPTH SHIM
5 - REAR BEARING
3 - 48 FRONT AXLE - 186FBIWJ
PINION GEAR/RING GEAR (Continued)

ADJUSTABLE PEDAL SWITCH
REMOVAL
(1) Remove the steering column opening cover
(Fig. 2)(Refer to 23 - BODY/INSTRUMENT PANEL/
STEERING COLUMN OPENING COVER - REMOV-
AL).
(2) Disconnect the electrical connector from the
adjustable pedal switch.
(3) Remove the switch from the steering column
opening cover by squeezing the retaining clips
together and pushing the switch outwards (Fig. 3).
INSTALLATION
(1) Install the switch to the steering column open-
ing cover by pushing the switch inwards seating the
retaining clips to the steering column opening cover
(Fig. 3).
(2) Reconnect the electrical connector to the
adjustable pedal switch.
(3) Install the steering column opening cover (Fig.
2)(Refer to 23 - BODY/INSTRUMENT PANEL/
STEERING COLUMN OPENING COVER - INSTAL-
LATION).
BRAKE LINES
DESCRIPTION
Flexible rubber hose is used at both front brakes,
rear brakes and at the rear axle junction block. Dou-
ble walled steel tubing is used. Double inverted style
and ISO style flares are used on the brake lines.
DIAGNOSIS AND TESTING - BRAKE HOSES
AND LINES
Flexible rubber hose is used at both front and rear
brakes and at the rear axle junction block. Inspect
the hoses whenever the brake system is serviced, at
every engine oil change, or whenever the vehicle is in
for service.
Inspect the hoses for surface cracking, scuffing, or
worn spots. Replace any brake hose immediately if
the fabric casing of the hose is exposed due to cracks
or abrasions.
Also check brake hose installation. Faulty installa-
tion can result in kinked, twisted hoses, or contact
with the wheels and tires or other chassis compo-
nents. All of these conditions can lead to scuffing,
cracking and eventual failure.
The steel brake lines should be inspected periodi-
cally for evidence of corrosion, twists, kinks, leaks, or
other damage. Heavily corroded lines will eventually
rust through causing leaks. In any case, corroded or
damaged brake lines should be replaced.
Factory replacement brake lines and hoses are rec-
ommended to ensure quality, correct length and supe-
rior fatigue life. Care should be taken to make sure
that brake line and hose mating surfaces are clean
and free from nicks and burrs. Also remember that
right and left brake hoses are not interchangeable.
Use new copper gaskets at all caliper connections.
Be sure brake line connections are properly made
(not cross threaded) and tightened to recommended
torque.
Fig. 2 STEERING COLUMN OPENING COVER
REMOVAL/INSTALL
1 - INSTRUMENT PANEL TOP PAD
2 - STEERING COLUMN OPENING COVER
3 - SCREW (3)
Fig. 3 ADJUSTABLE PEDAL SWITCH
1 - RETAINING CLIPS
2 - ELECTRICAL CONNECTION
5 - 8 BRAKES - BASEWJ

OPERATION
The master cylinder bore contains a primary and
secondary piston. The primary piston supplies
hydraulic pressure to the front brakes. The secondary
piston supplies hydraulic pressure to the rear brakes.
The master cylinder reservoir stores reserve brake
fluid for the hydraulic brake circuits.
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER
NOTE: Inspect and repair any external fluid leaks
before performing test.
(1) Start engine and check booster vacuum hose
connections. A hissing noise indicates vacuum leak.
Correct any vacuum leak before proceeding.
(2)
Stop engine and shift transmission into Neutral.
(3) Pump brake pedal until all vacuum reserve in
booster is depleted.
(4) Press and hold brake pedal under light foot
pressure. The pedal should hold firm, if the pedal
falls away the master cylinder or HCU may be faulty
(internal leakage).
(5) Start engine and note pedal action. It should
fall away slightly under light foot pressure then hold
firm. If no pedal action is discernible, power booster,
vacuum supply, or vacuum check valve is faulty. Pro-
ceed to the POWER BOOSTER VACUUM TEST.
(6) If the POWER BOOSTER VACUUM TEST
passes, rebuild booster vacuum reserve as follows:
Release brake pedal. Increase engine speed to 1500
rpm, close the throttle and turn off the engine.
(7) Wait a minimum of 90 seconds and try brake
action again. Booster should provide two or more vac-
uum assisted pedal applications. If vacuum assist is
not provided, some component of the booster is faulty.
POWER BOOSTER VACUUM TEST
(1) Connect vacuum gauge to booster check valve
with short length of hose and T-fitting (Fig. 48).
(2) Start and run engine at curb idle speed for one
minute.
(3) Observe the vacuum supply. If vacuum supply
is not adequate, repair vacuum supply.
(4) Clamp hose shut between vacuum source and
check valve.
(5) Stop engine and observe vacuum gauge.
(6) If vacuum drops more than one inch HG (33
millibars) within 15 seconds, booster diaphragm,
check valve or check valve seal/grommet is faulty.
POWER BOOSTER CHECK VALVE TEST
(1) Disconnect vacuum hose from check valve.
(2)
Remove check valve and valve seal from booster.
(3) Use a hand operated vacuum pump for test.(4) Apply 51-67 kPa (15-20 in.) vacuum at large
end of check valve (Fig. 49).
(5) Vacuum should hold steady. If gauge on pump
indicates vacuum loss the check valve and seal
should be replaced.
Fig. 48 Typical Booster Vacuum Test Connections
1 - TEE FITTING
2 - SHORT CONNECTING HOSE
3 - CHECK VALVE
4 - CHECK VALVE HOSE
5 - CLAMP TOOL
6 - INTAKE MANIFOLD
7 - VACUUM GAUGE
Fig. 49 Vacuum Check Valve And Seal
1 - BOOSTER CHECK VALVE
2 - APPLY TEST VACUUM HERE
3 - VALVE SEAL
5 - 24 BRAKES - BASEWJ
MASTER CYLINDER (Continued)