1977 Jeep Technical Service Bulletin (TSB)

TECHNICAL
BULLETINS/DRBs
77-82
Jeep®
* Technical
Bulletin
Manual
Diagnosis and Repair Bulletins
1977-82
MARCH 1984 U.S.AJCANADA EDITION
8981320465
iQk1 ç
All information and specifications in this manual are based on the latest data
available at the time of publication. American Motors Corporation reserves the
right to discontinue designs or change specifications without notice or
Incurring obligation.
Copyright © 1984, American Motors Sales Corporation. All Rights Reserved.

Litho in U.S.A.
DIAGNOSIS AND REPAIR BULLETIN INDEX
1982 ENGINES-FUEL SYSTEMS-ENGINE ELECTRICAL-COOLING
Subject Problem and Application Bulletin Number Page
An Inoperative Cruise Command Servo on 1981-82 Jeep Vehicles may 1-13-82 82-1
be due to a Cracked or Broken Manifold Vacuum Hose on the Servo.
ServIce Procedures and &R.T. Times for the New Separate Coolant 1-12-82 82-3
Temperature and Intake Manifold Heater EFE Control Switches and
Wire Harness Adapter on 1982, Six-Cylinder Jeep Models, With Fuel
Feedback System Built After February 18, 1982.
The Front Housing of Some 70 and 80 Amp Alternators on 1981-82 1-11-82 82-5
Wagoneer, Cherokee, and Truck Models With Eight-Cylinder Engine and
Air Conditioning may Crack at the Upper Mounting Boss and Cause a
Vibration.
The Pushrods in Some 1981-82 Jeep 258 CID Six-Cylinder Engines Built 1-10-82 82-8
Prior to May 1982, may Disengage From the Rocker Arms Causing
Noise, Backfire, or a Miss.
Normal Exhaust Pulses may Cause the Front Exhaust Pipe Support and 1-09-82 82-9
Mounting Bolt to Vibrate and Produce a Rattling Noise on Some 1982
Wagoneer, Cherokee, and Truck Models With Six-Cylinder Engine and
Autoffiatic Transmission.
Improving Performance of 1982 Jeep Vehicles Being Operated at 1-08-82 82-11

Altitudes Above or Below that which the Engine was Originally
Certified for and Adjusted to.
The Cylinder Head Cover Removaillnstallation Procedures Published in 1-08-82

the 1982 Jeep Technical Service Manual for Six-Cylinder Engines are
incorrect.
The Exhaust Manifold to Front Exhaust Pipe Stud Nuts on 1982 Jeep 1-07-82 82-18
Four-Cylinder Engines Built Prior to February 1982, may Loosen
Causing an Exhaust Noise.
Unnecessary Replacement of Electronic Regulator used with 1981-82 1-04-82 82-19
Jeep Cruise Command Systems.
The Four-Cylinder Engine identification Code information in the 1982 1-05-82 82-21
Jeep Technical Service Manual and 1982 Jeep Service Specifications
Handbook is Incorrect-
The Cruise Command Electronic Regulator may not be Properly 1-03-82 82-fl
Fastened on Some 1982 Wagoneer, Cherokee, and Truck Models.
1982 ENGINES-FUEL SYSTEMS-ENGINE ELECTRICAL-COOLING

Subiect Problem and Application Bulletin Number Page
The Procedure for Replacing the Distributor Vacuum Advance 1-02-82 82-24
Mechanism on 1982 Four-Cylinder CJ Models is incomplett The
Procedure does not Indicate that the Distributor Must be Removed in
Order to Replace the Vacuum Advance Mechanism.
The Cylinder Head-To-Block and Damper Pulley Hub Bolt Torques for 1-01-82 82-25
1982 Four-Cylinder Engines have been Changed.
1982 TRANSMISSION-TRANSFER CASE-CLUTCH-DRIVE SHAFTS

GEARLUBE Type "5" Campaign: original Lubricant Used in T4 and T5 2-10-82 82-26
Transmissions to be Replaced With a New EP Type Lubricant.
Some 1982-83 Wagoneer and Cherokee models with a 380 C1D Eight- 2-09-82 82-28
Cylinder Engine and Automatic Transmission may Develop a Shudder-
Type Vibration That Occurs When the Torque Converter Lockup Clutch
Engagee. The Condition Is Often Compared to Driving Over Toil Booth
Speed Warning Bumps and Occurs After the Third Gear Upshift and
When Road Speed is Approximately 40 mph.
1
1982 TRANSMISSION-TRANSFER CASE-CLUTCH-DRIVE SHAFTS Cont’d.
This Bulletin Supersedes The Manual Transmission and Transfer Case 2-08-82 82-32
Lubricant Specifications Published in Jeep Technical Bulletin Numbers .
2-01-8.2 and 2-06-82 And in the 1982 Jeep Technical Service Manual and
Service SpecificatIons Handbook.
Some Model 208 Transfer Cases Built Prior to April 5, 1982, may 2-07-82 82-34
Develop an Intermittent Clunk Noise that Only Occurs in 4-Wheel Drive
High or Low Range and Primarily When Driving on Pavement.
improper Servicing of the Reverse Gear Shift Rail on 1981-82 Jeep 2-04-82 82-38
T-176 Manual Transmissions Built After June 29, 1981 Beginning with
Lanai Number RGFA-2695.
Difficulty Shifting into and out of Four Wheel Drive on some 1980-82 CJ 2-05-82 52-37
and Scrambler Models with Model 300 Transfer Case.
The Clutch Plate Clearance Specification for Model 721 Automatic 2-03-82 82-39 *
Transmissions with 4 Disc Front Clutches, is incorrect in the 1980-81-82

Jeep Technical Service Manuals and 1980-81-82 Jeep Service
Specifications Handbooks.
Transfer Case Shift Lever Rattles or makes a buzzing noise in Some 3-04-82 82-40
1980-82 CJ and Scrambler Models.
Model 208 and 219 Transfer Cases are Being Unnecessarily Disassembled 2-02.82 82-42
When Only the Input Gear Oil Seal is Replaced.
1982 AXLES-SUSPENSION-BRAKES-STEERING .
Subject Problem and Application BulletIn Number Page
Occasional Suspension Spring Squeaks and a Hard or Stiff Ride on a 3-03-82 82-44
1982 CJ Limited Model may be Caused by Improperly installed
Suspension Spring Retainers.
Disc Brake Caliper Pistons in Some 1976-82 Jeep Vehicles may Develop 342-82 82-45
a Light coating of Rust on the Surface Under the Dust Seal Outboard .
of the Piston Seal.

Service Procedures and 550 Times for Air Adjustable Shock Absorbers 3-01-82 82-47
on 1982 Jeep Wagoneer, Cherokee, and J-10 Truck Models.
1982 WINDSHIELD-WINDOWS-BODY HARDWARE

Revisions Made to Certain Pans Have Improved the Operation of the 5-03-82 82-50
Lock Button and Latch on CJ Models with Metal Doors and Remote .
Door Handles.
Discoloration or Peeling of the Finish Coat on Wood Side Rails 5-02-82 82-53
installed onSome 1981-82 Scrambler and Sportside Truck Models.
Power Windows on Some 1980-82 Wagoneer, Cherokee, and Truck 5-01-82 82-54
Models may make a Scraping, ClIcking Sound when Operated or may
not Open Completely.
1982 BODY!CHASSIS ELECTRICAL

Oil Pressure Gauge Needle Flutters During Engine Operation on Some 8-05-82 62.56
1919-82 CJ and Scrambler Modelt
The Trailer Tow Harness Wires may be Improperly Connected to the 8-04-82 82-57
Receptacle on 1982 Wagoneer and Cherokee Models Equipped with a
Class lii Trailer Tow Package and Built Prior to May 3. 1982.
The Center Horn Button Cap on Some 1981-82 Jeep Vehicles with a 8-03-82 82-59
Sport Steering Wheel may Rattle when Driving Over Bumps.
2
1982 BODY!CHASSIS ELECTRICAL Cont’d
Subject Problem and Application Bulletin Number Pege
Incorrect Radio Speakers may have been Installed in 1982 Wagoneer, 8-02-82 82-61
Cherokee, and truck Models with the Optional Electronically Tuned
Cassette Stereo Radio ETA.
The Cherokee, Wagoneer, and Truck Windshield Wiper Linkage 8-01-82 8243
Removalllnstallatlon Procedures In the 1981-82 Jeep Technical Service
Manual are Incorrect.
1982 PAINT-CORROSION PROTECTION-DECALS-MISC.

Paint Codes and Intermix Formulas for 1983 Jeep Vehicles. 9-04-82 82-65
Hardtop Inner Panel Headliner Touches HardtopOuter Panel on 9-03-82 82-70

Some 1961-82 Scrambler Models Causing a Bun or Flutter Noise.
The Odometer onSome 1981-82 Wagoneer, Cherokee, and Truck 9-02-82 82-72
Models may Generate a High-Pitched Squeaking Noise that Occurs
Only Occasionally and at any Speed.
1982 Jeep Paint Color Names and Code Numbers - Dupont. 9-01-82 82-74
1981 ENGINES
An inoperative Cruise Command Servo on 1981-82 Jeep Vehicles may 1-13-82 82-I
be due to a cracked or broken Manifold Vacuum Hose on the Servo.
The Pushrods in some 1981-82 Jeep 258 CID Six-Cyiinder Engines built 1-10-82 81-1
prIor to May 1982, may disengage from the Rocker Arms causing noise,
backfire, or a miss.
Engine Knock may Recur on Some 1981 Jeep Four-Cylinder Engines 81-4 81-2
even after Carbon Build-Up has been Removed with Jeep Carburetor
and Combustion Area Cleaner,
Six-Cylinder EngIne Cylinder Head Cover - 1981 Jeep Vehicles with 81-3 81-3
Six-Cylinder Engine.
Carbon Knock - 1980-81 Jeep Vehicles With Four-, Six- or Eight- 81-2 81-6
Cylinder Engine.
EngIne Noise Diagnosis - 1981 Jeep CJ Models With Four-Cylinder 811 814
Engine.
Oil Pump Release Relief Valve Plunger - Six-Cylinder Oil Pump - 81-17 81-72
Revision to Service Technical Letter 81-15 Dated May 19, 1981 -
Service Technical Letter - Refer to Service General.
Oil Pump Release Valve Plunger - 1981 Six-Cylinder Engine - Service 81-15 81-74
Technical Letter - Refer to Service General.
Revision to 1981 Six-Cylinder PCV Valve Specifications - Service 81-14 81-15

Additions to Four-Cylinder Engine Identification Codes - ServIce 81-12 81-85
Revision to DAB No. 81-1, Engine Noise Diagnosis, Dated November 27, 81-9 81-88
1980, Filed Under POWER PLANT - Engines - Service Technical Letter
Refer to Service General.
Oil Leak From Distributor Base - 1980-81 Four-Cylinder Engines - 81-9 81-88
Short Oil Pump Attaching Screw Torque Revision - 1981 Six-Cylinder 81-6 81-92
Engines - Service Technical Letter - Refer to Service Generai.
1981 Six-Cylinder Main Bearing Capscrew Torque Revision - ServIce 81-4 81-94
Valve Train Noise - 1981 Six-CylInder Engines Built Prior to Engine 81-1 81-97
Code 008C01 - Service Technical Letter - Refer to Service General.
3
1981 COOLING SYSTEM
Air Conditioning Back Idler Pulley Noise - 1981 California Jeep 81-3 81-8
Cherokee, Wagoneer, and Truck Models Built Prior to
V1N 1 JTNA25N5BTO1SSO2 Equipped With Six-Cylinder Engine and Air
Conditioning
Serpentine Drive Belt - 1981 California Jeep Vehicles With 81-1 81-9
Six-Cylinder Engine, Power Steering, Air Conditioning and 55 or 63.Amp
Alternator.
Six-Cylinder Engine Block Heater - 1981 Jeep Six-Cylinder Engines 81-2 81-10
Equipped With Engine Block Heater and Built Prior to Engine Build
Date Code O1101.
1981 Jeep Six-Cylinder Engine Water Pump and Tempatrol Fan Drive 81-5 81-93
Assembly Usage - Service Technical Letter - Refer to Service
General.
1981 ENGINE ELECTRICAL

The Front housing of some 70 and 80 Amp. Alternators on 1981-82 1-11-82 82-5
Wagoneer, Cherokee, and Truck Models with Eight-Cylinder Engine and
Air Conditioning may crack at the Upper Mounting Boss and cause a
Vibration.
Unnecessary replacement of Electronic Regulator used with 1981-82 1-04.82 82-19

Jeep Cruise Command Systems.
New Voltage Regulator Tester - 1975-81 Jeep Vehicles 81-1 81-12

Revision to DRO 81-1, New Voltage Regulator Tester, Dated June 11, 81-18 81-71
1981, Filed Under POWER PLANT - Engine Electrical - Service
Technical Letter - Refer to Service General. .
1981 FUEL AND EXHAUST SYSTEMS

Catalytic Converter Heat Shield - 1981 California Six-Cylinder 81-3 81-13

Cherokee and Wagoneer Models Built Prior to VIN 1 JCNE15N7BTO331O9
Heated intake Manifold Diagnosis - 1981 Jeep Vehicles With Six- 81-2 81-14
Cylinder Engine.
Altitude Performance Adjustments - 1981 Jeep Vehicles 81-1 81-16
Correction to Carburetor Numbers and Usage - 1981 Jeep CJ Models 81-7 81-90
With Four-Cylinder Engine- Service Technical Letter - Refer to Service
General.
Correction to 1980-81 Cherokee and Wagoneer Fuel Tank Capacity 81-6 81-92
Specification Charts - Service Technical Letter - Refer to Service
General
Fuel Feedback Modules Damaged by Incorrect Battery Cable 81-4 81-94
Connection - 1980-81 Jeep Vehicles Equipped With Fuel Feedback
System - Service Technical Letter- Refer to Service General
1981 CLUTCH-MANUAL TRANSMISSION

improper ServIcing of the Reverse Gear Shift Rail on 1981-82 Jeep 2-04-82 82-36
T-176 Manual Transmissions built after June 29, 1981 beginning with
Serial Number RGFB-2695.
SR4 Four-Speed Manual.Transmisslon Vent - 1980-81 CJ and 81-1 81-17

Scrambler Models with SR4 Four-Speed Manual Transmission.
4
1981 CLUTCH-MANUAL TRANSMISSION Cont’d.
Correction to Clutch Aligning Tool Number - 1980 Jeep Technical 81-8 81-89
Service Manual Supplement and 1980-81 Jeep Technical Service
Manuals Service Technical Letter - Refer to Service General.
Reverse Gear Selector Pivot Pin Service - 1980-81 SR4 Four-Speed 81-4 81-94
Manual Transmission - Service Technical Letter - Refer to Service
General
1981 AUTOMATIC TRANSMISSION

The Clutch Plate Clearance Specification for Model 727 Automatic 2-03.82 82-39
Transmissions with 4 DIsc Front Clutches, is incorrect in the 1980-81-82
TSPRING Type ‘5" Campaign- 2-03-82 81’18
Automatic Transmission Throttre Control Rod Spring and Hitch Pin may
be Improperly Installed - 1981 - Jeep CJ-7, Cherokee, Wagoneer, and
Truck.
Torque Converter Turbine Hub and Transmission Input Shaft Sphnes - 81-2 81-21
1981 Jeep CJ Models With Four-Cylinder Engine and Model 904
Automatic Transmission.
Correction to Automatic Transmission Stall Speed Specifications Chart 81-11 81-86
in 1981 Jeep Technical Service Manual and 1981 Jeep Service
Specifications Handbook - Service Technical Letter - Refer to
Service General.
1981 TRANSFER CASE!QUATRA-TRAC

Transfer Case Shift Lever rattles or makes a buzzing noise in some 3-04-82 81-24
Difficulty Shifting into and out of Four-Wheel Drive on some 1980-82 2-05-82 82-37
CJ and Scrambler Models with Modei 300 Transfer Case.
Chirp Noise Caused by Transfer Case input Gear Thrust Bearing Race 81-2 81-26
or Front Output Shaft Thrust Bearing Races - 1981 Jeep Cherokee,
Wagoneer, and Truck Models with Model 219 Quadra-Trac Transfer
Case Built Prior to June 5, 1981.
Transfer Case Output Shaft Seal Leak Diagnosis - 1980-81 Jeep 81-1 81-27
Vehicles Equipped With Model 219 Quadra-Trac Transfer Case.
Oil Return Channel Access Hole Plug Service - 1980-81 Jeep Model 81-10 81-81
219 Quadra-Trac Transfer Case - Service Technical Letter- Refer to
Service General.
Revision to Part Number In DRB 81-1, Transfer Case Output Shaft Seal 81-10 81-87
Leak Diagnosis, Dated February 23. 1981 and Filed Under CHASSIS
-Transfer Case/Quadra-Trac - Service Technical Letter- Refer to
Service General.
1981 BRAKES-WHEELS-TIRES
Disc Brake Caliper Pistons in Some 1976.82 Jeep Vehicles may 3-02-82 82-45
Develop a Light Coating of Rust on the Surface under the Dust Seal
Outboard of the Piston Seal.
Parking Brake Lever to Equalizer Cable may Contact Transfer Case - 81-1 81-29
19$1 Cherokee, Wagoneer and Truck Models with Six-Cylinder Engine
and Automatic Transmission.
5
1981 STEERING AND SUSPENSION
Power Steering Pressure Test Gauge Adapter Set Tool Number 81-6 81-91
Revision - Service Technical Letter- Refer to Service General.
Front Wheel Alignment Specifications for 1981 CJ Models - Service 81-3 81-95
Technical Letter- Refer to Service General.
1981 BODY GENERAL

1981-82 CJ Metal Door Lock and Latch Service. 5-03-82 81-30

Discoioratlonof Finish Coat on Wood Side Rails - 1981-82 Scrambler 5-02-82 81-33
and Sportside Truck.
Power Windows on 1980-82 Wagoneer, Cherokee, Truck Models 5-01 -82 81-34
may Make Noise When Operated.
Improved Method for Retaining Electrically Operated Tailgate Glass 81-3 81-36
in Lower Channel - 1919-81 Cherokee and Wagoner Models with I
5132-Inch Thick Electrically Operated Tailgate Glass.
1981 Jeep Anti-Corrosion Program - All 1981 Jeep Vehicles. 81-2 81-39
New Inside and Outside Door Handles - 1981 CJ-7 Models With Metal 81-1 81-41
Doors.
Plastic Front Frame Crossmernber Cover Attachment - 1981 CJ 81-16 81-73
Models - Service Technical Letter - Refer to Service General.
1981 BODY ELECTRICAL

Subject Probiem and ApplicatIon Bulletin Number Page
Oil Pressure Gauge Needle Flutters - 1979-82 CJ and Scrambler. 8-5-82 81-44
Center Horn Button Cap On Some 1981.82 Jeep Vehicles may Rattle. 8-03-82 82-59
Cherokee, Wagoneer, Truck Windshield Wiper Linkage R&R Procedures 8-01-82 82-63
In 1981-82 Jeep Manuals are incorrect.
Windshield Wipers inoperative on Low and intermittent Speeds - 81-8 8189
1980-81 Cherokee, Wagoneer and Truck Models - Addition to Windshield
Wiper Service Diagnosis, Page 3T-11 In 1980-81 Jeep Technical Service
Manuals - Service Technical Letter- Refer to Service Generai.
1981 HEATER-AIR CONDITIONING

Air Control Cable Operation - 1978-81 CJ-5 and CJ-7 Modeis 81-1 81-45
Delco Air Conditioning Compressor Mainshaft Rotating Torque 81-16 81-73

Specification - 1981 Jeep Vehicles - Service Technical Letter -
1981 INSTRUMENT PANELS-SEAT ASSEMBLIES

Subject Probiem and Application Bulletin Number Page
The Odometer on Some 1981-82 Wagoneer, Cherokee. and Truck 9-02-82 8 1-46
Models may Generate a High-Pitched Squeaking Noise that Occurs
Only Occasionally and at any Speed.
Drivers Side Front Seat Abrasion - 1981 CJ-7 Models With Padded 81-2 8 1-48
Roil Bar and Shoulder Belt System.
C,JBELT Type "5" Campaign: Incorrect Rear Seat Belts May Have 81-1 81-50
Been installed - 1981 Jeep CJ-5 and CJ-7.
Stationary Center Armrest - 1981 Cherokee, Wagoneer, and Truck 81-2 81-96
Models - Service Technical Letter- Refer to Service General.
6
1981
HEADLINING-HARDTOP ENCLOSURE-EXTERIOR DECALS AND OVERLAYS
Hardtop inner Panel Headliner Touches Hardtop Outer Panel on 9-03-82 81-54
Some 1981.82 Scrambler Models Causing Buzz or Flutter Noise.
Hardtop Squeak Caused by Access Cover Position - 1981 Jeep 81-1 81-56
Scrambler Models Built Prior to VIN 1JXXXXXXXXXO70034 Equipped
with Hardtop.
Sun Roof Giass Frame Seal - 1980-81 Cherokee, Wagoner, and 81-2 81-57
Truck Modeis With Manual Sun Roof.
Fabric Top Kit Components - 1981 Scrambler Models Built 81-17 81-72
Between V1N 1 JXXXXXXXXXO4O711 and VIN 1JXXXXXXXXXD63179
Equipped with Fabric Top and Fabric Doors - Service Technical Letter
- Refer to Service General.
1981 METAL REPAIR-PAINTING-WATER LEAKIWIND NOISE

Hardtop Rear Window Water Leaks - 1981 Jeep Scrambler Models 81-5 81-58
With Hardtop.
1981 Phase-Out11982 Phase-in Program Paint information - 1981 81-4 81-59

1981 Jeep Vehicles.
Paint Peeling Off Road Wheels - 1981 Jeep Vehicles Built Between 81-3 81-62
VIN 1JXXXXXXXXXO15701 and ViN 1JXXXXXXXXXO42000 and Equipped
with Painted - White Road Wheeis.
Water Leak or Wind Noise Recommended Sealing Products - All 81-2 81-63
1980-81 Jeep Vehicles.
Paint Information - Au 1981 Jeep Vehicles. 81-1 81-64
interior Wind Noises - 1980-81 Cherokee, Wagoneer, and Truck 80-3 81-68
Models
1981 SERVICE GENERAL

Revision to Diagnosis and Repair Bulletin 81-1, New Voltage Regulator 81-18 81-71
Tester, Dated June 11, 1981, Filed Under POWER PLANT - Engine
Electrical.
Oil Pump Release Relief Valve Plunger - Six-Cylinder Oil Pump - 81-17 81-72
Revision to Service Technical Letter 81-15 Dated May 19, 1981.
Fabric Top Kit Components - 1981 Scrambler Models Built Between 81-17 81-72
VIN 1JXXXXXXXXXO4O711 and VIN IJXXXXXXXXXO63179 Equipped with
Fabric Top and Fabric Doors.
Plastic Front Frame Crossmember Cover Attachment - 1981 81-16 81-73

CJ Models.
Delco Air Conditioning Compressor Mainshaft Rotating Torque 81-16 81-73
Specification - 1981 Jeep Vehicles.
Oil Pump Release Valve Plunger - 1981 Six-CylInder Oil Pump 81-15 81-74
Revision to 1981 Six-Cylinder PCV Valve Specifications. 81-14 81-75
New Model Information - 1981 Jeep Scrambler. 81-13 81-76

Additions to 1981 Four-Cylinder Engine identification Codes. 81-12 81-85
Correction to Automatic Transmission Stall Speed Specifications Chart 81-11 81-86

In 1981 Jeep Technical Service Manual and 1981 Jeep Service
Specifications Handbook.
Revision to Part Number in ORB 81-1, Transfer Case Output Shaft 81-10 81-87
Seal Leak Diagnosis, Dated February 23, 1981, and Filed Under
CHASSIS - Transfer Case/Quadra-Trac.
7
1981 SERVICE GENERAL Cont’d,.
Subject Probiem and Application BulletIn Number Page
Oil Return Channel Access Hole Plug Service - 1980-81 Jeep Modei 81-10 81-87
219 Quadra-Trac Transfer Case.
Revision to Diagnosis and Repair Bulletin No. 81-1, Engine Noise 81-9 81-88
Diagnosis, Dated November 27, 1980, Filed Under POWER PLANT
- Engines.
Oil Leak From Distributor Base - 1980-81 Four-Cylinder Engines. 81-9 81-88
Windshield Wipers Inoperative On Low and intermittent Speeds - 81-8 81-89
1980-81 Cherokee, Wagoneer, and Truck Models - Addition to
Windshield Wiper Service Diagnosis, Page 3T-11 In 1980-81 Jeep
Technical Service Manuals.
Services Manual Supplement and 1980-81 Jeep Technical Service
Manuals.
Correction to Carburetor Numbers and Usage - 1981 Jeep CJ Models

With Four-CylInder Engine. ai-i 81-90
Water Leaks Caused By Dealer Installed Radio Antenna - 1981 Jeep 81-6 81-91
Vehicles.
Power Steering Pressure Test Gauge Adapter Set Tool Number RevIsion. 81-6 81-91
Specification Charts.
Correction to 1980 Jeep Four-Cylinder Engine Piston Fit information. 81-6 81-92
Short Oil Pump Attaching Screw Torque Specification Revision - 1981 81-6 81-92
Six-Cylinder Engines.
1981 Jeep Six-Cylinder Engine Water Pump and Tempatrol Fan Drive 81-5 81-93
Assembly Usage.
1981 Six-Cylinder Main Bearing Capscrew Torque Revision. 81-4 81-94

Reverse Gear Selector Pivot Pin Service - 1980-81 SR4 Four- 81-4 81-94
Speed Manual Transmission.
Fuei Feedback Modules Damaged By Incorrect Battery Cable 81-4 81-94

System.
Front Wheel Alignment Specifications for 1981 CJ Models. 81-3 81-95
Stationary Center Armrest - 1981 Cherokee, Wagoner, and Truck 81-2 81-96
Models.
Valve Train Noise - 1981 Six-Cylinder Engines Built Prior to Engine 81-1 81.97
Code 00801
1980 ENGINE
Carbon Knock - 1980-81 Jeep Vehicles With Four-, Six-, or Eight- 81-2 80-1
Cylinder Engine.
Six-Cylinder Camshaft Pin Breakage - 1977-80 Jeep Vehicles with 80-3 80-2
Exhaust Manifold to Exhaust Pipe Studs and Nuts - 1980 Jeep 80-2 80-4
Vehicles with Six-Cylinder Engine.
Rear Crossmeniber and Torque Reaction Bracket Reposition - 1980 80-1 80-5
Cl-i Four-Cylinder Equipped Vehicles Built Between VIN J0M93XX009040
and JOM93XXO1 4233
Oil Leak From Distributor Base - 1980-81 Four-Cylinder Engines - 81-9 61-88
Service Technical Letter- Refer to Service General.
8
Subject Problem and Application
1980 ENGINE Cont’d. -
Bulietin Number Page
Correction to 1980 Jeep Four-Cylinder Engine Piston Fit information - 81-6 80-94
Standard Oil Fliter Damaged During Severe Ott-Road Operation - 80-18 80-98
1974-80 Jeep Cherokee-Wagoneer-Truck Models with Six-Cylinder
Engine- Service Technical Letter - Refer to Service General.
Engine Dii Capacity - 1980 Jeep Four-Cylinder Engines - Service 80-13 80-103
Revised Crankshaft Main Bearing Clearance Specifications for 1980 80.11 80-105
Six-Cylinder Engines - Service Technical Letter. Refer to Service
General.
Camshaft Spring Pin Correction - Six-Cylinder Camshaft Pin 80-7 80-109

Breakage on 1977-80 Jeep Vehicles- DRB 80-3 dated Irebruary 4, 1980,
filed under Power Plant - Engines - Service Technical Letter - Refer to
Service General.
Assembling Piston and Connecting Rod - 1980 Four-CylInder Engines 80-6 80-110
-Service Technical Letter - Refer to Service General.
1980 COOLING SYSTEM

Coolant Recovery Return Hose Kinked - 1980 Cherokee, Wagoneer, 80-1 80-6
and Truck Modeis With Six-Cyilnder Engine.

Radiator Hose Clamp Torque Specifications - 1980 Jeep Vehicles - 80-12 80-104
Correct Tempatrol Fan Assembly Storage - 1980 and Prior 80-3 80-113
Jeep Models - Service Technical Letter - Refer to Service General.

Subject Problem and Application Bulletin Number Page -
New Voltage Regulator Tester - 1975-81 Jeep Vehicles. 81-1 81-12
Spark Knock Repair - 1980 49-State Cherokee and J-10 Truck Models 80-2 80-7
with Manual Transmission, 380 CID Engine, and Standard or Heavy-
Duty Cooling.
Fiectric Choke and idle Solenoid Feed Wire Routing - 1980 Jeep 80-1 80-10
Models with Slx-Cyiinder Engine.
Revision to Diagnosis and Repair Bulletin No. 80.6, Exhaust Gas 80-19 80-97
Recirculation EGR System Revision, Dated October 27, 1980, Filed
Under - POWER PLANT - Fuel and Exhaust Systems - Service
Technicai Letter- Refer to Service General.
Two-Stage Power Valve - Carburetor Models 2100 and 2150 - 1978-80 80-16 80-100
Jeep Vehicles- Service Technical Letter- Refer to Service General.
Revised Exhaust Pipe-to-Manifold Fastener Torque Specifications - 80-11 80-105

1980 Four-Cylinder Engines - Service Technical Letter- Refer to Service
General.
Relocation of Safety Certification and Emission Control Labels - 1980 80-1 80-116
Jeep CJ Models - Service Technical Letter - Refer to Service General.

Subject Probiem and Application BulletIn Number Page
Altitude Performance Adjustments - 1968-80 Jeep Vehicles. 80-7 80-11
9
1980 FUEL AND EXHAUST SYSTEMS Cont’d,,
Subject Problem and Appiication Bulletin Number Page
Exhaust Gas Recircuiation EGA System Revision - 1980 49-State 80-6 80-12
Cherokee, Wagoneer, and Truck Models with 360 C1D Engine,
Automatic Transmission, 2.73 or 3.31 Ratio Axles and Standard or
Heavy-Duty Coding System.
Running Change to Four-Cylinder Engine Choke System - 1980 CJ 80-5 80-15

Models with Four-Cylinder Engine.
Fuei Tank Sending Unit Service - 1980 Cherokee and Wagoneer 80-4 80-17
Models Built after December 17, 1979.
Microprocessor ECM Shield - 1980 California CJ Models With Four- 80-3 80-18
Cylinder Engine Built Prior to VIN J0M93AB058103.
Vacuum Diagram Correction to 1980 Jeep Technicai Service Manual - 80-2 80-20
1980 49-State Cherokee and J-10 Truck Models With 360 C1D Eight-
Cylinder Engine, Manual Transmission and Heavy-Duty Cooling.
Exhaust Pipe to Exhaust Manifold Leak - 1980 Six-Cyiinder Equipped 80-1 80-22
Jeep Models.
Correction to 1980-81 Jeep Vehicles Equipped with Fuel Feedback 81-6 81-92
System - Service Technical Letter - Refer to Service General.
Fuel Feedback Modules Damaged by incorrect Battery Cable 81-4 81-94
Connection - 1980-81 Jeep Vehicles Equipped with Fuel Feedback
System - Refer to Service General.

SR4 Four-Speed Manual Transmission Vent - 1980-81 CJ and 81-1 81-11

Scrambier Models with SR4 Four-Speed Transmission.
T-176 Four-Speed Manual Transmission Used in 1980 Four-Cylinder CJ 80-4 80-23

Models Built Batween ViN J0M93AB125578 and VIN J0M938727300
Ciutch Pedal Return Adjustment - 1980 CJ Models With Manual 80-3 80-24
Transmission and Six- or Eight-Cylinder Engine.
T-176 Four-Speed Manual Transmission Shift Problems - 1980 Jeep 80-2 80-25
CJ, Cherokee, and J-10 Truck Models With T-176 4-Speed Manual
Transmission.
inspection of Clutch Housing and Clutch Lever Clearance - 1980 80-1 80-28
Cherokee, Wagoneer, and Truck Models With Manual Transmission
Built Prior to VIN J0D25NN008776.
Correction to Ciutch Aligning Tool Number - 1980 Jeep Technical 81-8 80-93
Service Manual Supplement and 1980-81 Jeep Technical Service
Manuals - Service Technical Letter - Refer to Service General
Manual Transmission Service Technical Letter - Refer to Service
General.
Model T-116 Four-Speed Manual Transmission Released as a 80-2 80-114
Production Option to Model SR-4 4-Speed Manual Transmission - 1980
CJ-7 Models Built With Six-Cylinder Engine and Manual Transmission
- Service Technical Letter -Refer to Service General.

The Ciutch Plate Clearance Specification for Model 727 Automatic 2-03-82 82-39
Transmissions with 4 Disc Front Clutches, is incorrect in the 1980-81-82
Moan or Buzzing Noise From Automatic Transmission When Shifting 80-1 80-31
into Reverse - 1980 Jeep CJ Models With Model 999 Automatic
Transmission Built Prior to Build Date Code 6863.
10
1980 AUTOMATIC TRANSMISSION ConEd.
Speedometer Adapter 0-Ring Seal - 1980 Cherokee, Wagoneer, and 80-12 80-104
Truck Models With Transfer Case Model 208 or 219 - Service Technical
Letter - Refer to Service General.
1980 TRANSFER CASEIQUADRA-TRAC

Transfer Case Shift Lever Rattles or Makes a Buzzing Noise in some 3-04-82 80-33
1980-82 CJ and Scrambler Modela
Difficulty Shifting into and out of Four-Wheel Drive on some 1980-82 2-05-82 82-37
CJ and Scrambler Models with Model 300 Transfer Case.
Transfer Case Drive Sprocket Thrust Washer Noise - 1980 Jeep 80-3 80-35
Cherokee, Wagoneer, and Truck Models with Model 208 Transfer Case.
Transfer Case Output Shaft Seal Leak Diagnosis - 1980-81 Jeep 81-1 80-37
Vehicles Equipped With Model 219 Quadra*Trac Transfer Case.
Transfer Case Shift Lever Rattle - 1980 Cherokee. Wagoneer. and 80-2 80-39
Truck Models With Automatic Transmission.
Transfer Case Shift Lever and Shaft Replacement - 1980 CJ Models. 80-1 80-40
Revision to Part Number In DRB 81-1, Transfer Case Output Shaft Seal 81-10 80-92
Leak Diagnosis, Dated February 23, 1981 and Filed Under CHASSIS
- Transfer Case!Quadra-Trac - Service Technical Letter- Refer to
Service General.
Oil Return Channel Access Hole Plug Service - 1980-81 Jeep Model 81-10 80-92
219 Quadra-Trac Transfer Case- Service Technical Letter - Refer to
Service General.
Revision to Diagnosis and Repair Bulletin No. 80-1, Transfer Case Shift 80-17 80-99
Lever and Shaft Replacement, Dated January 9, 1980, Fiied Under
CHASSIS - Transfer Case/Quadra-Trac - Service Technical Letter
Correction to Quadra-Trac Differentiai End Cap Attaching Screw Torque 80-13 80-103
- 1976 Jeep Technical Service Manual - Service Technical Letter -Refer
to Service General.
Correction to in-Vehicle Torque Bias Check - 1980 Cherokee, 80-4 80-112

Wagoneer, and Truck Models With Model 219 Quadra-Trac Transfer
Case - Service Technical Letter - Refer to Service General.
Part Number Change - Service Technical Letter Number 80-2 Dated 80-3 80-113
November 10, 1979 - Service Technical Letter - Refer to Service General.
Four-Wheel Drive indicator Lamp Operation and Switch Usage - 1980 80-2 80-114
Jeep Cherokee, Wagoneer, and Truck Models With Model 208 or 219
Transfer Case - Service Technical Letter - Refer to Service General.
1980 AXLES-PROPELLER SHAFT

JEEPAXLE Type S" Product Recall Campaign; Rear Wheel Bearing 80-3 80-41
Retainers and Seals May Have Been Assembled improperly - 1979-80
Jeep Cherokee, Wagoneer, and J-10 Truck Models.
80-2 80-45
LJJO1NT Type "S’ Product Recall Campaign: Propeller Shaft U-Joint-to-
Yoke Attaching Dolts and Clamps - 1919-80 Jeep CJ
Revised Procedure for Measuring and Correcting Steering Knuckle Ball 80-1 80-48
Stud Preload - 1980 CJ Models.
80-5 80-111
New Propeller Shaft-to-Yoke Attaching Bolt - All 1980 Jeep Vehicles -
11
1980 BRAKES-WHEEL-TIRES
Disc Brake Caliper Pistons in Some 1976-82 Jeep Vehicles May 3-02-82 82.45
Develop a Light Coating of Rust on the Surface Under the Dust Seal
Outboard of the Piston Seal.
Disc Brake Noise - 1978-79-80 Cherokee, Wagoneer, and Truck 80-1 80-51
Models.
Tire Vibration - 1979-80 131-inch Wheelbase J-10 Truck Models With 80-16 80-100
H18-15, Load Range B, Firestone Town and Country Tires Service
Chrome Wheei Discoloration - 1980 Jeep Models Equipped With 80-10 80-108
Chrome Wheels- Service Technical Letter- Refer to Service General.

Correction to Camber Specifications - 1980 Cherokee, Wagoneer, and 80-4 80-112

Truck Models - Service Technical Letter - Refer to Service General.
1980 BODY GENERAL

Power Windows on some 1980-82 Wagoneer, Cherokee, and Truck 5-01-82 80-52
Models May Make Noise When Operated.
Improved Method for Retaining Electrically Operated Tailgate Glass in 81-3 81-36
Lower Channel - 1979-81 Cherokee and Wagoneer Models with
5/32-inch Thick Electrically Operated Tailgate Glass.
Underbody Spare Wheel Mounting Bar - 1980 Cherokee and Wagoneer 80-2 80-54
Models Built Prior to VIN J0M17NC065724 June 19, 1980.
Soft Top with Metal Door Fit - 198 CJ Models With Soft Top and 80-1 80-55
Metal Doors.
1980 Cherokee and Wagoneer Bumper Jack - Service Technical Letter 80-9 80-107

Oil Pressure Gauge Needle Flutters during Engine Operation on some 8-05-82 80-56
Power Sun Roof Option - 1980 Wagoneer Limited Modelt 80-8 80-57
instrument Cluster Lens - 1980 CJ-5 and CJ-7 Models. 80-7 80-66
Power Window Operation and Diagnosis - 1980 Cherokee, Wagoneer, 80-6 80-68
and Truck Models Equipped With Power Windows and Built Prior to
VIN J0D15NC053176. -
AMIFM Stereo Radio Option - 1980 CJ-5 and CJ-7 Modeis. 80-5 80-69
Stereo Radio Rear Speakers Missing - 1980 Cherokee Laredo Models 80-4 80-70
Built Prior to V1N JOE1 7NN027333.
JLAMP CAMPAIGN Type "5" Product Recali Campaign: Headlamp 80-3 80-72
Assembly.
Moisture Entering Parking and Front Directional Signal Lamp Assembly 80-2 80-74
- 1976-80 CJ Modeis.
Front Door Wire Router Plates - 1980 Wagoneer, Cherokee and Truck 80-1 80-75
Models With Door Speakert
12
1980 BODY ELECTRICAL Cont’dj
WIndshield Wipers inoperative on Low and Intermittent Speeds - 81-8 80-93

1980-81 Cherokee, Wagoneer and Truck Models - Addition to
Windshield Wiper Service Diagnosis, Page 3T-11 In 1980-81 Jeep
Technical Service Manuals - Service Technical Letter - Refer to Service
General.
Water Leaks Caused By Dealer-installed Radio Antenna - 1981 Jeep 81-6 80-95
VehIcles - ServIce Technical Letter - Refer to Service General.
AM/FM Radio Right to Left Balance Control Adjustment - 1980 Jeep 80-10 80-106
Vehicles - Service Technical Letter- Refer to Service General.
1980 Ci Oil Pressure Gauge - Service Technical Letter - Refer to 80-9 80-107
Service General.
Correction to DRB 80-4, Stereo Radio Rear Speakers Missing, Dated 80-8 80108
February 14, 1980 Filed Under BODY - Body Electrical - Service
Revised Fuse Rating for Cigar Lighter Circuit - 1980 Jeep CJ Models 80-5 80.111
With Four- and Six-Cylinder Engines - Service Technical Letter- Refer
to Service General.
Tape Player Inoperative Caused by Transit Screw - 1980 Jeep Models 80-1 80-116
With AM/FM/Cassette Radio - Service Technical Letter- Refer to
Service General.

Air Control Cable Operation - 1978-81 CJ-5 and CJ-7 Models. 81-1 80-76
1980 HEADLINING-HARDTOP ENCLOSURE-EXTERIOR DECALS AND

OVERLAYS
Sun Roof Glass Frame Seal - 1980-81 Cherokee, Wagoneer, and Truck 81-2 80-77
Models With Manual Sun Roof.
Sun Roof Arm Operator - 1979-80 CJ-7 Models With Type-i Sun Roof 80-2 80-18
New Sun Roof Vinyl Trim Ring - 1980 Cherokee and Wagoneer 80-1 80-79
Models.
Sun Roof Sealer - 1980 Jeep Vehicles - Service Technical Letter - 80-18 80-98
Fiberglass Hardtop interior Appearance - 1980 CJ-7 Models- 80-14 80-102

Service Technical Letter - Refer to Service General,
1980 METAL REPAIR-PAINTING-WATER LEAKIWIND NOISE

Water Leak or Wind Noise Recommended Sealing Products - All 81-2 80-80
Interior Wind Noises - 1980-81 Cherokee, Wagoneer, and Truck 80-3 80-81
Models.
1980 Phase-Outiig8i Phase-in Program Paint information - 1980 Jeep 80-2 80-84
Vehicles.
Paint information - All Jeep Vehicles - 1980 Jeep Vehicles. 80-1 80-88
13
Subject Problem and Application - BulletIn Number Page
Oil Return Channel Access Hole Plug Service - 1980.81 Jeep Model 81-10 80-92
219 Quadra-Trac Transfer Case.
Windshield Wipers inoperative on Low and Intermittent Speeds - 81-8 80-93
1980-81 Cherokee, Wagoneer and Truck Models - Addition to
Windshield Wiper Service Diagnosis, Page 3T-11 in 1980-81 Jeep
Technical Service Manualt
Service Manual Supplement and 1980-81 Jeep Technicai Service
Manuals.
Power Steering Pressure Test Gauge Adapter Set Tool Number 81-6 80-94
Revision.
Specification Charts.
Correction to 1980 Jeep Four-Cylinder Engine Piston Fit Information. 81-6 80-94
Manual Transmission.
Fuel Feedback Modules Damaged By incorrect Battery Cable 81-4 80-96

System.
Revision to Diagnosis and Repair Bulletin No 80-6 - Exhaust Gas 80-19 80-97
Recirculation EGR System Revision, Dated October 27, 1980, Filed
Under Power Plant - Fuel and exhaust Systems.
Sun Roof Sealer - 1980 Jeep Vehicles. 80-18

Standard Oil Filter Damaged During Severe Off-Road Operation - 80-18
1974-60 Jeep Cherokee, Wagoneer, and Truck Models With Six-Cylinder
Engine.
SR4 Four-Speed Manual Transmission Changed for 1980 Models. 80-17

Revision to Diagnosis and Repair Bulletin No. 80-1, Transfer Case Shift 80-17
Lever and Shaft Replacement, Dated January 9, 1980, Filed Under
CHASSIS - Transfer Case/Quadra-Ti-ac.
Two-Stage Power Valve - Carburetor Models 2100 and 2150 - 80-16 80-100
Tire Vibration - 1979-80 131-Inch Wheelbase J-10 Truck Models with 80-16 80-100
H78-15, Load Range B, Firestone Town and Country Tires.
Cracked Coupler Nut on Tow Bars Part Number SF2127000 Ordered 80-15 80-101
From a Jeep PDC Between January 1, 1980 Through May 31, 1980 - Cl
Models.
Fiberglass Hardtop Interior Appearance - 1980 CJ-7 Models. 80-14 80-102

Correction to Quadra-Trac Differential End Cap Attaching Screw Torque 80-13 80-103
- 1976 Jeep Technical Service Manual.
Engine Oh Capacity - 1980 Jeep Four-Cylinder Engines. 80-13 80-103

Radiator Hose Clamp Torque Specifications - 1980 Jeep Vehicles 80-12 80-104
Speedometer Adapter 0-Ring Seal - 1980 Cherokee, Wagoneer, and 80-12 80-104
Truck Models With Transfer Case Model 208 or 219.
Revised Crankshaft Main Bearing Clearance Specifications for 1980 80-11 80-105
Six-Cylinder Enginet
RevIsed Exhaust Pipe-to-Manifold Fastener Torque Specifications - 80-11 80-105

1980 Four-Cylinder Engines.
AM/FM Radio Right to Left Balance Control Adjustment - 1980 Jeep 80-10 80-106
Vehicles.
Chrome Wheel Discoloration - 1980 Jeep Modeis Equipped With 80-10 80-106
Chrome Wheels.
14
1980 SERVICE GENERAL ConEd.
Sub3ect Problem and Application Bulletin Number Page
1980 Cl Oil Pressure Gauge. 80-9 80-107
1980 Cherokee and Wagoneer and Bumper Jack. 80-9 80-107
80-8 80-108
Correction to Diagnosis and Repair Bulletin No. 80-4, Stereo Radio
Rear Speakers Missing, Dated February 14, 1980, Flied Under Body -
Body Electrical.
807 80-109
Camshaft Spring Pin Correction - Six-Cylinder Camshaft Pin
Breakage on 1977-80 Jeep Vehicles - DRB 80-3, Dated February 4, 1980,
Filed Under Power Plant - Engines.
Assembling Piston and Connecting Rod - 1980 Four-Cylinder Engines. 80-6 80-110
80-5 80-111
New Propeller Shaft-to-Yoke Attaching Bolt - All 1980 Jeep
Vehicles.
Revised Fuse Rating for Cigar Lighter Circuit - 1980 Jeep CJ 80-5 80-111
Models With Four- and Six-Cylinder Engines.
80-4 80-112
Correction to in-Vehicle Torque Bias Check - 1980 Cherokee,
Wagoneer, and Truck Models With Model 219 Quadra-Trac Transfer
Case.
Correction to Camber Specifications - 1980 Cherokee, Wagoneer, and 80-4 80-112

Truck Models-
80-3 80-113
Correct Tempatrol Fan Assembly Storage - 1980 and Prior Jeep
Models.
Part Number Change-Service Technical Letter Number 80-2, Dated 80-3 80-113
November 10, 1979.
80-2 80-114
Four Wheel Drive Indicator Lamp Operation and Switch Usage - 1980
Jeep Cherokee, Wagoneer, and Truck Models With Model 208 or 219
Transfer Case.
80-2 80-114
Model T-176 4-Speed Manual Transmission Released as a Production
Option to Model 519-4 4-Speed Manual Transmission - 1980 CJ Models
With Six-Cylinder Engine and Manual Transmission.
80-2 80-115
Revised Clutch Overcenter Spring Removal Procedures - 1979
CJ Models Built After Mid-April.
1980 Jeep Models 80-1 80-116
Tape Player Inoperative Caused By Transit Screw -
AM/FM Cassette Radio.
Relocation of Safety CertifIcation and Emission Control Labels - 1980 80-1 80-116
Jeep Ci Models.
1979 ENGINE
New Timing Chain Assembly and Deflection inspection Procedure - 9-01 79-3
1979 Jeep Vehicles with Eight-Cylinder Engines.
Standard Oil Filter damaged during Severe Off-Road Operation - 80-18 79-82
1914-80 Jeep Cherokee, Wagoneer, Truck Models with Six-Cylinder
Engine- Service Technical Letter - Refer to Service General.
Camshaft Spring Pin Correction - Six-Cylinder Camshaft Pin Breakage 80-7 79-84
on 1977-80 Jeep Vehicles - ORB 80-3 dated February 4, 1980, filed under
Power Plant - Engines - Service Technical Letter. Refer to Service
General.
Compression Pressure Specification Update - 1977-79 Six- and Eight- 9-05 79.94
Cylinder Engines - Service Technical Letter - Refer to ServIce General.
15
1979 COOLING SYSTEM
Correct Tempatrol Fan Assembly Storage - 1980 and Prior Jeep

Modeis - 80-3 80-113
Service Technicai Letter- Refer to Service General.

New Voltage Regulator Tester 81-1 19-4
Tachometer RPM Drop When Operating Cigar Lighter or Backup Lamps 9-04 19-5
- 1979 CJ Models Equipped with a Tachometer.
Oil Pressure Gauges and Sending Unite - All 1979 Ci Models. 9-03 19-6
Ammeter Circuit and Wiring Diagram Revisions - 1918-1979 Wagoner, 9-02 79-8
Cherokee and Truck Models,
Choke Jumper Harness - 1979 Wagoner Cherokee and Truck Models 9-01 19-9
Equipped With a V-a Engine and Electric Choke.
Two-Stage Power Valve- Carburetor Modeis 2100 and 2150 - 1978-80 80-16 79-83
Jeep Vehicles - Service Tethncai Letter - Refer to Service General.
1919 Jeep Models - Severe Engine Spark Knock While Trailer Towing 9-09 79-90
or During Heavy Load Operation - Service Technical Letter - Refer to
Service General.
Service Technical Letter No. 9-02, Dated October 2, 1978- All 1979 Jeep 9-03 79-96
Models- Starter Solenoid With Blade Terminals - Refer to Service
Generai.
Ail 1979 Jeep Models - Starter Solenoid With Blade Terminals - 9-02 79-98
1979 360 CID V-8 Engine Cold Engine Spark Knock- Service Technical 9-01 Revised 19-99
1979 FUEL AND EXHAUST SYSTEMS .
Subject Problem and ApplicatIon Bulletin Number Page
Altitude Performance Adjustments 80-7 79-11
Engine Performance Diagnosis - 1979 Jeep Six and Eight Cylinder 9-07 19-12
Engines.
BASCENS Campaign Type E Product Recail Campaign: Exhaust Gas 9-06 79-14
Recirculating EGR Back Pressure Sensor Replacement and Adjust
ment of idle Mixture Setting Lean idle Drop Specification Change to 50
RPM tot all Six-Cylinder Engines - 1974-79 Jeep Vehicles
Servicing Fuel Tank and Vapor Control System - Expansion of 9-05

Procedures in 1979 Technical Service Manual.
1978-79 Wagoneer and Cherokee 9-04 79-22
Left Rear Quarter Panel Rattle -
Models.
9-03 79-23
inaccurate Fuel Gauge Reading at Empty Caused by incorrect Gas
Tank Sending Unit Calibration - 1979 Cherokee and Wagoneer Modeit
9-02 19-25
Warm Engine Operation - Supplement to Diagnosis and Repair Bulletin
No. 9-01 Dated November 10, 1978 - Some 1979 Jeep Models Built
Before J9X15XX047200 and J9X25XX042459 Equipped With 360-2V
Engine and Automatic Transmission Except Model 46 Trucks J-20.
9-01 79-26
Warm Engine Drlveablllty - AU 1919 Jeep Vehicles Equipped With
380-2V Engines and Automatic Transmissions Except Model 48 Truck
J-20-
9-13 79-88
New Exhaust Manifold Gasket - Eight-Cylinder Engines- Service
16
1979 FUEL AND EXHAUST SYSTEMS ConEd.
1979 Jeep Warm Engine Operation Bulletins- Service Technical Letter- 9-11 79-88
Dashpot Adjustment - Addition to 1979 Jeep Technlcai Service Manual - 9-04 79-95
Engine Operation - Service Technical Letter - Refer to Service 9-04 79-95
General.
1979 CLUTCH*MANUAL TRANSMISSION

improved Procedures for Clutch Overcenter Spring and Clutch Pedal 9-02 79-29
Replacement - 1971-79 CJ Models.
C.JTRANS Campaign Type S Product Recall Campaign; Vehicle May 9-01 79-31
Have incorrect Transmission-to-Transfer Case Gasket - 1979 CJ-5 and
CJ-7 Models Equipped with Manual Transmission.
1979 CJ Model Revised Clutch Linkage Components- Service Technical 9-12 79-87

New Automatic Transmission Forward Clutch Direct Clutch and Oii 9-03 79-34
Pump Assemblies - 1979 Jeep Models With Automatic Transmission.
Fluid Overflow From Automatic Transmission Fill Tube or Vent Tube 9-02 79-35
Caused by Overfill or Vent Tube Restriction - 1977-79 Jeep Models
With Automatic Transmission.
1979 Jeep Technical Service Manual Correction - Automatic 9-01 79-36

Transmission DARS Chart - All 1979 Jeep Models With Automatic
Transmission.
Forward Clutch Piston Center Seal - All Jeep Models With Automatic 9-04 79-98
Transmission - Service Technical Letter - Refer to Service General.
Automatic Transmission Clutch and Band Application Chart - Service 9-03 79-96
1979 TRANSFER CASE!QUADRA-TRAC

Subject Problem and Application Bulletin Number * Page
improved Stick-Slip Correction Procedure - 1973-79 Jeep Vehicles 9-01 79-37

with Quadra-Trac Transfer Case.
All Jeep Models Equipped With Quadra-Trac - Transmission-to-Quadra- 9-02 79-97

Trac 0-Ring Seal - Service Technical Letter- Refer to Service General.
1979 AXLES-PROPELLER SHAFTS

JEEPAXLE Type ‘S" Product Recall Campaign: Rear Wheel Bearing 833 79-39
Retainers and Seals May Have Been Assembled Improperly - 1979-80
Jeep Cherokee, Wagoneer, and J-10 Truck Models.
U-Joint Type "S" Product Recall Campaign Propeller Shaft U-Joint to 80-2 79-43
Yoke Attaching Bolts and Clamps
Rear Axle Housing Cover Service - 1977-79 CJ Models. 9-02 79-48
Revised Ball Stud Preload Correction and Frcnt Wheel Shimmy 9-01 79-47
Procedures - All 1976-79 Jeep Models.
1979 Jeep Technical Service Manual Correction - Service Technical 9-02 19-98
17
Disc Brake Caliper Pistons in Some 1976-82 Jeep Vehicles may Develop 3-02-82 82-45
a Light Coating of Rust on the Surface under the Dust Seal Outboard of
the Piston Seal.
Disc Brake Noise - 197880 Cherokee, Wagoneer, and Truck Models. 80-1 80-51
Brakedrum and Rotor Repair vs. Replacement - All 1976-79 Jeep 9-01 79-48
Vehicles.

Power Steering Gear Repair vs. Replacement - All 1977-79 Jeep 9-01 Revised 79.52
Vehicles Equipped With Power Steering.
BRAMSTER Campaign Type ‘8" Product Recall Campaign: Loose 9-02 79-54
Steering Connecting Rod Adjuster Tube Clamp Bolts - 1979 Jeep CJ-5
and CJ-7 Models Built Between YiN Numbers J9A93EH800007 and
J9F93ECBO1734.
1979 BODY GENERAL

Improved Method for Retaining Electrically Operated Tailgate Glass in 81-3

Lower Channel - 1919-61 Cherokee and Wagoneer Models with
5/32-inch Thick Electrically Operated Tailgate Glass.
Electrical Operated Tailgate Glass to Lower Channel Retention - 1979 9-07 79-59
Cherokee and Wagoneer With 5132-inch Thick Tailgate Glass.
Hood Release Handle Binding or Inoperative - 1979 Wagoneer, 9-06 79-60
Cherokee and Truck Models Built Prior to V1N J9A15NN060233.
Wagoneer Limited. Front Fender Woodgrain Moulding Retention - 9-05 79-62

1978-79 Wagoneer Models With Limited Trim Option.
Tailgate Window Overtravei - 1979 Wagoneer and Cherokee Models 9-04 79-63
Built Prior to J9XXXXX056283.
Windshield Cracking During Extreme Cold Weather - 1978-79 CJ 9-03 79-64

Models Built Prior to J9XXXXHO35319 Toiedo and J9XXXXH8O4O1S
Brampton.
Door Lock and Latch Mechanism Freeze-Up - All 1978-79 Cherokee 9-02
Wagoneer and Truck Models.
1919 Wagoneer, Cherokee, and Truck Plastic Radiator Grille - Early 9-01 79-67
Built 1979 Wagoneer, Cherokee. and Truck Models.
improved Door Rain Shield Rivet - 1979 and Prior Cherokee, Wagoneer 9-11 79-88
and Truck Models - Service Technical Letter - Refer to Service General.
New Latch and Striker Assembly - 1979 Cherokee-Wagoneer-Truck 9-01 79-92

Doors and 1979 Cherokee-Wagoneer Tailgates - Service Technical
Frozen Door Handle Pushbutton Repair - 1978-79 Cherokee,

Wagoneer, 9-06 79-93
and Truck Models - Service Technical Letter- Refer to Service General.
Bronze Tone Tint Damage -CJ*7 Golden Eagle - Service Technical 9-06 79-93
Letter- Refer to Service General.
Roof Rack Moan - 1979 Wagoneer and Cherokee Models - Service 9-05 79-94
18
Oil Pressure Gauge Needle Flutters during Engine Operation on 6-05-82 79-68
some 1979-82 CJ and Scrambler Models.
Moisture Entering Parking and Front Directional Signal Lamp Assembly 80-2 79-69
- 1976-80 CJ Models.
Tailgate Glass Defogger Wire Repair - 1971-19 Wagoneer and Cherokee 9-01 79-70
With Tailgate Glass Repair.
Antenna Splitter Box Relocation - 1979 Cherokee, Wagoneer, and 9-08 79-91
Truck Models With CB Radio - Service Technical Letter - Refer to
Service General.

Heater Diagnosis and Repair - All 1978-79 Jeep Vehicles. 9-01 79-73

Subject Problem and Application Bulietin Number Page
Replacement of Watershield Paper - 1977-19 Cherokee-Wagoneer- 9-10 78-89

Early Built 1979 Cherokee and Wagoneer Models Equipped With a 9-01 79-99
Bench-Style One-Piece Front Seat - Service Technicai Letter - Refer to
Service General.
1979 HEADLINING-HARDTOP-ENCLOSURE-EXTERIOR DECALS AND OVERLAYS

Sun Roof Arm Operator - 1979-80 CJ-7 Hardtop Models with 80-2 79-75
Type I Sun Roof.
1979 METAL REPAIR-PAINTING-WATER LEAKSIWIND NOISE

1979 Phase-Out/1980 Phase-In Program Paint information - 1979 9-04 79-76

Jeep Vehicles.
1979 Silver Anniversary CJ-5 Model Paint Information - 1979 CJ-5 9-03 79-79
Model.
Wind Noise or Water Leaks at Door Glass - 1979 Wagoneer, Cherokee 9-02 79-80
and Truck Models.
Paint Information - All 1979 Jeep Vehicles. 9-01 79-81

Standard Oil Filter Damaged During Severe Off-Road Operation - 80-18 79-82
1974-80 Jeep Cherokee-Wagoneer-Truck Models with Six-Cylinder
Engine.
Two-Stage Power Valve - Models 2100 and 2150 - 1978-80 Jeep 80-16 79-83
Vehicles.

Breakage on 1977-80 .Jeep Vehicles - ORB 80-3, dated February 4, 1980,
lied Under Power Plant - Engines.
19
1979 SERVICE GENERAL Cont’dj
Difficult Starting after Parking Overnight - Expanded Application 80-5 79-86

of DRB 9-03, Power Plant, Fuel and Exhaust Systems.
New Exhaust Manifold Gasket - Eight-Cylinder EngInes. 9-13 79-86
1979 CJ Model Revised Clutch Linkage Components 9-12 79-87
Improved Door Rain Shield Rivet - 1979 and Prior Cherokee, 9-11 79-88
Wagoneer, and Truck Models.
1979 Jeep Warm Engine Operation BulletIns. 9-11 19-88
Replacement of Watershield Paper - 1977-79 Cherokee - Wagoneer 9-10 79-89

-Truck Models.
1979 Jeep Models - Severe Engine Spark Knock While Trailer Towing 9.09 79-90
or During Heavy Load Operation.
Antenna Splitter Box Relocation - 1979 Cherokee Wagoneer, and 9-08 79-91
Truck Models With C.B. Radio.
New Latch and Striker Assembly - 1979 Cherokee . Wagoneer 9-07 79-92
Tailgates. -
Frozen Door Handle Pushbutton Repair -L.. 1976-79 Cherokee, Wagoneer, 9 79-93
and Truck Models. -
Bronze Tone Tint Damage - CJ-7 Golden Eagle. 9-06 79-93
Tire Size Capacity of Swing-Out Spare Tire Carrier - 1976-79 CJ-5 and 9-06 79-93
CJ-7 Models.
Compression Pressure Specifications Update - 1977-79 Six- and Eight- 9-05 79-94
Cylinder Engines.
Root Rack Moan - 1979 Wagoneer and Cherokee Models. 9-05 79-94
Forward Clutch Piston Center Seai - All Jeep Models With 9-04 79-95
Hydramatic Transmission.
Engine OperatIon. 9-04 79-95
Dashpot Adjustment - Addition to 1979 Jeep Technical Service Manual. 9-04 79-95
Automatic Transmission Clutch and Band Application Chart. 9-03 79-96
Service Technical Letter No. 9-02 dated October 2, 1978 - All 1919 9-03 79-96
Jeep Models- Starter Solenoid With Blade Terminals.
Service Technical Letter Number 8-07, dated September 28, 19Th. 9-02 79-97
All 1979 Jeep Models Equipped With Quadra-Trac Tranmission-to-Quadra- 9-02 79-97
Trac 0-Ring Seal.
All 1979 Jeep Models - Starter Solenoid With Blade Terminals. 9-02 79-98
1978 Jeep Owners’ Manual Supplement. 9-02 79-98
1979 Jeep Technical Service Manual Correction. 9-02 79-98
Eariy Built 1979 Cherokee and Wagoneer Models Equipped With a Bench- 9-01 79-99
Style One-Piece Front Seat.
1979, 380 C1D V-8 Engine - Cold Engine Spark Knock. 9-01 79-99
1978 ENGINE

Breakage on 1977-80 Jeep Vehicles - DRB 80-3 dated February 4, 1980,
flied under Power Plant - Engines.
Six-Cylinder Camshaft Pin Breakage - 1917-80 Jeep Vehicles with Six- 80-3 78-1
Cylinder Engine.
20
1978 ENGINE Cont’d.
Oil Leakage At Cylinder Head Cover or Oil Pan Gasket Surface - All 8-03 78-3
1976-1978 Jeep Models.
V-S Engine OH Pressure - New Oil Pressure Relief Spring - 1971-1978 8-02 78-5
V-B Engines in Vehicles With Oil Pressure Gauges.
V.8 Engine OH Consumption - intake Manifold Gasket - All 1978 V-B 8-01 76-6
Engines.
Standard OH Filter Damaged during Severe Off-Road Operation - 80-18 80-98

1914-80 Jeep Cherokee, Wagoneer-Truck Models with Six-Cylinder
Engine - Service Technical Letter- Refer to Service General.
Camshaft Spring Pin Correction - Six-Cyilnder Camshaft Pin Breakage 80-7 80-109
on 1977-80 Jeep Vehicles- DRB-80-3 dated February 4, 1980, Flied
under Power-Plant Engine - Service Technical Letter - Refer to Service
General.
Compression Pressure Specification Update- 1977-79 Six- and Eight- 9-05 78-102
Cylinder Engines - Service Technicai Letter- Refer to Service General.
Engine OH Filters - All Cd Models Equipped With Six-Cylinder Engines - 6-05 78-107
Rocker Arm Pivot Hole Off Center- 1978 Models With V-B Engine - 8-01 78-112
Valve Train Noise - V-8 Engines - Service Technical Letter - Refer to 6-01 78-106
Service General.
1978 COOLING SYSTEM

Radiator Coolant Overflow - 1978 Cherokee, Wagoneer and Truck 8-01 78-7
Models With Air Conditioning or Heavy Duty Cooling.
Correct Tempatrol Fan Assembly Storage - 1980 and Prior Jeep 80-3 80-113

New Voltage Regulator Tester - 1975-81 Jeep Vehicles. 81-1 79-4
Ammeter Circuit and Wiring Diagram Revisions - 1978-1979 Wagoneer, 9-02 78-8
Cherokee, and Truck Models.
Two-Stage Power Valve - Carburetor Models 2100 and 2150 - 1978-80 80-16 79-83
Jeep Vehicles - Service Technical Letter - Refer to Service General. .
Batteries in CJ Models Built After May 16, 1978 - Service Technical 8-05 78-106
Letter- Refer to Service Generai.
Battery Post Contamination - All Models - Service Technical Letter- 8-02 78-111

BASCENS Campaign Type "E" Product Recall Campaign: 8-09 79-14

Exhaust Gas Recirculation EGA Back Pressure Senior Replacement
and Adjustment of idle Mixture Setting Lean idle Drop Specification
Change to 50 RPM for Au Six-Cylinder Engines - 1974-79 Jeep
Vehicles.
21
1978 FUEL AND EXHAUST SYSTEMS ConEd.
Subject Problem and Application Bulletin Number Peg.
Rough or High Engine Idle Speed or Dieseling When Warm Engine is 8-08 78-10
Shut Off - 1976-78 Cherokee, Wagoneer, or Truck Models Equipped
With 360 or 401 C1D Engine and 4V Carburetor.
Left Rear Quarter Panel Rattle - 1978-79 Wagoneer and Cherokee 9-04 78-12
Models.
Emission Components - All 1976-1978 Jeep Models. 8-07 78-13
Gas Tank Sending Unit - 1975-1978 Cherokee and Wagoneer. 8-06 78-18
inability to Obtain W.0T. or Actuate the Choke Unloader - 1978 8-05 78-20
Wagoneer, Cherokee and Truck.
Cold, Hard Starting - 1978 Cherokee and Truck Models With 258 C1D 8-04 78-22
Engine and 2V Carburetor.
California Emission, Carburetion and Tune-up Specifications - Addition 8-03 78-24
To Volume I of the 1978 Technical Service Manuai - 1978 california
Wagoneer, Cherokee and Truck Models With 360 C1D Engine, 2V
Carburetor and Automatic Transmission.
J-SPRING Type S Product Recall Campaign: Addition of Another 8-02 78-26

Accelerator Return Spring - 1918 Jeep Cherokee and Truck Models
With 258 CID Engine and 2V Carburetor Built Between J8XXXXC0000S
and J8XXXXCO31B66.
Possible Hesitation or Stumble on InitIal Acceleration - 1978 8-01 78-28
Wagoneer, Cherokee and Truck Modeis With 380 CuD, V.8 EngIne and
2V Carburetor Except California.
1976 Model BBD - 2V Carburetor - Accelerator Pump Change . Service 8-06 78-105
1978, six-Cylinder Engine Exhaust Manifold - Two Center Lower 8-05 78-106
Attaching Holes May Not Line Up With Cylinder Head Holes- Service
1918 Jeep Technical Service Manual, Volume 1 Correction - Model 2100 - 8-06 78-107
2V Carburetor - Service Technical Letter - Refer to Service General.
Color Coded Spark Plugs - Service Technical Letter - Refer to Service 8-04 18-108
General.
Spark Plug Fuel Fouling at Low Mileage- New Vehicles- ServIce 8-03 18-109

improved Procedures for Clutch Overcenter Spring and Clutch Pedal 9-02 18-29
Replacement - 1911-19 CJ Models.
Model T-150, Three-Speed Manual Transmission With interf low 8-03 78-31
Lubrication System - 1978 CJ Models Built After V1N J8FXXXXO97193.
TRANLUB Campaign Type "5" Product Recall Campaign: Three-Speed 8-02 78-33
Transmission Adapter Plate Seal May Be improperly Seated - 1976,
1977 and 1978 CJ-5, CJ-6 and CJ-1.
Manual Transmission Model T-15A Shift Control Housing Technical 8-01 18-37
Service Manual Correction - 1973-1978 Jeep Technical Service Manual.

Caused by Overf ill or Vent Tube Restriction - 1917-19 Jeep Models
Premature Part Throttle Kickdown - 1918 Wagoneer and Cherokee 8-04 Revised 13-39
Models With V’8 Engine and Automatic Transmission.
22
1978 AUTOMATIC TRANSMISSION ConEd.
Automatic lransmusslon vacuum Moduiator lestung Procedure - All 8-03 78-41
1974-1978 Jeep Models With Automatic Transmission.
Gear Shift Knob Replacement - 1976-1918 Jeep Models With 8-02 78-42
Automatic Transmission.
Transmission Hunting - 1978 Wagoneer, Cherokee and Truck Models 8-01 78-43
With 360 C1D, V-8 and 2V Carburetor Except California.
Automatic Transmission Clutch and Band Application Chart - Service 9-03 79-96
Technicai Letter - Refer to Service General.
Typographical Error - 1977 Technicai Service Manual, Page 7-50 and 8-02 78-111
1978 Technical Service Manual, Page 2C-53 - Service Technical Letter
1978 TRANSFER CASEIQUADRA-TRAC

Subject Problem and Application Bulletin Number Pege
Improved Stick-Slip Correction Procedure 1973-79 Jeep Vehicles With 9-01 78-44
Quadra-Trac Transfer Case
Quadra-Trac With Reduction Unit- Disengages From High Range - 8-01 78-46
1977-78 Jeep Vehicles With Quadra-Trac and Reduction Unit.
1978 Jeep Technical Service Manual Revision - Transfer Case - Service 8-03 18-109
Quadra-Trac Front Output Shaft Sphne Change - Service Technical 8-03 78-110
Quadra-Trac Use When Plowing Snow - Service Technical Letter - Refer 8-03 78-109
to Service General.
1978 AXLES-PROPELLER SHAFT

Rear Axle Housing Cover Service - 1977-79 C.J Models. 9’02 78-48
Revised Bail Stud Preload Correction and Front Wheel Shimmy Pro- 9-01 78-49
cedures - All 1978-79 Jeep Models.
Driveline Noise or Vibration - 1918 Jeep CJ Models Equipped With 8-02 78-50
Warn Selective Drive Hubs M-245 SE2063019 and M-243 SE2063021.
Lubrication - Double Cardan Universal Joint - 1976-1978 Models 8-01 78-51
Except CJ Models With Manual Transmission.
Disc Brake Caliper Pistons in some 1976-82 Jeep Vehicles May Develop 3-02-82 82-45
a Light Coating of Rust on the Surface under the Dust Seal Outboard
of the Piston Seal-
Disc Brake Noise - 1978-80 Cherokee, Wagoneer and Truck Models. 80-1 80-51
Brake Drum and Rotor Repair vs. Replacement - All 1916-19 Jeep 9-01 78-52
Vehicles.
Brake Master Cylinder Push Rod Retainer - 1911-1918 CJ Models With 8-05 76-106
Manual Disc Brakes ‘ Service Technical Letter- Refer to Service
General.
23
Sublect Problem and ApplicatIon Bulletin Number
Power Steering Gear Repair vs. Replacement - Au 1977-79 Jeep 9-01 78-56
Vehicies Equipped With Power Steering.
Rlvnut Replacement - 1977*1978 CJ Models Equipped With Front 8-03 78-58

Stabilizer Bar.
Sport Steering Wheel Repiacement - 1971-1978 Jeep Vehicles EquIpped 8-02 78-60
With Sport Wheel.
CJPOT Type S Product Recall Campaign: Steering Gear Intermediate 8-01 78-61
Shaft Coupling May Have Oversized Serrations - 1978 CJ-5 and CJ-7
Models With Manual Steering.
Power Steerjng Gear Diagnosis - Service Technical Letter- Refer to 8-06 78-105
Service General.
1978 BODY GENERAL

Wagoneer Limited, Front Fender Woodgrain Moulding Retention - 9-05 78-64

1918-79 Wagoneer Models With Limited Trim Option.
Windshield Cracking During Extreme Cold Weather - 1918-79 CJ 9-03 78-65
Models Built Prior to JYXXXXHOS5SI9 Toledo and J9XXXXH8O4O1S
Brampton.
Door Lock and Latch Mechanism Freeze-Up - All 1978-79 Cherokee, 9-02 78-66
Wagoneer and Truck Models.
Wagoneer Limited Trim Package - 1978 Wagoneer Models. 8-02 78-68
Transmission Shift Cover Contacting Floor-pan - 1916, 1971 and 1978 8-01 78-70
Cherokee and Truck Models With 4-Speed Transmission.
Frozen Door Handle Pushbutton Repair- 1978-79 Cherokee, Wagoneer, 9-06 78-101
and Truck Models - Service Technical Letter - Refer to Service General.
1978 Jeep Owner’s Manual Supplement - Service Technical Letter - 9-02 78-104
Refer to $ervioe General.
Canvaa Top Installation - CJ-7 Models Which Previously Had a Factory 8-05 78-106
Installed Hardtop and Rollbar - Service Technical Letter - Refer to
Service General,
1978 Wagoneer Rear Window Reveai Moulding - Service Technical 8-04 78-108

Moisture Entering Parking and Front Directional Signal Lamp Assembiy 80-2 78-71
- 1976-80 CJ Modelt
Tailgate Glass Defogger Wire Repair - 1977-79 Wagoneer and 9-01 78-72
Cherokee With Tailgate Glass Repair.
Electric Tailgate Regulator and Motor Change - 1978 Wagoneer and 8-07 78-74
Cherokee Models With Electrically Operated Tailgate Window.
Windshield Wiper Motor Disassembly and Assembly Procedure 8-06 78-76

Supplementary Technical Service Manual information - 1974, 1975,
1976, 1977 and 1978 Jeep Wagoneer, Cherokee and Truck Models.
CB Radio Antenna and Spiltterbox Adjustment Procedure - All 1978 8-05 78-78
Jeep Models With GB RadIo.
Electric Tailgate Window Regulator Pinion Gear Shaft Loose - 1974, 8-04 78-80
1975, 1976, 1977, and 1978 Wagoneer and Cherokee Models With
Electric Tailgate Window.
Brokep Electrical Connector - Tailgate Window Motor 1974, 1975, 8-03 78-82
1976, 1917 and 1978 WSgoneer and Cherokee Models With Electrically
Operated Tailgate Window.
24
1978 BODY ELECTRICAL ConEd.
Subject Problem and ApplicatIon Bulletin Number Page
CB Radio Antenna and Splitterbox Adjustment Procedure - 1918 8-02 78-64

Wagoneer, Cherokee, and Truck Models With CB Radio.
Cracked Headlamp Bulb - 1977 and 1918 CJ-5 and CJ-7 Models Built 8-01 78-86
Between V1Ns J7XXXXX1O87IS and JBXCXXX013865.

Heater Diagnosis and Repair - All 1978-79 Jeep Vehicles. 9-01 78-88
Heater Core Repair - 1918 Wagoneer, Cherokee, and Truck Models. 8-02 78-90
Heater Noise Moan - 1978 CJ-5 and CJ-7 Models With V-8 Engine. 8-01 78-92
1978 INSTRUMENT PANEL - SEAT ASSEMBLIES

Seat Cover Button Replacement - 1977-1978 Jeep Models With Seat 8-01 78-93
Cover Buttons.
1978 METAL REPAIR-PAINTING-WATER LEAKS!WIND NOISE

Bulletin Number Page
p Subject Problem and Application
Paint information Phase-Out17900 Phase-In Program Supplement - 8-02 78-95

7800 Jeep Vehicles.
Paint information 7800 Phase-Out17900 Phase-in Program - 7800 Jeep 8-01 78-96
Vehicles.

Repiacernent of Watershieid Paper - 1977-79 Cherokee - Wagoneer 9-10 78-100

Truck Models.
Frozen Door Handle Pushbutton Repair - 1978-79 Cherokee, Wagoneer, 9-06 78-101
and Truck Models.
Tire Size Capacity of Swing-Out Spare Tire Carrier - 1916-79 CJ-5 and 9-06 78- 101
CJ-7 Modei&
Compression Pressure Specifications Update - 1977-79 Six and Eight 9-05 78- 102
Cyunder Engines.
1978 Jeep Owners’ Manual Supplement. 9-02 78- 104
Power Steering Gear Diagnosis. 8-06 78-1 05
1978 Model BBD-2V Carburetor - Accelerator Pump Change. 8-06 78-106
1979 CJ-7 Models Equipped With Soft Top. 8-08 78-105
Canvas Top installation - CJ-1 Models Which Previousiy Had a 8-05 78-106
Factory Installed Hardtop and Roll Bar.
Manual Disc Brakes.
Batteries in CJ Models Built After May 16, 1978. 8-05 18-106
25
Valve Train Noise - V-8 Engines. 8-05 18-106
Engine Oil Filters - All CJ Models Equipped With Six-Cylinder Engine. 8-05 78-107
1918 Jeep Technical Service Manual, Volume I Correction - Model 8-05 78-107
2100 2V Carburetor.
1918 8-Cylinder Engine Exhaust Manifold - Two Center Lower Attaching 8-05 78-107
Holes May Not Line Up With Cylinder Head Holes.
1978 Wagoneer Rear Window Reveal Moulding 8-04 78-108
Color Coded Spark Plugs 8-04 78-108
Spark Plug Fuel Fouling at Low Mileage - New Vehicles. 8-03 78-109
1978 Jeep Technical Service Manual Revision - Transfer Case- 8-03 18-109
Quadra-Trac Use When Plowing Snow. 8-03 18-109
Quarda-Trac Front Output Shaft Spline Change. 8-03 78-110
Typographical Error - ion Technical Service Manual, Page 7-50 and 8-02 78-111
1978 Technical Service Manual, Page 2C-53.
Battery Post Contamination - All Models- 8-02 78-111
Correction of Rear Wheel Cylinder Diameter - 1976 Technical Service 8-02 78-111
Manual, Page 9-41 and 1977 Technical Service Manual, Page 9-47.
Rocker Arm Pivot Hole Off Center - 1978 Modeis With V-8 Engines- 8-01 78-112
1977 ENGINE
on 1977-80 Jeep Vehicles- DRB 80-3 dated February 4, 1980, filed under
Power Plant- Engines.
Six*Cyiinder Engine.
Oil Leakage At Cylinder Head Cover or Oil Pan Gasket Surface - All 8-03
1978-1978 Jeep Models.
V-8 Engine Oil Pressure- New Oil Pressure Relief Spring - 1977-1978 8-02 78-5
V-S Engines In VehIcles With Oil Pressure Gauges.
Oil Filter May Contact Right Front Engine Support Cushion During 7-02 77-5
Severe Off-Road Operation - 1978 and 1977 CJ Models With Six’
Cylinder Engine Built Prior to VIN J7XXXXXO249S4.
Connecting Rod Bearing Noise - Early 1977 Models With Six-Cylinder 7-01 77-7
Engine.
Standard Oil Filter Damaged During Severe Off-Road Operation 1974-80 80-18 80-08
Jeep Cherokee, Wagoneer-Truck Models With Six-Cylinder Engine
- Service Technical Letter- Refer to Service General.
on 1977-80 Jeep Vehicles. DRB 80-3 Dated February 4, 1980. Filed Under
Power Plant- Engine-Service Technical Letter- Refer to Service
General
Compression Pressure Specification Update - 1977-79 Six- and Eight- 9-05 77-111
Cylinder Engines - Service Technical Letter - Refer to Service General.
Crankshaft Pilot Bushing- Au Models - Service Technical Letter-Refer 7-07 77-118
to Service General.
26
1977 COOLING SYSTEM
Possible Coolant Leak Due to Punctured Bottom Radiator Tank- 7-01 77-9
Caused by Radiator Being Positioned Too Low - 1977 Wagoneer and
Cherokee Models With V-8 Engine and Power Steering - Built Prior to
VIN J7XXXXXO588SO.
Engine Overheating - 1976-77 CJ-5, CJ-7, Cherokee and Truck Models TB-i 77-11
WIth Six-Cylinder Engine- Built Prior to J7XXXXXOO28O7.
Correct Tempatroi Fan Assembly Storage - 1980 and Prior Jeep 80-3 80-113
Cooling System Thermostat Revision - Service Technical Letter- 7-04 77-122


New Voltage Regulator Tester - 1975-81 Jeep VehIcles. 81-1 81-12

BID Distributor Kit - 1975, 1916 and 1977 Models With BID Ignition 7-05 77-13
System.
Off-Road Driving Lamp Kit- installation and Aiming Procedures - 1977 7-04 77-17
J-10 Truck Models With Golden Eagle Trim Package.
Distributor Sensor Wiring Routing - All 1971 Models. 1-03 77-20
Engine Continues to Run After ignition Switch is Turned Off- Caused 7-02 77-21
by Alternator Feedback - 1976 and 1977 CJ Models With Six-Cylinder
Engine and Delco Alternator Built Prior to VIN J7XXXXXO3BS59.
Distributor Cap Holddown Clip Replacement 1975, 1976 and 1977 - 7-01 77-22
All Models.
Battery Post Contamination-All Models Service Technical Letter - 8-02 77-115

Cruise Command Control Regulators - All 1977 Models With Cruise 7-01 77-118
Command - Service Technical Letter- Refer to Service General.
improved Design Batteries - All 1977 Models - Service Technical 7-02 77-124
Revised Procedure for Storage and Protection of New Vehicle - All 7-02 77-124
1977 Models - Service technical Letter - Refer to Service General. .

BASCENS Campaign Type E Product Recall Campaign: Exhaust Gas TB-02 77-24
Recirculation EGR Back Pressure Senior Replacement and Adjustment
of idle Mixture Setting Lean idle Drop Specification Change to 50 RPM
for all Six-Cylinder Engines - 1974-79 Jeep Vehicles.
Rough or High Engine Idle Speed or Dieseling When Warm Engine 8-08 77-28
is Shut Off - 1976-18 Cherokee! Wagoneer, or Truck Models Equipped
With 360 or 401 C1D Engine and 4V Carburetor.
Gas Tank Sending Unit - 1975-1978 Cherokee and Wagoneer 8-08 77-30
Emission Components - All 1976-1978 Jeep Models. 8-07 71-32
Slow Fuel Fill - 1974, 1975, 1976 and 1977 Wagoneer and Cherokee 7-01 77-37
Models.
Front Exhaust Pipe-to-Exhaust Manifold Attachin9 Nuts - AU 1917 7-07 77-119
27
improved Procedures for Clutch Overcenter Spring and Clutch Pedal 9-02 7740
Replacement 1911-79 CJ Models.
TRANLIJB Campaign Type S’ Product Recall Campaign: Three-Speed 8-02 77-42

Transmission Adapter Plate Seal May Be improperly Seated - 1976,
1977 and 1978 CJ-5, CJ-6 and CJ-7.
Manual Transmission Model T-15A Shift Control Housing Technical 8-01 77-46
Service Manual Correction - 1973-1978 Jeep Technical Service
Manual.
Possible Gear Clash in Second and Third Gear-Caused by Worn 7-08 77-116
inserts in Synchronizer - 1977 CJ Models With T-150 Transmission
- Built Between V1Ns J7XXXXXIO6233 and J7XXXXX1O9229 - Service
Technical Letter - Refer to Service Generai.

Caused by Overfill or Vent Tube Restriction - 1977-79 Jeep Models
Automatic Transmission Vacuum Modulator Testing Procedure - All 8-03 77-48

1974-1978 Jeep Models With Automatic Transmission.
Gear Shift Knob Replacement - 1976-1976 Jeep Models With Automatic 6-02 77-49
Transmission.
improved Forward Clutch Apply Piston Center Seal - All 1977 Models 7-01 77-50
Automatic Transmission Clutch and Band Application Chart-Service 9-03 77-112
Typographical Error - 1977 Technical Service Manual, Page 7-50 and 8-02 77-115
1978 Technical Service Manual, Page 2C-53- Service Technical Letter
Automatic Transmission - Manual Shaft Hex Nut - Early 1977 Models 77-01 77-126
With Automatic Transmission - Service Technical Letter - Refer to
Service General.
1977 TRANSFER CASE!QUADRA-TRAC

improved Stick-Slip Correction Procedure 1973-79 Jeep Vehicles With 9-01 77-51
Quadra-Trac Transfer Case.
Quadra-Trac With Reduction Unit- Disengages From High Range - 8-01 77-53
1977-1978 Jeep Vehicles With Quadra-Trac and Reduction Unit.
Quadra-Trac Drive Chain Replacement - 1973 Through 1977 Wagoneer, 7-01 77-55
Cherokee and Truck Models and 1976 and 1977 CJ-7 Models With
Quadra-Trac Transfer Case.
Automatic Transmlsslon-to-Quadra-Trac Installation - All Models 7-08 77-116
With Automatic Transmission and Quadra-Trac- Service Technical
Ouadra-Trac Front Cover-to-Case Gasket - All Models With Quadra- 7-08 77-117
Trac - Service Technical Letter - Refer to Service General.
Quadra-Trac Chain Tension Measurement* Service Technical Letter - 7-05 77-121

28
1977 AXLES-PROPELLER SHAFTS
Rear Axle Housing Service - 1977-79 CJ Models 9-02 77-56
Lubrication - Double Cardan Universal Joint - 1976-1978 Models 8-01 77-51

Except CJ Models With Manual Transmission-
Front Propeller Shaft May Contact Starter Motor During Severe Off- 7-01 77-58
Road Operation - 1977 Cherokee and Truck Models With Six-Cylinder
Engine and Cherokee, Wagoneer and Truck Models With V-S Engine.
Front Axle Application - 1978-77 Cherokee and J10 Truck Models. TB-i 77-60
Wheel Lug Studs Of f Center In Rear Axle Shaft Flange - 1976 and
1911 Wagoneer Cherokee, and Truck Models - Service Technical Letter - 7-05 77-121
Relubabie Propeller Shaft Slipjoints and Spiders - 1971 CJ Models- 7-04 77-122
Warn Lock-O-Matic Hub installation - 1977 Cherokee and J-i0 Truck 7-02 77-124
Models Built Between VINe J7XXXXX021438 and J7XXXXXO31194
- Service Technical Letter - Refer to Service General.
Rear Axle Application - Early 1977 Cherokee, Wagoneer and Truck 77-01 77-126
Disc Brake Caliper Pistons in some 1976-82 Jeep Vehicles May Develop 3-02-82 82-45
a Light Coating of Rust on the Surface under the Dust Seal Outboard
of the Piston Seal.
Brake Drum and Rotor Repair vs. Replacement - All 1976-79 Jeep 9-01 77-61
Vehicles.
Possible Brake Drag - Caused by Brake Pedal Not Returning Fully 7-01 77-65
When Released - 1976 and 1977 CJ Models Equipped With Manual
Drum Brakes and Manual Transmission Built Prior to VIN
J7XXXXX042579.
Manual Disc Brakes - Service Technical Letter- Refer to Service .
General.
Correction of Rear Wheel Cylinder Diameter - 1976 TechnIcal Service 8-02 17-115
Manual, Page 9-41 and 1977 Technical Service Manual, Page 9-47
-Service Technical Letter - Refer to Service General.

Power Steering Gear Repair vs. Replacement All 1977-79 Jeep 9-01 77-66
-
-
Vehicles Equipped With Power Steering.

Rivnut Replacement - 1971-78 CJ Models Equipped with Front 8-03 77-68
Stabilizer Bar.
Sport Steering Wheel Skirt Replacement 1977-78 Jeep Vehicles 77-70

EquIpped 8-02
With Sport Steering Wheel.
Momentary Delay in Power Steering Assist During Cold Start-Up - 7-01 77-71
All 1975, 1976 and 1977 Models With Power Steering.
7-07 17-118
Vibrations- Mechanical and Audible - All Jeep Vehicles-Service
1977 BODY GENERAL
Transmission Shift Cover Contacting Floor-pan - 1916, 1977, and 8-01 7172
1978 Cherokee and Truck Models With 4-Speed Transmission.
Body-to-Rear Wheelhouse Strainer Pulled Loose - 1976 and 1977 CJ 1-06 71-73
Models With Hardtop Enclosure.
Water Leak Around Liftgate Hinges- Caused By Loose Hinges - 1977 7-05 77-14
CJ-7 Models With Hardtop Enclosure Built Prior to ViN J1XXXXX053859.
Seized or Binding Windshieid, Door, or Tailgate Hinges - Caused by TB-2 77-75
Rust or Corrosion - 1976 and 1977 CJ-5 and CJ-7 Models Built Prior to
VIN J7XXXXXO1451O. -
Jeep Vehicles With Snow PiowlWinch Overheating at Highway Speeds 7-02 71-125
- 1977 Models Service Technical Letter- Refer to Service General.
- 1977 BODY ELECTRICAL

Moisture Entering Parking and Front Directional Signal Lamp Assembly 80-2 7777
- 1976-80 CJ Models.
Tailgate Glass Defogger Wire Repair - 1977-79 Wagoneer and Cherokee 9-01 77-78
With Tailgate Glass Repair. -
Windshield Wiper Motor Disassembly and Assembly Procedure 8-06 77-80

Supplementary Technical Service Manual information - 1974, 1975,
1976, 1977, 1978 Jeep Wagoneer, Cherokee, and Truck Models. -
Electric Tailgate Window Regulator Pinion Gear Shaft Loose- 8-04 17-82
Broken Electrical Connector - Tailgate Window Motor - 1974-78 8-03 77-84
Wagoneer and Cherokee Models with Electrically Operated Tailgate
Window. -
Cracked Headlamp Bulb - 1977 and 1978 ëJ-5 and CJ-7 Models Built 8-01 17-86
Between VINs J6XXXXX1OS71S and JSXXXXXO13665. -
Off-Road Driving Lamp Kit - Installation and Aiming Procedures - 7-04 71-87
1977 J-10 Truck Models With Golden Eagle Trim Package.
Citizens Band CB Mobile Radio and Antenna Diagnosis Procedure - 7-01 77-90
1976 and 1977 Models.
Replacement of Off-Road Driving Lamp Kit - 1977 J-10 Truck Models 7-08 11-116
With Golden Eagle Trim Package - Service Technical Letter- Refer to
Service General.

Air Conditioning System Not Cooling Caused by Obstruction in Suction TB-i 77-94
Hose - Late 1976 Models and Early 1977 Models Built Prior to V1N
J7XXXXXO1 5089 Equipped With Air Conditioning.

Seat Cover Button Replacement - 1977-1978 Jeep Models With Seat 8-01 77-95
Cover Buttons.
Truck Models - Service Technical LetterS Refer to Service General.
Rear Seat Retaining Strap - 1977 Wagoneer and Cherokee Models- 7-04 71-122
1977
HEADLINING-HARDTOP ENCLOSURE-EXTERIOR DECALS AND OVERLAYS
Cracks or Tears in Door Exterior Sheetmetal - 1976 and 1977 CJ-7 7-07 77-97
Models With Hardtop Enclosure.
Whitco Top Loose at Front Former Caused by Insufficient Stitching 7-04 77-101
at Front Edge of Top or Screws Loose in Front Former - 1976-1977 CJ
Models Built Prior to VIN J7XXXXX035464.
Rear Headlining Sag - 1976 and 1977 Wagoneer and Cherokee 7-03 77-103
Models.
1977 METAL REPAIR-PAINTING-WATER LEAKSIWIND NOISE

Paint information - All 1977 Jeep Vehicles. TB-i 77-104
Golden Eagle Intermix Paint Formulas - 1977 CJ-7 and Truck Models 7-07 77-119
With Golden Eagle Trim Package - Service Technical Letter- Refer to
Service General.
Painted Bumpers - 1977 Cherokee and Truck Models - Service Technical 7-07 77-1 19
Touch-Up Spray Paint identification - 1977 Models - Service Technical 7-02 77-124

Replacement of Watershieid Paper - 1977-79 Cherokee-Wagoneer- 9-10 77-109

Truck Models.
Tire Size Capacity of Rear Swing-Out Spare Tire Carrier - 1976-79 9-06 77-110
CJ-5 and CJ-7 Models.
Compression Pressure Specification Update - 1977-79 Six and Eight- 9-05 77-111
Cylinder Engines.
Automatic TransmIssion Clutch and Band Application Chart 9-03 77-112
Brake Master Cylinder Push Rod Retainer - 1977-78 Cd Models With 8-05 77-113
Manual Disc Brakes.
Typographical Error - 1977 Technical Service Manual, Page 7-50 8-02 77-115
and 1978 Technical Service Manual, Page 2C-53.
Battery Post Contamination - All AMC Models. 8-02 77-1 15
Correction of Rear Wheel Cylinder Diameter - 1976 TechnIcal Service 8-02 77-115
Manual, Page 9-41 and 1977 Technical Service Manual, Page 9-47.
Replacement Parts for Off-Road Driving Lamp Kit - 1977 J-10 Truck 7-08 77-116
Models With Golden Eagle Trim Package.
Automatic Transmission-to-Quadra Trac Transmission installation 7-08 77-116
- AU Models With Automatic Transmission and Quadra-Trac.
Possible Gear Clash in Second and Third Gear - Caused by Worn 7-08 77-116
inserts in Synchronizer - 1977 CJ Models With 1-150 Transmission
- Built Between V1N J7XXXXX1O6233 and J7XXXXX1O9229.
Quadra-Trac Front Cover-to-Case Gasket - All Models With Quadra- 7-08 77-117
Trac.
Vibrations Mechanical and Audible - All Jeep Vehicles. 7-07 77-118
Crankshaft Pilot Bushing - All Models. 1-07 77-118
Cruise Control Regulators - All 1977 Models Equipped With Cruise 7-07 77-118
Command.
Front Exhaust Pipe-to-Exhaust Manifold Attaching Nuts - All 1971 7-07 77-119
Models.
31
Painted Bumpers - 1977 Cherokee and Truck Models. 707 77-119
Golden Eagle Intermix Paint Formulas - 1977 CJ and Truck Models 7-07 77-119
With Goiden Eagle Trim Package.
Golden Eagle Trim Package - 1977 J*10 Truck Model. 7-06 77-120
Wheel Lug Studs Of f Center in Rear Axle Shaft Flange - 1976 and 7-05 77-121
1977 Wagoneer and Cherokee Models.
Quadra-Trac Chain Tension Measurement- 7-05 77-121
Golden Eagle intermix Paint Formula - 1977 CJ Models with Oak 7-05 77*121
Leaf Brown, Code 7E.
Cooling System Thermostat RevIsion. 7-04 77-122
Rear Seat Retaining Strap - 1977 Wagoneer and Cherokee Models. - 7-04 77-1 22
Relubabie Propeller Shaft Slip Joints and Spiders - 1977 Cd Models. 7-04 77-122
Golden Eagle Trim Package - 1917 Cd-S and CJ-7. 7-03 77-123
Improved Design Batteries - All 1977 Models. 7-02 77-124
Revised Procedure for Storage and Protection of New Vehicles. 7-02 77-124
Warn Lock-O-matlc Hub instaiiatlon - 1977 Cherokee and J-10 Truck 7.02 77*124
Models Built Between ViNe J7XXXXX21438 and J7XXXXXO31794.
Touch-up Spray Paint identification. 7-02 77-124
Jeep Vehicles with Snow PiowlWinch Overheating at Highway Speeds. 7-02 77-125
Automatic Transmission - Manual Shaft Hex Nut - Early 1977 Models 7-01 77-126
Rear Axle Brake Application - Eariy Cherokee, Wagoneer and Truck 7-01 77-126
Models.
32
Diagnosis and Repair Bulletin
Subject: Six-Cylinder Camshaft Application: 1977-80 Jeep Vehicles File: POWER PLANT
Pin Breakage With Six-Cylinder Engines Engines
No. 80-3 Feb. 4, 1980
If incorrect valve timing is indicated after checking CAUTION: Do not loosen or disconnect
valve timing, the cause may be a broken camshaft pin, any air conditioning system fittings.
It is no longer necessary to replace the camshaft be- Move the condenser aside as a complete
cause of pin failure. A spring pin is now available as a assembly.
service replacement part. c Remove air conditioning condenser attach
ing bolts and move coüdenser up and out
Service correction involves replacing a broken of way
camshaft pin with a new spring pin. -
6 Remove all drive belts.

The following parts are available and will be
required. 7 Remove crankshaft vibration damper.
8 Remove timing chain cover.
Description Quantity Part No. Group
9 Remove camshaft gear bolt and remove gear
PIN, Sprmg and chain.
Camshaft 1 GM456384 1.040
CAUTION: The following procedural step must be
GASKET SET, performed to prevent the camshaft from damaging
Timing Case Cover 1 8129097 1.121 the rear camshaft plug during pin installation.
SCREW, Hex 10 Remove fuel pump. Insert suitable tool into

Washer Head fuel pump opening and wedge tool against side of
Tapping 1 G448423 17.671 opening and camshaft to prevent camshaft move
ment.
PROCEDURE 11 Inspect damaged camshaft pin.
a If pin is spring pin, remove broken pin
1 Disconnect battery negative cable. by inserting G448423 screw into pin and
carefully pulling pin from camshaft.
2 Drain radiator. b If pin is dowel pin:
CAUTION: Be sure the exact center is
NOTE: Do not waste usable coolant. Collect drained located when center punching the pin.
coolant in a clean container. 1. Center punch pin.
2. Drill through pin center using 5/32-inch
3 Remove fan and shroud. 3. Insert G448423 screw into drilled pin
and carefully pull pin from camshaft.
4 Disconnect overflow hose, radiator hoses and
transmission cooler lines from radiator and remove NOTE: Cover the open oil pan area to
radiator, prevent metal chips from entering the pan.
12 Clean camshaft pin hole of any loose material.

5 If equipped with air conditioning:
a Remove air conditioning belt intermediate 13 Compress replacement spring pin in center
pulley. using vise grips. Carefully drive pin into camshaft
b Disconnect and remove alternator. until it is seated.
S.rvlc. Enqinaring D.portinsnt * 14250 Plymouth Rood * D.trolt, MichIgon 48232

Additional copies of this bulletin are available thmugh your zone office.
CAUTION: If the camshaft moves reanuard, repo- light film of AMC Perfect Seal, or equivalent, on out-
* *sition the tool wedged against the camshaft so that side diameter of seal.
the camshaft cannot move. If the camshaft moves
rearward, damage to the rear camshaft plug may 22 Position tool and seal in front cover opening.
result. Use vibration damper bolt to pull seal into front
14 Install camshaft gear and timing chain. Tighten cover. Turn bolt until tool bottoms against cover.
camshaft gear bolt to 50 foot-pounds 68 N-m
torque. Check valve timing as outlined in 1980 23 Remove tool and install vibration damper on
Jeep Technical Service Manual. crankshaft. Tighten damper bolt to 80 foot-pounds
108 N-m torque.
15 Remove tool wedged in fuel pump opening.
Install fuel pump. Tighten pump bolts to 16 foot- NOTE: If the crankshaft turns before the damper
pounds 22 N.m torque and connect fuel lines. bolt torque value is reached, the damper can be held
from turning by placing two 5/16 X 1-1/2-inch bolts
16 Remove timing case cover seal and clean cover. into the vibration damper front pulley holes and
wedging a bar between them. Rotate the bar until it
contacts the frame member to prevent the damper
17 Position oil pan tab gaskets on oil pan and use
RTV type sealer to hold gasket in place. Coat both from turning.
sides of timing case cover gasket with sealer. Apply 24 If equipped with air conditioning:
j/8.inch 3 mm bead of sealer to joint formed at a Install air conditioning belt intermediate
oil pan and cylinder block. pulley.
b Install alternator.
18 Loosen front four oil pan bolts about 3 turns c Install air conditioner condenser.
to allow oil pan movement during timing case cover
installation. 25 Install drive belts on pulleys.
19 Position timing case cover on engine. Place 26 Install radiator. Connect radiator hoses, trans
timing case alignment tool and seal installer J-22248, mission cooler lines if equipped and fill cooling
in crankshaft opening of cover. system.
20 Install and tighten oil pan and front cover 27 Install fan and shroud.
screws.
28 Follow belt tightening procedure outlined in
NOTE: Tighten 1/4-20 oil pan screws to 7 foot- 1980 Jeep Technical Service Manual.
pounds 9 N-rn torque and 5/16-18 oil pan screws
to .11 foot-pounds 15 Mm torque.
29 Tighten fan assembly nuts to 18 foot-pounds
24 N’m torque.
21 Remove cover aligning tool and position replace
ment oil seal on tool with lip facing outward. Apply 30 Connect battery negative cable.
The following operation and standard work times will apply:
YEAR AND TIME

COST OPERATION SKILL
OPERATION DESCRIPTION MODEL - --
COOE NUMER LEVEL
77 78 79 80
PIN, SPRING CAMSHAfl GEAR

DRIVE- REPLACE 1.040 1163 6-CyL 1.7 1.7 1.7 1.7 0
With Air Conditioning-Md 0.3 03 0.3 0.3
With Power Steering- Add 0.4 0.4 0.4 0.4
Includes 6 minutes helper time.
-
8O-044-O1AJJ
Su bjeet: Oil Leakage at Cylinder Head Cover Application: All 1976-1978 Jeep File: POWER PLANT
or Oil Pan Gasket Surface Models Engines
Group 1.000
No. 8-03 July l, 1978
If oil leaks occur at either the cylinder head cover or oil Procedures for sealing cylinder head covers and oil pans
pan gasket surfaces of the subject vehicles, two methods are published in the appropriate Jeep Technical Service
of sealing may be used. A room temperature vulcanizing Manual. The following chart lists the engine, model,
RTV adhesive such as Gasket-in-a Tube, part number year, Technical Service Manual and page number of the
8993317. or equivalent may be used in place ofagasket; procedures applying to the vehicles involved.
or a gasket coated on both sides with a quick drying
adhesive such as AMC part number 8127960. or
equivalent may be used.
Year and Technical Service Manual Page Number
6 Cyl. Engine
Ci-5 & 7
lA-9 1977 Jeep I .4-9 16-16. Volume I
Cyl. Head Cover
Technical Service
Manual
I A-2 I 1.4-22 18-21, Volume I

Oil Pan
Cherokee
1.4-9 1977 Jeep I .4-9 18-16. volume I
Cyl. Head Cover
Techniesi Service
Manual
IA-Il I 4-22 18-2!. Volume I

Oil Pan
Truck
1.4-91977 Jeep I .4-9 18-16. Volume
Cyl. Head Cover
Technical Service
Manual
I .4-21 IA-22 16-21. Volume I

Oil Pan
3-Cyl. Engine
0-5 & 7
I 6-Il 18-12 lB-Si. Volume I
Cyl. Head Cover
18-24 18-25 I 6-56. Volume I
Oil Pan
Wagoneer
‘B-Il 18-12 lb-SI, Volume I
Cyl. Head COVeT
16-24 18-25 I 6-56. Volume I
Oil Pan
Cherokee 18-51, Volume I
Cyl. Head CoveT I B-Il 18-12
18-25 16.56, Volume I

Oil Pan 18-24
Truck
lB-I 18-12 lB-SI. Volume I
Cyl. Head Cover
18-25 6-56. Volume I
Oil Pan 18-24
OVER
Fl American Motors Sales Corporation

S.rvlc. Englnnrlng D.partm.nt * 14250 Pycncutk Road * Detroit, Michigan 48232
Add;t,onal copies of this bulletin are available through your zone Offtce
.,-, 0
The following operations and standard work times will apply:
WARRANTY YEA R AND I IME
OPERATION SKILL
OPERATION DESCRIPTION REPORTING MODEL
N UMBER 78 LEVEL
CODE 76 77
COVER, CYL. HEAD - RESEAL WITH

RTV 6 Cyl. 1.072 1011 6 Cyl. 0.5 0.5 03 6
. 8 Cyl. One S Cyl. 0.5 0.5 o.s
I
Both S Cyl. 0.7 0.7 0.7
Material Allowance For Sealer is $1.30
Oil Pan - Renal With RTV 6 Cyl. 1,152 A 6 Cyl. 0.8 0.8 0.8 C
8 Cyl. 8 Cyl. 0.8 0.8 0.8
* Material Allowance For Scaler i8 $1.30
PAN, 6 OR 8 CYL. ENGINE OIL - RESEAI.
WITH RTV 1.152 1013 6 I. 0.9 0.9 03 C
8 Cyl. 0.9 0.9 0.9
77.4
Diagnosis and Repair Bulletin No.7-02
May 26, 1977
Subject: Oil Filter May Contact Right Front Engine ApplIcation: 1976 and 19770
Support Cushion During Seven Off-Road Operation MOdels With SIx.Clhider Engine
Built Prior to VIN J7XXXXX024954
This bulletin I. being bused to replace Diagnosis and Repair Bulletin No. 7-05, File: Group 3.000, dated May 18, 1Q77 which
was Incorrectly assigned to the wrong group. Remove and discard DRIJ No. 7-05 from Group 3.000 of your DRII hinder and
Insert the corrected DRB In Group 1.000 of your binder.
ENGINE SUPPORT CUSHION
AND RESTRICTOR PLATE
During severe off-mad operation of some 1976 and 1977
CJ models, built prior to yIN J7XXXXXO249S4, it is
possible that the oil filter may contact the right front
engine support cushion.
Service correction on a complaint basis involves moditing

the right front engine support bracket and installing the
following engine support cushion as necessary.
Cushion,
Engine Support 1 8128488 1.009 OLD SUPPORT CUSHION
Nut. 7/16-14 1 4003975 10.290
PROCEDURE
I Raise vehicle.
2 Remove right front support cushion stud nut and

ENGINE
lockwasher. Discard nut.
CUSHION W/INTERLOCK
3 Remove fuel line clamp from right front support

bracket,
NEW SUPPORT CUSHION
4 Raise and support engine under oil pan skid plate to

provide sufficient clearance for removaL of engine support Fig. 1 Right Front Engine Support Cushion
etishion.
Remove right front support bracket and support

8 Measure 3/4 inch from front edge of support bracket
and scribe a mark Fig. 2.
6 Remove support cushion from support bracket.
a If equipped with a restrictor plate and support 9 Cut off marked edge of bracket. Remove rough
cushion, discard plate and cushion Fig. I. edges.
b If not equipped with a restrictor plate and 10 Install support bracket. Tighten nuts to 37
support cushion has interlock, retain support cushion Fig.
footpounds torque.
11 Install support cushion. Tighten cushion attaching

7 Position support bracket in a vise with support bolts to 37 foot-pounds torque.
cushion mounting holes facing outward.
OVER

Service Engineering Dept. * 14250 Plymouth Rd. * Detroit, MIch. 48232
Additional copies of this bulletin are available through your zone office.
77.5
NOTE: Install support cvshion with interlock positioned 13 Install support cushion replacement nut and
downward see illustration. lockwasher. Tighten nut to 38 foot.pounds torque+
12 Lower engine and remove support. 14 Install flielline clamp to right front support bracket.
3/4 INCH
Fig. 2 Right Front Engine Support Bracket
The following standard operations and work times will apply.
WARRANTY YEAR AND TIME

OPERATION DESCRIPTION REPORTING OPERATION MODEL SKILL
CODE NUMBER 76 77 78 LEVEL
BRAOCET. RIGHT FRONT B’CIP& StflOKf
-MOCIFY 1.004 1207 Ci 0.4 0.4 - G
Includes installing rir front &çport

cushion
776
April iS, 1977
Subjectz Connecting Rod Bearing Nobe Application: Earty 1977 Models With File; Group 1.000
Six-Cylinder Engine
Some six-cylinder engines may produce bearing noise PROCEDURE

which is noticeable either while the engine is idling or
while decelerating from 35-to-is mph with the throttle 1 Drain oil and remove oil pan refer to Section 1A of
closed. the 1977 Technical Service Manual.
The noise may be the result of excessive connecting rod 2 Visually inspect upper end of connecting rod at
bearing clearance which can be caused by one or more of piston pin area to determine that the rod is in the center of
the following conditions: the piston and is not misaligned. If the rod isn’t centered,
it could be bent or the rod may not have been pressed to
* Foreign matter trapped between connecting rod and the center of the pin. A. bent or damaged rod should be
cap mating surfaces. replaced refer to Section lÀ of the 1977 Technical Service
Manual, Check all connecting rods in this manner.
S Incorrect connecting rod cap nut torque.
NOTE: When replacing a bent or damaged rod, always
* Incorrect bearing inserts installed. replace the rod bearing.
* Burrs on back of bearing insert preventing proper 3 Rotate crankshaft until connecting rod is at the
seating of insert to cap. bottom of its stroke.
* Cap misalignment due to undersize bolts. 4 Check connecting rod bolt nut torque to verif’ that it
is within specified range.
* Step at bearing insert mating surface breaking up oil
film. 5 Remove connecting rod bearing cap and bearing
inserts.
In most instances, the above conditions can be corrected
without replacing the bearing inserts by diagnosing and CAUTION: Be careful when rotating crankchaft while
correcting the problem as follows: bearing cap is removed. Connecting rod bolts could
contact the rodjournals and scratch thefinish. A length of
rubber hose installed over the connecting rod bolts will
DIAGNOSIS prevent damage to the journals.
6 Examine connecting rod and cap for the following

Engine Noise At Idle Speed conditions:
a Sharp edges at parting line on inside of bearing
Disconnect spark plug wires, one at a time, using insert.
insulated pliers. When affected cylinder is located, the b Burrs or foreign material on back of bearing
noise will be less noticeable or may stop completely, inserts usually at parting line.
Proceed with repair procedure.
NOTE: Emery cloth may be used to remove burrs or to
CAUTION: On vehicles with catalytic converters, do not smooth the edges of the bearing inserts.
leave a spark plug wire disconnected for more than 30
seconds as damage to the converter could result. 7 Wipe insert bearing surfaces and rod journal clean
with a lint-free cloth and check bearing clearance using
Engine Noise Upon Deceleration Plastigage refer to Section tA of the 1977 Technical
Service Manual.
On a smooth road, accelerate to 35 mph, release the a In most cases, the clearance will now check
accelerator, leave the vehicle in gear, and allow vehicle to within the acceptable range of 0.0010.0.0030 inch.
coast to 25 mph. If noise is apparent, proceed with repair Proceed to step 8.
procedure. OVER

Service Engineering Dept. * 14250 Plymouth Rd. * Detroit. Mich. 48232
77.7
b If clearance is over 0.0030 inch, install new 9 Lubricate beating surface of insert with engine oil
bearing inserts to reduce the clearance to 0.0015-0,0020 and position rod on crankshaft.
inch. Recheck clearances after replacing bearing inserts,
then proceed to step 8. NOTE: When lubricating bearing surfaces. SAE 50 or 40
weight oil iz recommended to help align the rod cap.
NOTE: l3lten required, different-sized upper and lower
bearing inserts may be used as a pair. 10 While holding rod cap, install rod bolt nuts and
tighten finger tight. Alternately tighten nuts to 33
EXAMPLE: A standard size insert may be used in foot-pounds torque.
combination with a 0.001 inch undersized insert to reduce
clearance by 0.0005 inch. Do not use a pair of bearing 11 Install oil pan refer to Section lÀ of the 1977
inserts with a size difference of more than 0. ow inch. Technical Service Manual, Fill crankcase with new oil to
specified level.
8 Check alignment of upper rod bearing insert with
rod. The Standard Servicing Operations and work times as
published in the current SSO Manual are not affected by
this bulletin.
77-8
Diagnosis and Repair Bulletin No.7-01.
February 24. 1977
Subject: Possible Coolant Leak Due to Punctured Application: 1977 Wagoneer and File: Group 2.000
Bottom Radiator Tank -Caused by Radiator Being Cherokee Models With Y-8 Engine
Positioned Too Low and Power Steering - Built Prltr to
YIN_17XXX1XX058859
On some 1977 Wagoneer and Cherokee models, with V-8 9 Connect upper and lower radiator hoses.
engine and power steering, the radiator may be positioned
too low.Under severe conditions the bottom tank may 10 Install flexibletransmissioncoolerlines, if equipped.
contact the overcenter adjusting screw and become
punctured resulting in a coolant leak. 11 Fill radiator with coolant drained in step 1.
When a 1977 Wagoneer or Cherokee, built prior to VIN 12 Check and adjust fluid level of automatic
J7XXXXX058859 is brought in for any type of service the transmission, if equipped.
clearance between the bottom radiator tank and
overcenter adjusting screw should be checked. If the 13 Check cooling system and transmission cooler lines
bottom tank contacts the adjusting screw, the radiator for leaks.
should be repositioned, in accordance with the following
procedure, to obtain proper clearance.
PROCEDURE
Radiator Repositioning
I Drain radiator coolant.
2 Disconnect upper and lower radiator hoses at

radiator.
3 Remove flexible transmission cooler lines, if C

equipped.
-th 3/B INCH
4 Remove radiator and shroud attaching bolts and move
shroud back on top of fan.
5 Remove radiator. Repair bottom tank if necessary

refer to Radiator Bottom Tank Repair Procedure.
/T
DRILL
5/16 INCH
HOLE
4-
1/2 INCH
4 PLACES
6 Measure down 3/8 inch from center of existing DR 1033
mounting holes and centerpunch see illustration.
Radiator Mounting I-tote Relocation
7 Drill four 5/16 inch holes at positions marked in step 4 places
8 Position radiator in vehicle, align shroud and install Radiator Bottom Tank Repair
attaching bolts.
NOTE: It may be necessary to elongate one or more holes 1 Cut a 1 inch square patch from a piece of copper or
for proper alignment. brass shim stock at least 0.040 inch thick.
OVER
PU American Motors Sales Corporation

Service Engineering Dept. * 14250 Plymouth Rd. * Detroit, MIdi. 48232
Additional copios of this bulletin are available through your zone office.
77.9
2 Position radiator in vice with bottom tank up. 5 Position tinned side of patch on tank and apply
enough heat to bond patch to tank.
3 Clean area to be patched thoroughly with a wire brush NOTE: Make sure all edges and corners are contoured to
and if necessary fine grit sandpaper.
tank.
4 Using a 60-40 solder and flux tin area of tank to be 6 Complete patching operation by applying flux and
patched and one side of patch. soldering all four sides.
The following operations and standard work times will apply.

CODE NUMBR 77 78 79 LVEL
RADIATOR-REPOSITION 2.020 2001 WAG. 0.4 - - G
CKE
Radiator Bottom Tank - Repair 2.020 A 0.2 - - G
If equipped with automatic transmission

add 0.1 - - G
77.10
SERVICE
vu Jeep
No. TB 1 7700 Series
3 7600 Series
TECHNICAL Group: 2.000
BULLETIN Date: September 28, 1976
Subject: Engine Overheating- 1976 and 1977 CJ.5, CJ-7, Cherokee and Truck Models With Six.Cylinder
Engine-Built Prior to J7XXXXXOO28O7
ALL JEEP DEALERS
Some of the subject vehicles may have an engine INSPECTION

overheating problem. Overheating is usually caused
by improper belt tension, low coolant level or other Perform the following steps and compare results
cooling system malfunctions. However, some vehi with application chart for standard cooling, heavy
cles built prior to VIN J7XXXXXOO28O7 may have duty cooling or air conditioning.
incorrect cooling system components which will 1 Measure and record diameter of fan. Count
also cause this problem. Vehicles built after this number of fan blades.
YIN number are all equipped with the correct com
ponents as outlined in this bulletin. 2 Count radiator tubes.
3 Count radiator fins-per-inch by placing a piece

If a vehicle is brought in with an overheating of paper against the radiator and marking a line
complaint and the cooling system is functioning 6 inches long. Count the number of fins within the
properly, inspect cooling system as outlined under 6 inch line and divide by 6, this is the number of
inspection and replace any incorrect components. fins per inch.
4 Inspect for fan shroud.
COMPONENT APPLICATION
NOTE: The Radiator Tubes/Fins per Inch columns show the minimum acceptable radiator. If a vehicle has
either more tubes or more fins per inch than shown, do not replace it.
Radiator Shroud Fan Fan Spacer

Type of Model Dia. Number Number Fins Part Part Part
Cooling Inches of Blades of Tubes per Inch Number Number Number
Standard CJ 16.25 4 2 7 no 3224499 no

Cooling Truck 16.25 4 2 7 no 3224499 no
Cherokee 16.25 4 2 7 no 3224499 no
Heavy Ci 15.62 7 2 10 5356475 998795 3213700

Duty Truck 15.62 7 2 10 5355271 998795 3213700
Cooling Cherokee 15.62 7 2 10 5356475 998795 3213700
Air Ci 15.62 7 2 10 5356475 "5357390 3213700

CondiL Truck 15.62 7 2 10 5355271 998795 3213700
tioning Cherokee 15.62 7 2 10 5356475 998795 3213700
A few Ci models with standard cooling were built with a shroud and 7-blade fan. Remove shroud and install
designated 4-blade fan on these models.
"Fan blade part number 5357390 is the same as fan blade part number 998795, except it is notched to provide
proper radiator clearance on Ci models equipped with air conditioning. Part number 5357390 may be used
in place of part number 998795 for all other applications.
Service Publications Department, American Motors Sales Corporation

14250 Plymouth Road * Detroit, Michigan 48232
77-11
Service procedures - 550 times for replacing * On some Ci models the cooling system may be
necessary somponents remain as outlined in the operating properly, have all the correct compo
appropriate Technical Service Manuals and SSO nents, and still have a high reading on the tem
Manual with the following exceptions: perature gauge. For these models only, install
a 2.7 ohm 1 watt resistor in the temperature
When installing the large diameter 4.blade fan sender wire refer to Resistor Installation Proce
on CJ-7 models with automatic transmission it dure. The 2.7 ohm 1 watt resistor is available
will be necessary to relocate the radiator 1/2 inch from most TV and radio repair shops at a cost of
higher to provide sufficient clearance. Refer to approximately $0.18.
Radiator Relocation Procedure.
PROCEDURE
Resistor Installation Ci Models Only Radiator Relocation Ci Models Only
1 Trace wire lead from temperature sending unit to 1 Drain radiator.

wiring harness.
2 Disconnect hoses.
2 Cut wire lead at a point 3 inches from harness.
3 Remove radiator,
3 Thm insulation enough to allow soldering resistor
pigtails. 4 Elongate attaching holes downward 1/2 inch.
4 Solder resistor pigtails between wire leads. 5 Install radiator using bottom of elongated holes
for positioning.
NOTE: Be careful not to overheat resistor wizen
soldering. 6 Connect hoses.
5 Wrap soldered joints using plastic electrical tape. 7 Fill radiator and check for leaks.

RADIATOR MID FM INSPECT FOR

-
INCORRECT COOUNS SYSTEM COMPONENTS 2029 0.1 0.1 - C

Rnistor-Install 3.800 A 0.2 0.2 - C
Radiator-Relocate 2.020 B 0.4 0.4 - C
Subject: BID DIstributor Sensor Kit Application: 1975, 1976, and 1977 File: Group 3.000
Models With BID Ignition System Electrical
No. 7-05 August 10, 1977
A new distributor sensor kit has been developed which 1 Remove distributor cap, rotor and dust shield.
eliminates the possibility of a resistance build-up in the
2-wire connector. The new sensor kit has a 4-wire 2 Remove trigger wheel using a small gear puller fig.
connector which combines the sensor with an ignition 1. Position a thick flat washer or nut as a spacer, between
adapter harness. puller screw and inner shaft. Do not position puller screw
directly on inner shaft.
This new BID sensor kit supersedes sensor part number
8127317 and harness part number 3229757. CAUTION: Be sure puller jaws grip inner shoulder of
trigger wheel or damage to trigger wheel may result.
Dlscription Quantity Part Number Group
3 Remove sensor locking screw.
Kit, BID Sensor 1 8128999 3.038
NOTE; Sensor locking screw has a tamper-proof head,
NOTE: The BID Sensor Kit will be available front your use Special Driver Bit Tool .1-25097 to remove screw. If a
pans distribution center the week ofAugust 22, 1977. Do driver bit is not available. small needlenose pliers may be
not order parts before this date used to remove screw. Replacement screw has a standard
slotted-head.
PROCEDURE
Distributor Sensor Replacement 4 Lift sensor lead grommet out ofdistributor bowl. Pull
sensor leads out of slot around spring pivot pin. Lift and
NOTE: It is not necessary to remove distributor from release sensor spring, making sure it clears leads, then
engine to install sensor kit However, if a distributor is slide sensor off of bracket fig. 2.
removed it should be placed in a suitable holding device.
SENSOR
ASSEMBLY
SENSOR
SUMMING AROUND
BAR PIN
PULLER JAWS MUST

GRIP SHOULDER
Fig. 2 Sensor Removal
Fig. 1 Trigger Wheel Removal OVER
1 American Motors Sales Corporation
Service Engineering Depautment * 14250 Plymouth Road * Detroit, Michigan 48232
Adcj,t,onal copies of this bulletin are availab!e through vow zone office.
77-13
S Install replscement sensor assembly on vacu 16 Seat trigger wheel on yoke using an 11/16 inch deep
ëhamberbracket, making sure that tip of sensor is located well socket and small hammer.
properly in summing bar fig. 2-
NOTE: If distributor has been removed from engine be
6 Install sensor spring on sensor. sure to support distributor shaft when seating trigger
wheeL
7 Route sensor leads around spring pivot pin.
17 Bend 0.050 inch OD wire gauge contained in kit as
CAUTION: Do not use a screwdriver or other sharp tool illustrated in figure 4.
to route leads around spring pivot pin;
18 Check clearance between trigger wheel and sensor
8 Install sensor lead grommet in distributor bowl, base using 0.050 inch OD wire gauge. Trigger wheel
making sure that leads are positioned so they will not get should just touch wire gauge fig. 4.
caught by trigger wheel.
9 Install positioning gauge over yoke against flat side

of yoke. fig. 3.
FLAT SIDE
OF YOKE
POSITIONING
‘GAUGE
SENSOR
Fig. 4 TrIgger Wheel Clearance
19 Apply to S drops of SAE 20 oil to felt wick in top of

yoke.
20 Install dust shield, rotor and distributor cap.
Fig. 3 Sensor Positioning 21 Proceed to applicable wiring procedure.
10 Move sensor sideways until positioned in gauge.

Wiring Procedures
11 Install replacement slotted-head screw. Do not
tighten. Spade Type Coil Tenninals
12 Check sensor position by removing aniI installing

positioning gauge. When sensor is properly positioned 1 Remove nuts and channel washers from coil
gauge can be removed and installed without any side terminals and discard.
movement of sensor.
2 Cutoff wire leading to coil negative terminal if patch
13 Remove positioning gauge and tighten retaining harness was not preivously installed. Also cutoff two wires
screw. Tighten screw to S to 10 inch ounces torque. previously connected to sensor.
14 Install trigger wheel, do not press into position. NOTE Cut wires flush with harness wrapping. It is
not necessary to tape cut wire ends.
15 Check position of sensor core to be sure it is
positioned approximately in center of trigger wheel legs 3 Cut terminal ends from wires previously attached to
and that legs do not touch sensor core. coil positive terminal.
77-14
4 Turn ignition switch to run position. With a NOTE: Be sure wires are muted away from spark plug
voltmeter or test lamp, determine which wire removed wires and are secured so as not to contact drive belts or
from positive terminal has voltage. pulleys.
5 Cutoffwire that does not have voltage. Cut wire flush 15 Fill unused 4-wire connector with Gasket-in-a-Tube
with harness wrapping. Sealer, part number 8993317, or equivalent.
6 Cutoff ground wire that was attached to coil bracket

or alternator. Push-On Type Coil Terminals
7 Turn ignition switch off. 1 Disconnect wires from coil terminals and capacitor.
8 Attach harness wire with female bullet connector to 2 Connect male bullet terminal of sensor harness into
coil wire that had voltage and solder connection. female bullet connector of capacitor wire Fig. 6,
NOTE: Do not use acid core solder or acid flux on solder

joints. Use rosin core solder or rosin flux only.
9 Wrap soldered joint with 3M electrical tape or

equivalent.
10 Remove capacitor attaching screw and cutoff spade

terminal.
II Attach harness wire with male bullet connector and

solder connection if applicable. Wrap soldered joint with
electrical tape.
12 Connect capacitor, connect push-on connectors to
coil terminals and connect coil feed wire to male bullet
connector on new sensor harness Fig. 5.
FEMALE BULLET
TERMINAL P05 NEG Fig. 6 Sensor Harness With ignition Coil
Push-On Terminals
BULLET
COIL FEED TERMINAL
WIRE
3 Connect sensor harness push-on connectors to coil
terminals.
4 Disconnect 4-wire and single wire connector from

control unit.
5 Connect 4-wire and single wire connector of new

sensor harness to control unit.
SOLDER
JOINT
6 Connect ground wire of new sensor harness to coil
bracket.
FIg. 5 Sensor Harness With ignition Coil
Spade Terminals NOTE: Be sure wires are routed away from spark plug
wires and are secured so as not to contact drive belts or
13 Attach capacitor and sensor harness ground wire to pulleys.
coil bracket.
7 Fill disconnected 4’wire connector and coil positive
14 Connect 4-wire connector and plug-in ground lead with Gasket-in-a-Tube, part number 8993317, or
terminal to control unit. equivalent.
77-15
The following standard servicing operations and work times apply:

REPORTING
OPERATION
MODEL SKILL
OPERATION DESCRIPTION
KIT, BID SENSOR INSTALL

- 3.I6 3165 All 0
WITH SPADE COIL TERMINALS A 0.4 0,4 - I
WITHPUSH-ONTERMIPJALS B - 0.3 0.3
77-16
April 21, 1977
Subject: Off-Road Driving Lamp Kit- Installation ApplicatIon: 1977 J-1O Truck
and Aiming Procedures Models With Golden Eagle Trim
Package
This bullctin is being issued to provide the necessary

instructions for installing and aiming the off-road driving
lamp kit used on 1-10 truck models with the Golden Eagle
trim package.
The following off-road driving lamp kit will be shipped

directly from the manufacturer to the dealer for
installation on the vehicle.
Kit, Off-Road
Driving Lamp 1 8997207 15.162
Each kit contains:
Description FIg. 1 Off-Rood Driving Lamp Kit Installed

Qty. Description Qty.
Lamp, 12 volt 2 -Bushing, 2 PROCEDURE

with Cover Strain Relief
-Switch, Rocker 1
Kit, Wiring
Consisting of: - Bracket, Switch 1 1 Position driving lamps on roll bar mounting brackets
and tighten nuts Fig. 1.
- Wire, Black -
-Screw, Bracket 2
6 inches 2 Attach end of 25 ft. yellow wire terminal end to a
- Connector, snake wire.
-Wire, Red 3-Way Butt NOTE: A suitable snake wire can be fabricated by
-
18 inches
6 joining the ends of 3 or 4 lengths of welding rod together.
-Tie, Cable
-Wire, Brown -
Holder, Fuse
-
3 Insert snake wire with yellow wire attached into
12 inches bottom left corner of pick-up box and feed through stake
-Fuse, 20 AMP I box section and into roll bar. Continue snaking wire
-Wire, Yellow -
through roll bar until end of wire reaches access hole in

6 inches -Terminal, underside of roll bar at right hand lamp Fig. 2.
Spade Female 1
Wire, Yellow -
4 Remove snake wire and attach terminal end of yellow

-
25 feet Instruction Sheet 1

-
wire to right hand lamp.
NOTE: For missing or damaged items contact the kit 5 Insert bushing in right hand access hole of roll bar.
manufacturer direct:
6 Pull a loop of wire from left hand access hole in roll
bar.
CIBIE Lights EFPE Company -
33195 Harper Street 7 Cut wire loop and strip 1/ inch of insulation from
St. Clair Shores, Michigan 48082 each end Fig. 3.
OVER
Fl Ametican Motors Sales Corporation

Service EngIneering Dept. * 14250 Plymouth Rd. * DetroIt, MIch. 48232
77-17
__
FIg. 2 RoIl Bar Access Hole L. H. Shown
8 Connect terminal end of 6 inch yellow wire to left

hand lamp.
9 Strip ‘I. inch of insulation from other end of 6 inch

yellow wire.
10 Insert both ends of yellow wire from roll bar and 6

inch yellow wire from lamp into 3-way butt connector and
crimp securely.
FIg. 3 Roll Bar Wire Routing
11 Puch 3-way connector and wires into left hand access
hole in roll bar.
20 Attach one end of 6 inch black wire to negative -J
12 Insert strain reliefbushing into left hand access hole. terminal of rocker switch. Attach other end to steering
column collar trim screw or other suitable ground.
13 Route yellow wire extending from pick-up box along
inner side of left frame rail to engine compartment. 21 Route yellow wire from lamps to rocker switch and
cut off excess.
14 Route wire up dash panel firewall and through 22 Strip % inch of insulation from yellow wire, install
heater vacuum control hose grommet into passenger female spade terminal and crimp.
compartment.
15 Drill a ½ inch diameter hole in lower instrument

panel 2-½ to 3 inches left of fresh air vent knob.
- -
-
16 Install fuse holder Fig. 4.
17 Drill two 1/8 inch holes under instrument panel,

below fuse holder. Use rocker switch as template.
NOTBi On vehicles equipped with air conditioning locate

switch holes left of discharge duct
18 Install rocker switch Fig. 4.
19 Attaehoneendofl2 inch brown wire to positive

44 terminal of rocker switch. Attach other end to straight
side terminal of fuse holder.
FIg. 4 Fuse Holder and Switch Location
page 2
77-18
23 Attach female spade terminal to remaining terminal 2 Remove lamp covers.
on rocker switch.
3 Loosen lamp attaching bolts. Turn ignition stch
24 Attach one end of 18 inch long red wire to fuse block and lamp switch on, adjust beams as follows:
terminal above "transmission kickdown" fuse. Attach
other end to center terminal of fuse holder.
a Horizontal distance between light beams on
wall should be same as distance between lamps on roll bar.
25 Secure all loose wire using cable ties.
b Vertical height oflight beams on wall shouldbe
26 Install 20 amp fuse in fuse holder, remove lamp 1 inch less than installed height of lamps on roll bar.
covers and check lamp operation.
4 Tighten lamp attaching bolts.
NOTES Lamps are switched through ignition switch and
will only operate when ignition switch is in on position. 5 Turn off ignition switch and lamp switch.
ASIIII1 LamPs 6 Install lamp covers.
I Position vehicle on a flat level surface, facing and NOTE: On vehicles sold in California the fuse must be
approximately 25 feet from a wall. removed from the fuse holder for street use.

WARRANTY YEAR AND TIME .

LAMPS, OFF*ROAD DRIVING-

INSTALL 15.162 15.659 IRK 1.0 - - G
Includes aiming lamps
page 3
77-19
Revised

March 11, 1977
This bulletin is being revised to correct the illustration of Before attempting any other diagnosis or repair for
distributor sensor wire routing for six-cylinder engine ignition system problems, cheek the sensor wire muting
applications. Remove and discard DRB 7.03, Group and, if necessary, reroute it. The following illustrations
3.000, dated February 17, 1977 and insert this revised show the most desirable routing for each engine. These
bulletin in your DRB binder. routings should be followed whenever the ignition system
is being serviced,
Sqme engines may be sensitive to the routing of the
djstributor sensor wires. If they are routed near the
high-voltage coil wire or spark plug wires, the
electromagnetic field surrounding those high-voltage
wires could possibly generate an occasional disruption of
the normal operation of the ignition system.
V-8 Distributor Sensor Wire Routing Six-Cylinder Distributor Sensor Wire Routing
NOTE: On V-S model, wIthout air conditioning route

sensor wIre away from coil wire and plug wire.
1 American Motors S&es Corporation

Service EngIneering Dept. * 14250 Plymouth Rd. * Detroit, MIch. 48232
77-20
_____________________________________ __________________________________
____________________________________________
Diagnosis and Repair Bulletin No. 7-02

February 8, 1977
JSubject: Engine Continues to Run After Ignition Application: 1976 and 1977 Cl I I File: Group 8.000
lstth is Turned Off-Caused by Models With Six-Cylinder Engine II
Feedback Alternatorl and Delco Alternator Built Prior I
to 17XXXXX038559 1I 1
On some of the subject 1976 and 1977 Cl models INSERT RED WIRE
WITh BLACK TRACER
with sixcylinder engines and Delco alternators the REMOVED FROM TWO
engine may continue to run after the ignition switch WIRE CONNECTOR
is turned off. This condition may be caused by alter
nator feedback.
Service correction involves disconnecting the lead

from the No. 1 terminal of the alternator and install
ing the following jumper wire between the discon
nected lead and the No. 1 terminal of the alternator. INSERT INTO
TWO WIRE CONNECTOR
REMOVED FROM
Description Quantity Part No. Group ALTERNATOR
DR1O19
Wire, Jumper 1 8128393 3.130 Jumper Wire
PROCEDURE
1 Disconnect two wire connector from No. 1 t 4 Insert male terminal of jumper wire into alter
nal of alternator. nator two wire connector.
NOTE: Be sure male terminal of jumper wire is

2 Remove black wire with red tracer from connector.
inserted securely into two wire connector.
3 Insert black wire with red tracer into female
terminal of jumper wire assembly see illustration. 5 Connect two wire connector to No. I terminal
of alternator.
NOTE: It may be necessary to bend the locking barb
of the terminal so it will engage securely in the 6 Tape or tie jumper wire assembly to main harness
jumper wire terminal, to prevent chaffing against engine.
The following operation and standard work time will apply:

WIRE JUMPER-INSTALL 3.221 3033 83,84,93 0.2 0.2 - S
TI American Motors Sales Corporation

ServIce EngIneerIng Dept. * 14250 Plymouth Rd. * Detroit, Mich. 48232
77.21
________________TIdee

December 27, 1976
It is no longer necessary to install a new distributor NOTE: On eight-cylinder distributor it may be

as a means of repair when the distributor cap hold- necessary to also use a screwdriver to aid in spread
down clips are damaged and cannot be re-formed. ing the clip open.
Replacement holddown clips are now available and
can be easily installed on the distributor, in the 3 On eight-cylinder distributors- if rear clip is
vehicle. In most cases the clips can be replaced with being replaced:
out moving the distributor, except for the rear clip a Loosen distributor holddown bolt.
on eight-cylinder models. b Disconnect sensor connector.
c Disconnect vacuum hose.
The following parts will be required as necessary. d Rotate distributor sufficiently to gain access
to rear clip.
NOTE: Parts will be available from your Parts
Distribution Center the week of January 19, 1977. 4 Install replacement clips on retaining brackets.
Do not order parts before this date.
NOTE: It may be necessary to open clip slightly to
Description Quantity Part No. Group slkleit on to retaining bracket.
Clip, Distributor Cap As Required 8128421 3.030 5 Close clip around retaining bracket using a pair
Holddown of needlenose pliers.
Six-Cylinder
NOTE: If bracket is bent during clip replacement,
Clip, Distributor Cap As Required 8128420 3.030 re-form bracket.
Holddown
Eight-Cylinder 6 Install dust cap, rotor and distributorcap.
PROCEDURE
7 On eight-cylinder distributors proceed as follows:
1 Remove distributor cap, rotor and dust cover. a Rotate distributor back to its original position.
b Connect sensor connector.
2 Spread rolled over portion of clip using a pair c Check timing and adjust to specifications.
of needlenose pliers. Remove clip from retaining d Tighten distributorholddownbolt.
bracket. e Connectvacuumhose.
The following Standard Servicing Operations and work times will apply:

OPERATION OESCRIPTION REPORTING OPERATION MOOEL SKILL
CUP, DISTRIBUTOR CAP HOLDDOWN -
REPLACE 3.030 3009 0

One or both 0 Cyl. 0.2 0.2 0.2
Front Clip o Cyl. 0.2 0.2 0.2
Rear mid/or front clip B Cyl. 0.3 0.3 0.3

Service Engineering Dept. * 14250 Plymouth Rd. * Detroit, Mich. 48232
77.99
Subject: Altitude Performance Application: 1968-80 Jeep File: POWER PLANI
Adjustments Vehicles Fuel and Exhaust
No. $ft-7 Nos!. 10, 1981
This bulletin is being issued to outline the altitude per After performing these adjustments, attach emission
formance adjustments for 1968-80 Jeep vehicles re control label, part number EF 8130457, to the engine
quired under a newly established Federal standard. The compartment dash panel. Do not attach the label to any
adjustments are intended to improve driveability perfor component that ran be readily removed from the
mance as well as emissions performance at altitudes vehicle.
other than that for which the vehicles were originally
certified.
These adjustments apply to all 1968-80 Jeep vehicles
Any Jeep vehicle that has been so adjusted must have a that were sold for principal use at altitudes below 4,000
unique emission control information label installed. feet. Refer to the vehicle emission control label in the
These unique labels are available in a kit, part number engine compartment to identify these vehicles.
3242106 from the following facility:
American Motors Corporation
Distribution Services On 1968-80 Jeep vehicles originally sold fur operation at
37200 Amrhein Road altitudes ahuve 4,100 feet that are being operated below
Livonia, Michigan 48150 4,000 feet, the ignition timing, as shown on the vehicle
emission control label located in the engine compart
The adjustment procedures and unique labels must be ment or specified in the apropriate Jeep Thchnical Ser
made available at no cost to independent repair facilities vice Manual should be retarded 5°. The engine idle
and the general public. A notification is also provided in speed should be reset according to the procedures and
current owners manuals to make customers aware of idle speed specifications outlined in the appropriate
these adjustments. Jeep Thchnical Service Manual for the year of the ve
ADJUSTMENT PROCEDURES hicle being serviced. After performing these adjust
ments, attach emission control label, part number EF
On Jeep vehicles originally sold for operation at 8130458, to the engine compartment dash panel. Do not
altitudes below 4,000 feet that are being operated above attach the label to any component that can be readily
4,000 feet, the ignition timing, as shown on the vehicle removed from the vehicle.
ment or specified in the appropriate Jeep Technical Ser
vice manual should be advanced 5° not to exceed 15° These adjustments apply only to 1968-80 Jeep vehicles
total advance. The engine idle speed should he reset ac that were sold for principal use at altitudes above 4,000
cording to the procedures and idle speed specification feet. Refer to the vehicle emission control label in the
outlined in the appropriate Jeep Technical Service engine compartment to identify these vehicles.
Manual for the year of vehicle being serviced.
81-I 14-04Ai3

service EngIneering Department * 14250 Plymouth Rood * Detroit. MIchigan 48232
Additional copies ot this bulletin are available through your zone office.
77-23
VI Jeep
PRODUCT RECALL CAMPAIGN
Diagnosis and Repair Bulletin No. Below
Subject: BACSENS CAMPAIGN 1jpe E Product Recall Date: October 22, 1979
Campaign: Exhaust Gas Recirculating EGR Back- Application: 1974-1979
Pressure Sensor Replacement and Adjustment of Idle Jeep Vehicles See
Mixture Setting Lean Idle Drop Specification Change Application Chart Below
to 50 RPM for all Six-Cylinder Engines File: See Chart Below
JEEP APPLICATION CHART
1974 1975 1976 1976 1977 1978 1979

California California 49-State California California California California
360 CID 258 CID 232 CID 258 CID 258 CID 304 CID 304 CID
304 CID 258 CID 304 CID 304 CID
306 CID 304 CID 360 CID
401 CID 401 CID
FILING INSTRUCTIONS
Model TB/DRB
Year Group No. No.
1974-1975 4000 TB.8
1976 4.000 TB-4
1977 4.000 TB-02
1978 Power Plant, Fuel & Exhaust Systems DRB 8-09
This is a ¶ipe E Campaign, subject to campaign proce Idle Drop Emissions Control Information Label. This
dures and involving emission-related elements which service is to be perfonned on all vehicles, regardless of
may result in non.compliance with Federal or State mileage returning for the recall repair.
emissions requirements. The combined owner notifica
tion and correction reporting card for this campaign is NOTE: THE LEAN DROP SPECIFiCATION DIF
shown in Figure 1. FERS FROM THE SPECIFICATION IN THE SERV
ICE MANUAL AND ON THE EMiSSIONS LABEL
The zone will provide a VIM list for each dealer with any 6-CYLINDER ONLY. A LEAN IDLE DROP OF 50
vehicles involved. However, the campaign procedures RPM IS TO BE USED.
apply to all dealers. BACSENS Campaign Kits will be
NOTE: if any portion of the EGR system has been
at the Zone PDC’s the week of October 22, 1979.
altered or made inoperative, the vehicle is still eligible for
a free replacement back-pressure sensor and 6-cylinder
Parts can be ordered, as needed, on or after October 24,
vehicles are also eligible for an idle mixture adjustment.
1979. Additional parts and/or labor required to snake an al
tered system operational will be on a customer-pay basis
Some 1974-1979 Jeep vehicles have defective exhaust only. If you encounter this situation, make sure
customer
gas recirculation EGR back-pressure sensor valves. consent is obtained before proceeding with repairs.
Refer to Jeep Application Chart for model year and
engine displacement. Service correction involves re The 6-cylinder kit contains a new EGR back-pressure
placing the EGR back-pressure sensor with a newly sensor, gaskets and a combined Campaign and Lean Idle
designed sensor regardless of sensor’s present condi Drop Emissions Control Information Label and blue
tion, performing an idle mixture adjustment on all idle screw mixture limiter caps. The 8-cylinder kit,
6-cylinder engines, and affixing a Campaign Label 8- contains a new EGR back-pressure sensor, askets and a
cylinder or a combined Campaign and 6-cylinder Lean Campaign Label.

$eMcs Englnsetlng Deparimint * 142511 Plymouth Road * Detroit, MIchigan 48232
7724
The following kits will be required:
Kit Sensor Year Engine Carb. Model ¶I’ansinlsslon

8130500 8129586 1976 Cal. 258, IV Cd M,A
8130502 8129588 1976 N/Wide 258, All CJ A

N/Wide 258, All Cd M
N/Wide 232, IV Cd M
8130505 8130392 1975 Cal. 360, 4V J-Series A
Cal. 401, 4V J-Series A
1976 N/Wide 304, 2V Cd M
Cal. 304, 2V Cd A
Cal- 360, 4V J-Series M4
Cal. 360, 4V tI-Series A
Cal. 401, 4V tI-Series A
8130506 8130393 1976 N/Wide 304, 2V CJ A
8130508 8130395 1976 Cal. 304, 2V Cd M3
1977 Cal. 304, 2V Cd M3
1978 Cal. 304, 2V Cd MS
1979 Cal. 304, 2V Cd M3
8130507 8130396 1976 Cal. 304, 2V Cd A
BACSEN’S REPAIR PROCEDURE
1 Remove air cleaner. 9 Install air cleaner.

L 2 Remove vacuum lines from exhaust back-pressure 10 Start engine and veri’ EGR valve operation Refer
sensor and EGR valve. to appropriate Thchnical Service Manual for EGR check
3 Remove EUR valve, back-pressure sensor, restrictor ing procedure.
plate if applicable, and gaskets. 11 On S-cylinder vehicles, affix campaign label beside
4 Manually pull EGR valve pintle off seat to ensure present underhood maintenance label See Figure 2-b.
freedom ofmovement, If EGR valve pintle moves freely,
proceed to step 5. NOTE: Type campaign number 795 and dealer code
If EGR valve pintle does not move freely, clean pintle number on campaign label before affixing to vehicle.
area; if pintle does not move freely after cleaning, Apply clear film overlay to label.
replace EGR valve and proceed to step 6. 12 On 6-cylinder vehicles:
5 Clean EGR valve mounting surface. a Readjust idle mixture setting by idle drop
6 Clean manifold, restrictor plate if applicable, and method new specification is 50 RPM on all
all mating surfaces. 6-cylinder engines. Refer to appropriate ‘Ibchnical
7 Using new gaskets, install restrictor plate if appli Service Manual for idle drop procedure.
cable, new back-pressure sensor, and EGR valve. b Install blue limiter caps alter 6-cylinder idle
lighten attaching nuts to 13 foot-pounds 17 N.m tor mixture adjustment.
que. c Affix combined Campaign Label and 6-Cylinder
8 Connect vacuum lines to back-pressure and EGR Lean Idle Drop Emissions Control Infonnation
valve See Figure 2-A & 2-b. Label beside present underhood maintenance label
See Figure 2-a.
NOTE: Vacuum line from CTO switch must be NOTE: Type campaign number 795 and dealer code
connected to back-pressure sensor nipple that has number on campaign label before affixing to vehicle.
.030-inch restrictor Apply clear film overlay to label.
77-25
___________
EGR VALVE EXHAUST SACK

PRESSURE SENSOR
INNER
FRONT SPORT
Vacuum
0
Hose RoutIng for 6-Cylinder coi* Vacuum Hose RoutIng for 8-Cylinder A.J41263
TYPE RECALL CAMPAIGN NO. 795

HERE BEFORE AFFIXING LABEL
Fl American Motors Corporation Motors Corporation

RECALL CAMPAIGN CALL CAMPAIGN
‘C NUMBER NUMBE’I__________
Cr
z BACK-PRESSURE TRANSDUCER BACK-PRESSURE TRANSDUCER
0 TO THE EGR VALVE
U
w TOTHE EGR VALVE
w
I
z z
C
0- UNIT REPLACED BY DEALER C
0- UNIT REPLACED BY DEALER
CODE NUMBER CODE NUMBER
I A1TENTION
A LL6CYL ENGINES I TYPE DEALER CODE HERE
I A DJUST TO 50 RPM BEFORE AFFIXING LABEL
LEANIDLEDROP I
L I
Campaign Laboi for 6-Cylinder Campaign Label for 8-Cylinder
including Lean Idle Drop
Emissions Control Information
Fig. 2-a Fig. 2-b
The following operation and standard work thne will apply:
WARRANtY YEAR AND TIME

OPERATION DESCRIPTION REPORTING OPERATION - SKILl.
CODE NUMBER MODEL 74 75 76 77 18 79 LEVEL
SENSOR EOR BACK-PRESSURE 4.690 4.295 6-wi .4 .4 -4
Replace BACSENS Campaign 8-cyl .3 .3 .3 -3 .3 .3
Includes idle mixture adjustment

on 6-cylinder and replace EGR
valva II required
Condition Code Defect Code: 56
77-26
CLAIM HANDLING
Several vehicles may be listed on a single warranty CAUTION: On multiple vehic/e claims, do not delay
claim, reference Warranty Administration Manual, any claim so that CCL? will receive it beyond the time
Section 7, Product Recall Campaigns. outlined in the Warranty Administration Manual.
The EGR Back-Pressure Sensor that is removed and
replaced is a returnable part and must be tagged and
returned with your regular claim material shipment. NOTE: All 1977 and prior model Jeep vehicle warranty
claims are eligible fora25% parts mark-up. All /978 and
Complete and mail the reporting half of the notification subsequent Jeep vehicle warranty claims are eligible for
card Figure 1 for each vehicle as soon as campaign a30% parts mark-up. See Warranty Bulletin 79-08 fAIJ
service is complete. dated 9/1/79 for details.
ztzsp 0*1ev. IloJita

p.o IiirioulMa ocnt Nolka of Product Recall Cacrcaign Involving Your VeNd.
0o’Res k,!UOdat. usc UitdWl3
UOltJOdJO3 tails SJOIOYI UflitUkV
- -
L ±ldj
Lr
i! II c.-., 0-lj r-.-t t.a..
Nofj of Product Recall Cancaign Involving Your Vehicle Product flecul carcipeign Reponing Curd
_,_.,.._ o_lE* *1
_!* !.,I.,-,,,.,I-.,,.,,., Ifrls.-l.. .....l...
FIg. 1 Owner Notification and Correction Reporting Card

-
77-27
Subject: Rough or High Engine Idle Speed or Application: 1976-78 Cherokee, File: POWER PLANT
Dieseling When Warm Engine is Shut Off Wagoner, or Truck Models Equipped Fuel and Exhaust Systems
witb 360 or 401 GD Engine and 4V
Carburetor
No.8-OS June 19,1979
Some of the subject vehicles may have a rough idle, high 5 Remove accelerator pump link.
idle speed, or may diesel when shut off after the engine
reaches normal operating temperature. These conditions 6 Install new acceleratoT pump link into lower
may be the result of worn accelerator pump linkage or forward hole of throttle lever see illustration.
the secondary throttle plates not closing completely.
NOTE: There are two types of throttle levers in use, a
Service correction involves replacing the accelerator two-hole and a three-hole lever. The lower, forward hole
pump link and installing a secondary throttle plate helper is the only hole used on Jeep applications.
spring.
7 Install new accelerator pump link-to-throttle lever
The following parts are required and will be available retainer.
after August 6, 1979. Do not order parts before this date. 8 Install nylon nut on accelerator pump link. Adjust
nut until notch in accelerator pump arm is in position
Description Quantity Part No. Group No, recorded in step 2.
KIT, Secondary NOTE: If the nylon nut on the accelerator pump
Throttle Repair 1 8132560 4.00! appeared to have been tampered with prior to removal.
refer to the Metering Rod Carrier Stroke Adjustment in
Kit Contents: the applicable Technical Service Manual go correctly
position nylon nut.
SPRING, Secondary
Helper 9 Remove air horn cover screw located above primary
throttle shaft on accelerator pump side of carburetor.
WASHER, Spring Install washer on screw and start screw in hole. Hook one
end of helper spring around screw and tighten screw see
LINK, Accelerator illustration.
Pump
10 Hook other end of helper spring between secondary
RETAINER throttle link rod retainer and primary linkage see
illustration.
PROCEDURE
CAUTION: Prior to starting engine check the carburetor
1 Allow throttle to return to closed position. linkage for proper operation and be sure secondary
throttle plates are closing completely.
NOTE: Thefast idle screw should not contact thefast idle
cam and the throttk solenoid should not be energized. II Spray choke and linkage cleaner 8993549 on both
ends of secondary shaft to clean shaft.
2 Observe position of notch in accelerator pump arm.
Measure distance between notch and index mark cast in 12 Hold choke open and operate carburetor linkage to
air horn see illustration. Record this dimension. wide open throttle position several times to ensure proper
operation.
3 Remove nylon nut from accelerator pump link.
13 Adjust curb idle speed.
4 Remove acceleratgr pump link-to-throttle lever
retainer.
OVER
P1 American Motors Sales Corporation

Service Englnnrlng Department * 14260 Plymouth Road * Detroit, Michigan 48232
AddItIonal copies at this bulletin are available through your zone office.
77-28
ACCELERATOR iv&’r * I I I - 1-t
PUMP ARM
NOTCH
NYLON
C SPRING
WASHER
SECONDARY
HELPER
SPRING
ACCELERATOR
PUMP LINK
THROTTLE
LEVER
/
LINK-TO-THROTflE/
LEVER RETAINER
Coip
SECONDARY
HELPER
SPRING
LINK ROD RETAINER

SECONDARY -
THROTTLE
LINK ROO
-
?C1 J
77-29
Subject Gas Tank Sending Unit ApplIcation: 1975-1978 Cherokee and File: POWER PLANT
Wagoner Fuel and Exhaust System
Group 4.000
No. 8-06 May 9, 1978
The fuel gauge in some 1975-1978 Cherokees and REPAIR PROCEDURES

Wagoneers may indicate 3/4 full when the tank is known
to be full. This condition may be the result of inaccuracy I Remove fuel tank, as described in appropriate
in the fuel tank sending unit. Technical Service Manual.
Service correction involves removing the fuel tank from 2 Remove sending unit.
the vehicle, removing the sending unit from the fuel tank,
and reshaping the sending unit lever arm to correspond 3 Check sending unit with an ohmmeter for
with the attached template. continuity through resistor for normal resistance change
as lever is moved through its full arc of travel.
Before proceeding to the repair procedure, verify the a If sending unit is electrically faulty, replace it.
accuracy of the fuel gauge by using the DARS Charts on b If sending unit is electrically sound, proceed to
page I L-8, Volume 1 of the 1978 Technical Service step 4.
Manual. If the tests indicate inaccuracy in the sending
unit, proceed to the repair procedure. If the tests indicate 4 Reshape sending unit lever to attached template.
inaccuracy in the fuel gauge, refer to the appropriate
model/year Technical Service Manual for the correct 5 Install sending unit in tank.
replacement procedure.
6 install fuel tank as described in appropriate
NOTE: The procedures found in the DARS Charts on Technical Service Manual.
page JL-8 of the 1978 Technical Service Manual are
applicable to 1975-1978 vehicles.
The following operation atd standard work time will apply:

OPERATION SKILL
OPERATION DESCRIPTION REPORTING MODEL -
NUMBER LEVI
CODE 76 77 -
78
SENDING UNIT, FUEL TANK - DIAGNOSIS 3.614 4197 CKE-WAG 0.2 0.2 0.2 6
Sending Unit, -Remove, Adjust, and install. . . . 3.614 A CKE-WAG 0.9 0.9 0.9 G
With Skid Plate ADD
- 0.3 0.3 0.3
Sending Unit, Replace

- 3.614 B CKE-WAG 0.9 0.9 0.9 G
With Skid Plate ADD
- 0.3 0.3 0.3
NOTE: Combination A and B cannot be used

together. Both include drain, R&R and refill fuel
tank as required

Service Engineering D.partm.nt * 14250 Plymouth Road * Detroit, Michigan 48232
Additional copies at this bulletin are available thmugh your zone office.
77-30
1975-1978 Cherokee and Wagoneer
Sending Unit Template
77-31
Subject Emission Components Application: All 1976-1978 Jeep ModeLs File: POWER PLANT
Fuel and Exhaust Systems
Group 4.000
No.8-07 April 23,1979
The following charts reflect emission components using * Engine CID

the information found on the "Vehicle Emission Control * Engine Family
Information Label" located in the engine compartment. * Evaporative Family 1978 CJ models only or
These charts identify the latest emission control devices carburetor type Jeep Heavy Duty
used on the applicable models. Correct part numbers are
also identified for certain devices with multiple d Determine from the V.E.C.I.L. the certification
applications. area i.e., 49S 49 State, Alt r High Altitude, Cal
To use the charts: California. Use this information to locate the correct
box in the third column on the chart.
a Select the chart with the correct model year heading
i.e., 1978 Jeep, etc. e Determine what transmission the vehicle has and
use this information to select the correct box in the fourth
column of the chart.
b Locate the model in the first column of the chart.
c Open the hood and find "Vehicle Emission Control 1 The above information aligns across the chart. The
Information Label" V.E.C.I.L. or Jeep Heavy-Duty remainder of the information should be used to check the
vehicle for correct component application.
Emission Control Label. Record the following
information for use in the second column on the chart.
LEGEND
Vehicle Emission Control Information Label VECIL Trans. Transmission Type
Engine CID Man 3- or 4-speed Manual
Engine Family M4 = 4-Speed Manual
Evaporative Family 1978 models only M3 3-Speed Manual
A Automatic
Jeep Heavy-Duty Application
Carburetor Number = Number on Tag Attached to
Engine CID Carburetor
Carburetor Type:
IV One Venturi Distributor Number z Number on Tag Attached to
2V Two Venturi Distributor
4V Four Venturi
EGR Valve Number = Number on Face of Diaphragm
Housing
* On All Models Specified
- Not Applicable EGR Code = Number or Letter Adjacent to Valve
Number
V.E.C.I.L. = Vehicle Emission Control Information
Label EGR CTO Temp Nominal Temperature at Which
CTO Switches
Area 49S = 49 State, Alt High Altitude, Cal r 115°F Valve Part Number 3228288; Optional with
California 3225912
OVER

Service Engineering Deportment * 14250 Plymouth Rood * Detroit, MIchigan 48232
Additional copies at this bulletin are available through your zone office.
77-32
160°F Valve Part Number 3228894; Optional with DP: Dashpot
3226361, 3229449
TM Throttle Modulator
AG Air Guard
Cat. Cony. Catalytic Converter Q + Pre-Catalytic Converter
TVS r Thermal Vacuum Switch i Nominal Temperature for EGR CO Switches
SVV Solenoid Vacuum Valve C EUR Back-Pressure Transducer 3229120; Orifice

Plate 3233536
PCV = Positive Crankcase Ventilation Nominal Temperature for Spark cro Switches
TAC Type = Thermostatically Controlled Air Cleaner

V r Vacuum Delay Valve
M = Mechanical
Spark CTO Type 0= Anti_diesel Solenoid in PCV Line
160° F Valve Standard Switch, Part Number Warm-up + Pellet type

3216448; Optional with 3229450
220° F Valve Heavy-Duty Switch, Part Number Delay Valve in Vacuum Line Between Manifold
5358881 Vacuum and Diverter Valve
Spark CTO Temp. = Nominal Temperature at which Optional Switch 5358$80 Used on Heavy-Duty
CTO Switch Starts to Open Cooling Package
NLV = Nonlinear Valve Special Air Pump Pulley and Diverter
TCS = Transmission Controlled Spark Includes Vacuum Check Valve
CVTC Carburetor Vented to Canister
FTVC = Fuel Tank Vapor Control
TS = Throttle Solenoid
[C Electric Choke
1978 JEEP
101 Sp.rb
Corb. CTO pcv DC CO
MS.I VICIL An. iront 01st lOt Valve COt *a Ta CVTC FTVC 0 IC OP TM
Numb., Number Number CS. C..,v Type TUmPC
as. 7 232 495 M3 7230 3237434 3230189

I-i P ll5’f * * V l5Q’F * * * - -
E-I-1
05. 7 232 ALT M3 7731 3737434 3230183
l-TC % llS’F e * * V lQfl - * * - --
E-l-t
05, 7 258 495 MAN 7230 3232134 3230184
-i 5i*.l. I ll$’F C V fl * . .
El-i
as. 7 258 495 MAN 7230 3232434 373079
I-T 4094l.. F llS’F * * V l6OF C C C
El-i
CJ, 7 258 495 A 7228 3732434 3730179
IT F 115’F * * V l60F C C - - --
CJ5. 7 258 AlT MAN 723 3732434 3230191

I-IC I 115’F e . * V ttO’F C * C
8-I-I
CTh. 7 258 CAL MAN 7230 3232434 3230189
l-TC P 1151 C C * V - - . . . --
E-l-T -
77.33
1978 JEEP Cont’d.
-
‘G - - - - ir - -
Model VICIL A,ec Trolls Corb. DIII IGI Valve COt CTO AG CCI pcv TAC CTO KS CVTC FTVC TS IC OP TM
Numb.. Number Number Cede T.mp Cenv. Type Y.mP. - -
Ci.? 258 CAl, A 7201 3732431
‘
3230175
I-IC 1 1151 C C V 160°F C C
I-iT
Cm. 7 304 495 M3 8DM2 3231310 323097
ll*T 1354A.lei ij .15°F C C C V C C
E-4-T
Cfl.7 304 195 M3 80*42 3231340 323018$
Il-I 409A.lei 0 1151 C C C V C C
E.1-T
Ci, 7 304 495 A 80A2J 3230443 3230189
H-T P 115°F * C C V - - C C C
-4-I
05.7 304 ALT M3 80*474 3731340 373094 - -
Il-I W 115°F C C V 60°F
C C C C - -
E-1-T
Ci,? 304 ALT A 80474 3730443 3230191
NT T 115°F C C * V 160°F C C C C C --
8-4-I .
CJ5. 7 304 CAL M3 8DM2C 3231340 3223980 - -

N-TCc/o ted 155°F C C C V - C C C C C
8-4-1 ® - - - -
-
CJ.7 301 CAL A &DA2JC 3231340 3230839

fl-I 1 115°F C C C V 60°F C C C C C --
1-4-I Q
258
Ch.,OLCC 495 MANIA 8107 3232134 3218739 lIve P60°F * V 160°F
Truck I-ND
2V 0
ChCrOICC 360 jy MAN 8RtIA2C 3230443 329052 - v 160°F -
C -
Truck Ill-ND
2V C
: ::
Cherokee 360 495 A 65MA2 3231341 329052 - -
Wogoneer
Iruck
ChCrokee
W98OnCCr
Ill-lID
2V
360
Ill-MD
CAL A 8RHA2C 3233114
C
3233596
None
AN
140°f
115°F
C - C V
L c_ .
C C C V 220°F C C C
Truck 2V
360 - - - -
3230443
CI,CrOCC
Iruck
Cherokee
Wa9oneCr
NI-lID
4V
340
495
495
Ml
A
6TMM4
ÔTHA4 3231341
3219052
329052
®
160°F . -
* L 160°F
S
P60°F
- - -
C
Ill-ND None 160°f C C V C - -

Truck 4V C 0 - -
Chere¾e. 10 A ZTW 323341 3219057 160°! . V 160°! C

Woqoneer Ill-MD 0 - -
Truck ‘V 0 - - - - - - - - - - --
1977 JEEP
IGI
lot - Sperk - -
*4Sel VEClk ArCo Tren. Corb 0.,,

Valv
Ga CTO AG Cot Pcv TAC CTO ICS CVTC FTVC 0 CC OP TM
Numb., Number Cede iCmp. Cen, lype lemp - - -
NumI,.
- - 0____ 0
CiS.7 232 754 3229759 323084 1 115°!
C C
160°!
C
I-I 3.54 Axle C C -- -
CJS, 7 232 495 M3 7154 3229719 3230179 T C

-
C -
M C
-
C
-
C
IT 4,09 ASIC
CJ3. 7 232
I-IC
ALT M3 710 372979 3230183 K 1151 160°! n ‘ ;
05,7 258
IT
495 MAN
I3.S4AxIe
7154 322979 3230184 1 515°! 160°!
C ° C
-
-
-
: -
C,t5. 7 258 495 MAN 754 327979 323079 F 115°F 1601

*
I-I 4.09 ASk °°; °°° - C C C -
CL? 258
l-T
.495 A 7131 323979 323090 5 115°F -
C
-
C M °! T : :
C..? 25$ ALT A 711 322979 323092 LI 115°! * * M
160°!
C C
-- -
l-TC C - - --
C, 7 258
l-TC
CAt MAN 7154 3729’19 323086 * 1151 -
C C
-
C M
-
- C
-
C C :
A
CJ.7 258 CAL 753 3229719 323086 Fl p5° C C M 160°!
C C C C
- - -
I-TC 3,54 Ae C -- -
Ci.? 258 tT A 7153 322979 3230846 AD 55°!

C C C M 160°F
C C
-
C
-
C
- - -
I.TC 4O9A4e -- -
CiS. 7 304 495 M3 60*42 3228264 323018$ 0 115°F V - -

8-I C C C C - - C -
Ci.? 304 495 A 6DA2 3728263 3230193 V 115°! -- -

C C V C - - -
C C
77.34
1977 JEEP Cont’d.
- - - - - - - - - -
IG8 Spark
IGI
MC4CI VICIL Ar.. Trans h VoIv IGR CTO ‘ v TAC CTO ICS CVTC FTVC I’S COP TM
NombCr Number C.dC Temp® Cony Type TCITIPr
Number
- L
05.7 °°° ALT -- -
M3 7DM2A 3228764 3230194 w ‘15°F C C C V 60°F C C - -
N-T
0. i 30’
04
ALT A TDA2A 3228263 3230191 1 115°F * * °°°° TT ‘° ° 7 ; ;
05. 7 304 3223980
CAL M3 6DM2J 3228264 Red Its’! C C C V 560°F * - e - - -
Il-IC c/a
**
C.? 304 e C - - -
CAL A 6DA2J 3278264 3230186 N 115°f C C C v 160°F C
Il-I
Cherokee
258 - -
p 495 MAN I A 8107 3229719 3218739 8Ln ‘60’P C M 160°F
Truck 2V C - -
Cherokee MAN 60°F C

Ill-MD 495 6RMM2 3728263 3219052 None 140°F C C V -
Truck
2V
Cherokee 340 - -
3219052 C V 140°F C - - -
Wogoneer Il-MD 495 A 6RMA7 3728265 None ‘60°F C
Truck 2V c - - -
Cherokee 360 321095

Ill-MD 49S Ml 6TMM4 3228263 None I 601- C C v l60°r C - C
Truck
- - - - - -
Cherokee 360 3219052
Wagonce. 495 A oTIIAI * . ioo°r - C - - -
Truck
Ill-MD 3728765
C v
- -
Cherokee 401 32’ 905

Wogoneer 81-MD 495 A 611144 3228265 None 160° C C 60°F - - - - - -
Truck 4V
Cherokee °°°° C lo0°r C -- - -

IV.HD CAL Ml 01MM4 3228163 3230161 V l01 * C v C - C
Truck
4V -
Cherokee 360
CAL A 6114A4C V 6°F C V I60’F C - - C
Wogoneer V-MO 3228265 3230261 C C
Truck 4V -
Cherokee 401
Wogoneer IV-MD CAL A 61HA4C C C V 60°F - C C - -
3728265 3230261 V 601- C - C
Truck 4
-
- Or,l.ce Plate 3225145 / Bock Pressure Transducer 3229120
1976 JEEP
Carb Dist lOt Valve IGR Rack PrCnurC

r-r
CIa Car TAC CI0
Model VICIt Area Iran. AG ICS DV FTVC I S IC TM
Number Number Number Cede IronsducCr ICmP Cony lype TemPc - - - -
- -___-__- - - - -
CIS 7 232 495 M3 7109 3227331 3223980 Red 3228838 I I5’F
I-I Or.l-cePla°e - - C *4 - - C - -
3275242 - - -
CJ5 7 258 495 MAN 7109 3777331 3273980 Red 3228838 IS’s
I-T Orrf,cePlote - - C M - C - -
- ,,...2?2522 -- -
CiS 7 258 CAL MA 7084 327733’ 3273980 Red 3228836 II 5’F

I-TC OrlcePlote C C C *4 C - -
3226657 - - - - - -
CI? 258 495 A 7083 3227331 3223980 Red 3228838 115°F

IT Or,l,cePlore C M - - - C - - -
3775144 - - - -- -
-
Ci? 258 CAL A 7085 3227331 3723980 Red 3728830 15°F 160°F
I-TC Or,l,cePlote C C C M - C C -
C
3275956 - - -
CJS. 7 304 495 *43 6DM? 32282o 3223980 Red 3279117 15°F
N-I Or,F,cePlole C C C V C - -
3228338 - - -
Ci? 304 495 A aDA? 3228263 3223980 Red 3229118 115°F

Il-I Or,l,crPlOtr C C C V - - C C - -
3225145 - -
C5, 7 304 CAL *43 60M2i 3228264 3223980 Red 3229120 115°F ‘60°F
Il-TC Ori,celloie C C C V C C - -
322 5956
77.35
1976 JEEP Cont’d.
FGR - Spark - - -- --
Cork, Di.’ EGO VcrI°e EGO Bock PrCtSure CI0 AG Car PCV IAC CT0 TCS DV FIVC I S IC
Model VICIL Area Trans TM
Number Number Number Code Transducer Temp Cony lype Temp
- - -
0 -- --
Ci? 304 CAL A 6DA23 3228264 3273980 Red 3229159 115°! 160°F
III . OriliceRlote C C C V * - C C --
32 25956
Cherokee °°‘ 495 MAN 7088 3227331 3228739 Blue 560°F - -

60°!
-
-- -
Iruck I-HO M
IV
258
Cherokee 495 A 7088 3227331 3228739 Blue 160°F 60°F
I-HO - - - C M - -- --
Truck
IV
360
Cherokee 495 MAN 60HM2 3228263 3229052 None 160°F 60°F
lIMO C C V -_ - C
Truck
2V
Cherokee 360 495 A 60HA2 3228265 3229052 None 560°! 60°F
Wogoneer Ill-NO C - C V - - ---C -
Truck 7V
Cherokee
Truck
Ill ND
IV
495 MAN 61HM4 3228263 3279052 None 60°! 7T j ‘ : .
Cherokee 360 495 A 6111A4 3228265 322905? None 560°! - 560°!

Wogoneer 1111-ID C C V C --
Truck Iv C
360
Cherokee CAL MAN 6TNM4 3228265 3223981 Vellori 322340? 160°! 160°F
Il-ND
Truck C C *
4V C V - C
Cherokee 360 CAL A 6TNA4C 3228265 3223981 YeIloa 327340? I60°F 60°F - -
Wagoneer Ill-ND C C V C C - - C
Iruck 4V
Cherokee 401 495 A oTHAI 3228265 3225952 None
Wogoneer Ill-HO 60°f e C V 160°! C -C -
Truck 4V
Cherokee ‘ CAL A 6TNA4 3228765 3225951 Block 322340? - - - - - - - -
wogoneer Ill-ND 60°! C C C --
- C V 160°! - C
Truck IV
9-009-04A J
71-36
Subject: Slow Fuel Fill Application: 1974, 1975, 1976 and 1977 File: Group 4.000
Wagon..: and Cherokee Models Fuel
No. 1-01 February 6. 1978
A new fasterfuel fill system has been developed for use on Description Quantity Part No. Kit Application
the above vehicles. The system is available in kit form as a
service replacement. Three kits are available; one for Hose, Filler I 5358649 All
1974 Nationwide and 1974, 1975, and 1976 California Tube-to-
models, one for 1975, 1976, and 1977 Nationwide models, Extension
and one for 1977 California models.
Clamp, Hose 1 3203077 All
Description Quantity Part No. Group Application
- Clamp, Hose I 3203079 All
Kit, Fuel I 8129295 - 1974 Nationwide
Filler 1976 Cap, Gas I 5358207 All
Kit, Fuel I 8129294 - 1975, 1976. Reinforcement, 1 5461119 All

Filler and 1977 Filler Neck
Nationwide
I 8129296 - 1977 California PROCEDURE
Parts for this bulletin will not be available until February 1 R emov e gas a p.
13,1978. Do not order parts before this date.
2 Remove filler neck-to-body panel screws.
Each kit contams the following components:
Description Quantity Part No. Kit Application 3 Lower tailgate.
Filler, Fuel 1 5358650 8129294 4 Remove left rear quarter trim panel.
Tank
5 Remove radio speaker, if equipped.
FilIer,Fuel 1 5358670 8129295
Tank 6 Disconnect fuel vent hose at filler neck.
Filler, Fuel 1 5358671 8129296 7 Raise vehicle.

Tank
8 Loosen filler hose-to-filler tube hose clamp and
Gasket, Filler I 936433 All separate connection.
Screw 10- 6 8120054 All CAUTION: & careful of gasoline in filler tube.
16x 1/2"
9 Push filler neck assembly inside vehicle.
Grommet, Fuel 1 5358648 All
Filler Tube 10 Remove filler tube attaching nut and bolt at rear
tube bracket.
Screw, 10- 3 8120056 All
16 x 3/4" II Remove filler tube attaching nut at shock absorber
stud.
929831 All
OVER

S.rvlc. Engln..rlng D.partm.sit * 14250 Plymouth Road * D.trolt, Mlchigon 48232
77.37
EXISTV4G
FILLER TUBE
-1
ee5 -
CAP,
r
GAS
a
HOSE, FILLER TUBE-
TO-EXTENSION
GROMMET
Fuel Filler Kit Installation
12 Remove filler tube-to-fuel tank inlet hose clamp. NOTE: Position holes infl/kr gasket and reinforcenen:
for best access.
13 Remove filler tube.
21 Punch three holes for No. 10 screw in inner body
NOTE: Filler tube can be removed towardsfront of the panel using an awl or other suitable tool.
vehicle. It a not necessary to remove the spare tire.
22 Connect filler tube and insert in to hose at fuel tank
14 Cut 2 1/2 inches off of filler neck end of the filler end.
tube see illustration.
23 Position filler tube bracket on shock absorber stud
IS Lower vehicle. and loosely install nut.
16 Remove filler neck assembly from inside of vehicle. 24 Position filler tube bracket on fuel filler end and
loosely install bolt and nut.
17 Position Range gasket on filler assembly and insert
the ifiler assembly through the body opening. 25 Position filler hose and clamps on filler and filler
tube, Tighten hose clamps.
NOTE: The filler flange and gasket, when correctly 26 Tighten reinforcement ring and gasket attaching
installed are on the exterior of the body panel see screws.
illustration.
27 Tighten filler tube attaching nut at shock absorber
18 Raise vehicle. stud.
19 Slide lower filler tube gasket on filler and align 28 Tighten clamp at filler tube to fuel tank filler hose,
reinforcement ring with three holes in the gasket. and install rear filler tube attaching bolt and nut at
bracket.
20 Mark hole locations on inner body panel see
illustration. 29 Lower vehicle.
77.A
30 Tighten filler neck screws at body panel. 33 Install left rear quarter trim panel.
31 Install vent hose on filler neck and tighten hose 34 Close tailgate.
clamp see illustration.
35 Install gas cap.
32 Install radio speaker, if equipped.

WMRANIY YEAR AND TIME SKILL
OPERATION DESCRIPTION OPERATION MODEL
REPORTING ________
LEVEL
NUMBER 74 75 76 77
CODE
KIT, FUEL FILLER - INSTALL .... 4.141 4227 WAG- 0.6 0,6 0.6 0.6 C
. CKE
7-081-04.
77fl0
Subject: Improved Procedures for Clutch Application: 1977.79 CJ Models File: CHASSIS
Overcenter Spring and Clutch Pedal Clutch Manual
-
Replacement Transmission
Group 6.000
No. 9-02 July18, 1979
Improved procedures for replacing the clutch over- NOTE: As the spring is pulled forward, it will ride
center spring and clutch pedal on CJ Models have along the pedal edge until it seats in the pedal slot.
been developed. They supersede the procedures
outlined in the 1977-79 Jeep Technical Service 9 Remove boards and mechanics wire.
Manuals. The new procedures are as follows:
10 Install windshield washer hose grommet in
PROCEDURES dash panel.
Clutch Overcenter Spring Replacement 11 Check and adjust clutch pedal free play if
necessary.
1 Remove windshield washer hose grommet
from engine compartment side of dash panel
see illustration.
Clutch Pedal Replacement
2 Feed 3-foot long double strand of mechanics
wire through grommet hole. Wrap wire around 1 Disconnect clutch pedal push rod at bellcrank.
end of clutch pedal overcenter spring and feed
wire back out of grommet hole. Twist ends of 2 Disconnect battery negative cable.
wire together securely to form loop.
3 Remove fuse panel attaching screws and
3 Insert 2 x 4 board through looped end of remove fuse panel.
wire. Position second 2 x 4 board against dash
panel to pry against. 4 Remove windshield washer hose grommet
from dash panel see illustration.
CAUTION: Be sure the 2 x 4 boards do not
contact any of the brahelines during overeenter 5 Feed 3-foot long double strand of mechanics
spring removal or installation. wire through windshield washer grommet hole.
Wrap wire around end of clutch overcenter spring
4 Position bottom end of 2 x 4 board inserted and feed wire back out through grommet hole.
in looped end of wire against 2 x 4 on dash panel Twist wire ends together securely to form loop.
and pull back on board to release clutch overcenter
spring from clutch pedal. 6 Insert 2 x 4 board through looped end of
5 Disconnect overcenter spring from brake pedal panel to pry against.
support bracket under instrument panel.
6 Connect replacement overcenter spring to contact any of the brakelines during overcenter
brake pedal support bracket. spring removaL
7 Install mechanics wire on overcenter spring 7 Position bottom end of 2 x 4 board inserted
and position spring on lower portion of clutch in looped end of wire against 2 x 4 on dash panel
pedal. and pull back on board to release clutch overcenter
spring from clutch pedal.
8 Pull 2 x 4 board with wire wrapped around it
forward until overcenter spring slides into and seats 8 Remove snap ring on end of pedal shaft and
in pedal slot. remove clutch p da1 from shaft.

Service Engineering D.partm.nt * 14250 Plymouth Road * Detroit, Michigan 48232
7740
DRAKE PEOAL
SUPPORT BRACKET
CLUTCH OVERCENTER SPRING INSTALLATION
9 Install replacement clutch pedal on shaft and NOTE: As the spring is pulled forward. it will ride
install snap ring. along the pedal edge and snap into the pedal slot.
10 Install fuse panel. 14 Remove mechanics wire and 2 x 4 boards.
11 Connect clutch pedal push rod to belicrank. 15 Install windshield washer hose grommet
in dash panel.
12 Position overcenter spring-end on brake pedal
support bracket. 16 Connect battery negative cahle
13 Pull forward on 2 x 4 board until overcenter 17 Check and adjust clutch pedal free play if
spring slides into and seats in pedal slot. necessary.

REPORTINGIOPERATION SKILL
OPERATION DESCRIPTION MODEL
CODE
I NUMBER -
77 78 79
LEVEL
PEDAL, CLUTCH-REPLACE 5.135 5006 83-93 - 4 - 4 - 4 G
SPRING, CLUTCH OVERCENTER-

REPLACE 5.973 5010 83-93 - 3 3 - 3 G
9- 100-05.J
77-41
P1 Jeep
Diagnosis and Repair Bulletin No. 8-02 AprIl 11, 19Th
Application: 1976, 1977, and
1ff78 CJ-5, CJ$, and CJ-7
Models as Specified Below
File: CHASSIS Clutch -
Manual Transmission
This is a ‘Ipe S Campaign, subject to all campaign TRANSMISSION OIL LEVEL INSPECTION
procedures and involving safety-related elements. PROCEDURE
Copies of the combined owner notification and cor
rection reporting cards for this campaign are shown 1 Obtain a paper cup and remove lip so excess
in Figure 4 and Figure 5. transfer case lubricant can be caught when fill plug
is removed.
1976, 1977, and 1978 CJ-5, CJ-6, and C.J-7 Jeep vehi
cles equipped with a 3-speed transmission may have 2 Remove transfer case fill plug and catch all excess
been built with the transmission adapter plate seal oil that flows out filler hole see fig. 1. Pour excess
improperly seated. This condition could allow the oil into measuring cup graduated in ounces.
gradual transfer of lubricant from the transmission
to the transfer case. If lubricant transfer takes place
the transmission could eventuaily become damaged
and inoperative.
Vehicles involved include 1976 CJ models between
VINs J6F93FH000015 and J6F93AH102513, 1977
CI models between VINs J7F83AA00000S and
J7F93AA128208, and 1978 CJ models between VINs
J8FS3AH00007I and J8F93AA064933.
Vehicles built before April, 1977 will require a transfer
case lubricant level inspection. If the inspection in
dicates that four or more ounces of excess lubricant
are present in the transfer case, seal replacement is
required. Proceed to the TRANSMISSION OIL
LEVEL INSPECTION PROCEDURE.
Vehicles built from April 1, 1977 through December FIg. 1 Collecting Excess Lubricant with Paper Cup.
16, 1977 require mandatory transmission adapter
plate seal and spacer replacement. THESE VEHI NOTE; In the event that a graduated cup is not
CLES DO NOT REQUIRE INSPECTION; proceed available, the inside cavity of Installer Tool 1-26852
to the TRANSMISSION ADAPTER PLATE SEAL can be used to measure the lubricant see fig. 2.
REPLACEMENT PROCEDURE.
The following parts may be required:
Part Dealer
Description Qty. Number Group Net
Seal, Transmission 1 5358980 6.053-2 1.29 ea.
Adapter Plate
Spacer 1 5359069 6.053-20 .15 ea.
Gasket, transfer 1 5358840 18.001-3 .21 ea.
case to transmission
The Zone will provide a VIN list and an initial supply
of parts for each dealer with any vehicles involved -
However, the campaign procedures apply to all

dealers. On any undelivered, campaign-involved
vehicle, the correction must be made before the vehi
cle is sold or otherwise put into service.
Additional parts can be ordered, as needed on or
after May 22, 1978. Fig. 2 Using Tool J-26852 to Measure Lubricant.

Service EngineerIng Department * 14250 Plymouth Reid * Deirolt, MichIgan 48232
3 If excess lubricant exceeds four ounces, trans 11 Remove bolts attaching transfer case to trans
mission adapter plate seal replacement is necessary. mission and remove transfer case. Remove transfer
Refer to the Transmission Adapter Plate Seal Re case gasket.
placement Procedure in this Diagnosis and Repair
Bulletin. NO’FE: One transfer case attaching bolt must be
removed from the front end of the case. This bolt is
4 If excess lubricant is less than four ounces, located at the bottom right cornerof the transmission.
adapter plate seal is properly positioned. Install fill
plug. 12 Remove transfer case mainshaft gear, washer,
and locknut.
5 Remove transmission fill plug and check lubricant
level. Correct lubricant level if necessary. 13 Remove adapter plate seal from rear bearing
adapter.
6 Install transmission fill plug.
14 If oil slinger is found behind seal, remove it.
7 Apply a daub of white paint above transmission
fill plug to identify campaign completion. 15 Clean oil from transmission adapter plate and
rear bearing adapter.
TRANSMISSION ADAPTER PLATE SEAL 16 Inspect transfer case mainshaft gear sealing sur
REPLACEMENT PROCEDURE face for smooth finish to assure seal lip seating.
1 Remove shift lever knob, trim ring, and boot from Replace the gear if the sealing surface is not smooth.
transmission and transfer case shift levers. 17 Inspect inside diameter of rear bearing adapter
2 Remove floor covering if equipped and remove for smooth surface to assure proper sealing between
transmission access cover from floorpan. adapter bore and seal housing. Replace the rear bear
ing adapter if the inside diameter surf4ce is not
3 Place transmission lever in first gear position smooth.
and firmly secure it using rope or equivalent material.
18 Install spacer in place of oil slinger, if originally
NOTE: The shift lever must be secured as described equipped with oil slinger.
to prevent the rear bearing retainer from moving out NOTE; If the transmission did not originally have an
ward when the transfer case mainshift gear locknut oil slinger, a spacer must not be installed.
is removed. If the rear bearing retainer is allowed
to move outward the internal transmission parts may 19 Coat adapter plate seal lip with gear lubricant.
separate. If the internal pans separate, the trans
20 Slide seal onto Installer Tool .1-26852.
mission will have to be removed for reassembly.
NOTE: The adapter plate seal is stamped FRONT
4 Raise vehicle. and REAR on the seal housing. When the seal is
NOTE: A visual inspection of the transmission and correctly positioned on the seal installer, the side
transfer case should be made. If oil leakage is evident, marked REAR is against the seal driving surface of
the cause of leakage must be eliminated. the installer. see Fig. 3
5 Drain transfer case and transmission lubricant. NOTE: Seal Ins taller Tool 1-26852 must be used to
install the adapter plate seal to assure proper align
6 Disconnect torque reaction bracket from
crossmember. ment and sealing.
21 Slide transfer case mainshaft gear onto main-
7 Position support stand under clutch housing to
support engine and transmission. shaft. Apply hand pressure against gear and check
clearance between forward surface of transfer case
8 Remove rear crossmember. mainshaft gear and rear face of adapter plate seal.
9 Disconnect front and rear propeller shaft yokes Clearance should be no less than .050" at any point
between seal housing and mainshaft gear. If clearance
and mark for assembly reference. is less than .050" use Installer Tool J-26852 to reseat
10 Disconnect speedometer cable at transfer case. adapter plate seal and repeat clearance check.
Fig. 3 Adapter Plate Seal.

22 Install transmission mainshaft washer and lock- 29 Remove dowel pins and install remaining tran&
nut. Tighten nut to 150 foot pounds torque 205 fer case attaching bolts. Tighten all bolts to 30 foot
newton meters, pounds torque 22 newton meters.
23 Install transmission-to.transfer case gasket on 30 Connect speedometer driven gear to transfer
transmission, case.
24 Shift transfer case to 4L position. 31 Connect front and rear propeller shafts to trans
fer case.
25 Install one 3/8 16 x 4-inch dowel pin on each
-
side of transmission to assist in guiding transfer case 32 Connect torque reaction bracket.
into place during installation. 33 Fifi transmission and transfer case with SAE
26 Install and position transfer case on dowel pins. 80W-90 gear lubricant API-G14. Fill each unit to
bottom of fill plug hole.
27 Rotate transfer case output shaft by turning
yoke until mainshaft gear on transmission engages 34 Apply a daub of yellow paint above transmission
rear output shaft gear in transfer case. Slide transfer fill plug to identify campaign completion.
case forward until case seats against transmission. 35 vehicle and remove rope or equivalent
CAUTION: Be sure the transfer case is flush against material securing shift lever.
the transmission. Severe damage to the transfer case 36 Install transmission plate on floorpan. Install
will result if the attaching bolts are tightened while floor covering, if equipped.
the transfer case is in a bind or is cocked.
Install boots, trim rings and shift knobs.
28 Install two transfer case tightening bolts but do
not tighten completely.

OPERATION OPERATION YEAR & TIME SKILL
DESCRIPTION WRC NO. MOOEL 16 77 Th LEVEL
TRANLUB CAMPAIGN LUBRICANT
LEVEL-Inspect 6.613 6033 83-84-93 .2 .2 - 6
Seal. Adapter Plate-Replace 6.614 A 83-84-93 12 1.2 - 6
SEAL, ADAPTER PLATE-Replace 6.615 6035 83-84-93 - 1.2 1.2 6
Applicable Defect Code: 56 -
Product Recall Campaign
CLAIM HANDLING
Several vehicles may be listed on a single warranty Complete and mail the reporting half of of the notifica
claim, reference Warranty Administration Manual, tion card Figs. 4 and 5 for each vehicle as soon as
Section 7, Product Recall Campaigns. The transmis- campaign service is complete.
sion adapter plate seal and oil slinger that is removed
and replaced is a returnable part and must be tagged CAUTION; On multiple-vehicle claims, do not delay
and returned with your regular claim material any claim so that we will receive it beyond the time
shipment. limit outlined in the WAM.
See Reverse Side

______________________
Side ‘I Notice of Product Recall Campaign Involving Your Vehicle
This notice is sent to you in accordance with the requirennents of LI.. National Traffic and Motor Vehicle Safety Act.
Jeep Corporation has determined that a defect which relates to motor vehicle safety exists in some 1976. 1977 and lOIN
CS-S. CJ-6 and CJ-7 vehicles equipped with three-speed manual traneanissions. A condition that allows * gradual dis
placement of lubricant from Lhe transmission to the transfer case easy exist in some of the vehicles. Your vehicle,
Identilied on the reverse side of this card, should be inspected by your Jeep dealer. Any necessary corrections will be
performed by your dealer nt no charge to you.
Lubricant in the transmission may be displaced during normal vehicle operation. A low lubricant condition could cause
the transmission to become damaged or inoperative and could lead to a lose of vehicle control and a crash without any
prior wernin g.
II your transnuaaion beconses diflicult to ahilt. It may be a warning that the lubricant level is low and should be
checked and refilled, if necessary. However, you may have no prior wanting of lubricant displacement and should avoid
driving at prolonged highway speeds until your vehicle has been inspected and repaired, if necessary, by your dealer.
Your dealer will have the necessary parts and will be prepared to niake repairs by May 22, 1978. The correction usually
requires no more than ninety minutes and in many cases will require lean than thirty minutes.
If your dealer should be unable to handle this campaign service promptly alter May 22.1978. please contact the local
Zone Office Iliated in your Owners Manual or Jeep Corporation. Owner Relations. 14250 Plymouth Road, Detroit.
Michigan 48232 Itelephonc 313-493-23411. If you are unable toobtain this campaign service without charge end within
60 days alter your tender of the vehicle to your deeler any time lollowiug May 22,1978. you may contact the Adminis
trator. National Highway Traffic Salety Administration. Washington. D.C. 20590.
When your vehicle goes in for the required attention! Please be sure this complete notification card goes with it
because the card is to be used by the dealer for reporting purposes. In case you do not floe own this vehicle please
send us the ‘Change of Ownership information, using side 2 of this card.
Product Recall Campaign Reporting Card

a Inatfuctlent OWNER Inatruclions: DEALER
V
C If you do not now own
this vehicle, please just fill in
a This section is for the dealer louse when your vehicle
a below leither a, I. Or C and MAIL DIRECTLY TO
a goes in tor the required alfention
AMERICAN MOTORS SALES CORPORATION
a
0. E Correcluon made
ci a Sold Or Traded to 0 Correction not required
a Nama Epicene pr,nn}
V
it
Zone and Dealer Code
Ado en
C.ly Siaie
b Present owner name and address not known
flesie, 5, unatute
c. Removed Iron, service because of collision
damage or otherwise
Date Veh.c ie Sein.ce
campaign Dais Reporting Secluon
vi.. ivahicie ioeni. scat! on Nunibe,l
FIg. 4 Owner Notification and Correction Reporting Card for all 1976 Vehicles and 1977 Vehicles
Built Before April 1977.
Li
IV’
Instructions: OWNER Inslructions: DEALER
0
If you do not now own this vehicle, please lust fill in This section is for the dealerto use when your vehicit
below either a. b. or Cl and MAIL DIRECTLY TO goes in for the required attention
a AMERICAN MOTORS SALES CORPORATION
a
e
a. 0 Correction made
N
a Sold or Traded to.
0 Naee Please Pnni
Address
e and Dealer Code
J
Cily Siaie
1 Present owner name and address fbI known 0

ieaie, S. griatare
c Removed from service because of collusion
damage or otherwise
Daio Veis,cie Ser,,cao
Campaign Dsts Repoet ing Seclion

yiN venicie ioeniiticai, On NL}n,be,
Fig. 5 Correction Reporting Card for 1977 and 1978 Vehicles Built from April 1, 1977
through December 16, 1977.
Subject: Manual Transmission Model T-ISA Application: 1973 through 1978 Jeep File: CHASSIS
Shift Control Housing Technical Service Technical Sn vice Manuals Clutch Manual
-
Manual Cosrecilon Tranantion

Group 6.000
N.. 8.01 March 6, 1978
This bulletin is being issued to correct an error in the

illustration of the shift control housing used on Model
T-l5A manual transmissions.
The Technical Service Manual5 page number, and

illustration Fig. numbers are listed below. Also
included is a corrected illustration.
VS
Technical Illustration SHIFT
Service Manual £5!! Fig. Numba RAIL
11.0*-
1973 6-5 Fig. 22
1974 6-8 Fig. 6-24
1975 6-8 Fig. 6-24

p0-c, SHIFT
SECOND.
1976 6-17 Fig. 6-34 ThlRDl ‘tuna
1977 6-17 Fig. 6-34 SHIFT

LEVER
SUPPORT
SPRING
1978 Vol. 2 2B-18 Fig. 2B-35 SHIFT
FORK
S-04506J

S.rvic. Englnnring D.partm.nt * 14250 Plymouth Rood * D.troit, Michigan 48232
Additional Copies of this bulletin are available through your zone office.
Subject: Fluid Overflow From Automatic Application: 1977-79 Jeep Models with File: CHASSIS
Transmission Fill Tube or Vent Tube ‘aused Automatic Transmission Automatic Trans.
by O%erfill or Vent Tube Restriction Group 7.000
No.9-02 April 30. l979
On some 1977-79 Jeep models wtth automatic 3 Check transmission fluid level as outlined in
transmission, fluid may overflow from the transmission appropriate Jeep Technical Service Manual. lltluid level
fill tube or vent tube. is incorrect, adjust to proper level and road test vehicle
with owner.
Service correction Involves verifying the overflow a If overflow does not occur during road test.
condition, inspecting the vent tube for restrictions, return vehicle to owner.
checking the fluid level and calibrating the transmission h II overflow does occur during road test.
dipstick if necessary. proceed to step 4.
NOTE: If an overt/ott eone/ition Dec ‘uts rn/i’ tihzet,

PROCEDURE lotting a trailer, the road te.t ititist he eondueted ii’,,!, the
trailer in jolt’.
I Inspect transmission fill tube and vent tube for 4 Raise vehicle on hoist, loosen vacuum modulator
evidence of fluid overflow, adapter retainer bolt. Pull modulator outward
a If tubes do not have evidence of overflow, approximately I / 2 to I-inch and drain one pint of fluid
return vehicle to owner. from transmission. Seat modulator and tighten
b If tubes exhibit evtdence of overflow, proceed modulator attaching bolt after draining fluid. Lower
to next step. vehicle and road test to verify correction.
2 Check transmission vent tube for restriction by 5 Check fluid level again and file new mark on
inserting length of stiff wire into tube, transmission dipstick at adjusted fluid level.
a If tube is restricted, repair as necessary and
return vehicle to owner.
b If tube is not restricted, proceed to next step.

OPERATION SKItt
NUMBER tEVEL
,
OVERFLOW. ALTOMA1’I’ TRANSMISSION-

lIAGNOSE ANt ‘ORREIT 16.022 16205 O.K 1.8 0.8 C
I 7.1

Service EngIneering Department * 14250 Plymouth Road * Detroit, Michigan 48232
Add,t,onaI cop,es of this bullet,n are available through your Zone i’tlice
77.47
Subject: Automatic Transmission Vacuum Application: All 1974-1978 Jeep File: CHASSIS
Modulator Testing Procedure Models With Autom* tic Transmission Automatic Transmission
Group 6.000
No.8-03 April 21, 1978
A new procedure has been developed for bench testing 2 Measure distance of plunger travel with maximum
automatic transmission vacuum modulators. This vacuum applied. Distance from plunger to edge of
information is supplemental to the procedures in Volume cylinder should measure approximately 5/8 inch see
2, page 2C-59 of the 1978 Technical Service Manual, but Fig. 2.
also applies to 1974-1977 vehicles.
NOTE: Maximum applied vacuum should remain
If transmission operating characteristics, pressure tests constant for at least 30 seconds. If modulator will not
or other diagnostic work indicates that a modulator may hold vacuum as required, replace the modulator.
not be operating properly, use the results of the following
tests to determine the condition of the modulator.
PROCEDURE
1 Apply vacuum to modulator and observe plunger
travel. Refer to Vacuum Modulator Movement
Specifications Chart for vehicle model year, transmission
model and vacuum readings, for approximate beginning
and ending of modulator plunger travel.
NOTE: The transmission serial num bet is stamped on a

metal plate attached to the right side of the transmission
case. The serial number must be included in any
communication involving parts ordering or requests for
transmission information.
TRANSMISSION MODEL
YEAR IC JH JJ JK JM JR iS
1974
w" S Fig. 2 Vacuum Modulator
1976
i
1977 4e . 3 Disconnect vacuum source from modulator.
1978
4 Roll lower half of the main housing of modulator on
B - Approximate Vacuum at B - Approximate Vacuum at a flat surface and observe concentricity of plunger
Which Beginakig of
J Plunge, Movement
Which Ending of
Plunger Movement
cylinder to housing. If plunger cylinder is concentric and
plunger is free, modulator is acceptable.
Should Occur Should Occur
AU vacuum readings are in inchel HG
C Not Applicable
Fig. 1 Vacuum Modulator Movement

Specifications Chart
WARRANTY
REPORTING
OPERATION
I
I MODEl
I YEAR AND TIME I SKILL
NUMBER I LEVEL
77178j
CODE
176
VACUUMMODULATOR-TEST 16.260 6272 0.1 0.1 0.1
f C
8MW-I 7J
VU American Motors Sales Corporation
Servic. EngineerIng D.partm.nt * 14250 Plymouth Road * DetroIt, MIchIgan 48232
Additional copies ci this bulletin are available through your zone oil ice.
77.48
Subject: Gear Shift Knob Replacement Application: 1976-1978 Jeep Models File: CHASSIS
With Automatic Transmission Automatic Transmission
. Group 7.000
No. 8-02 March 28,1978
When a shift lever knob is in need of replacement on a PROCEDURE

1976-1978 Jeep model with automatic transmission, it is
no longer necessary to replace the shift lever and knob as 1 Using a punch and hammer, drive out shift lever
an assembly. retaining pin and remove shift lever from steering
column.
NOTE: Replacement shI? lever knob can also be used on .
1973-1975 Jeep Models with automatic transmission. 2 Place shift lever in vice equipped with padded jaws.
3 Using a hammer and chisle, drive off shift lever

knob.
The following part is available and required:
4 Using a plastic mallet, install replacement shift lever
Description Quantity Part No. Group knob.
Knob, Shift Lever I 3216462 7.030 5 Attach shift lever to steering column with retaining
pin.

OPERATION SKILL
NUMBER 76 77 78 LEVEL
CODE
KNOB, GEAR SHIFT LEVER- REPLACE 7.030 7022 .2 .2 .2 C
8-043-BSA/J
VIAmerican Motors Sales Corporation

S.rvlc. Engin..rlng Department * 14250 Plymouth Road * D.trolt, MIchIgan 48232
Addittonal copies of this bulletin are available through your zone office,
77.49
April 21, 1977
Appllcalion All 1977 Models With FIle Group 6,000
Automatic Transmslon Automatic
Tranamlul.n
An improved forward clutch apply piston center seal is Apçl..

Dnedptlon QuisatIty fln Na. Gr.
presently being used in all 1977 built automatic 1977 .-;
transmissions. This new seal has a beveled edge and is Kit, Forward clutch X i 8i28656 6.595
interchangeable with the old lip type seal in transmissions x I 86239i7 6,595
built prior to 1977. The old lip type seal is not Kit. Overhaul Repair x I 8128525 6,501
X i 8625967 6.501
interchangeable with the new beveled edge seal and
should not be used in transmissions built in 1977 see
illustration. Servicing procedures for removal and installation of the
forward clutch apply piston center seal remains as
Therefore, when transmission repairs are necessary it is outlined in the appropriate Technical Service Manual.
important that the transmission build date be determined When installing the new beveled edge seal in a 1977 model
to assure that the proper kits are ordered. To determine transmission be sure that the beveled edge of the seal is
the build date of a transmission, locate the transmission facing upward. This information, or reference to this
serial number stamped on a metal tag attached to the bulletin, should be noted on page 7-46 of your 1977
right side of the transmission. The first two digits of the Technical Service Manual,
serial number denote the year the transmission was built. The Standard Servicing Operations and work time as
The following chart should be used when ordering repair published in the current SSO Manual are not affected by
kits for the transmission. this bulletin.
NEW BEVELED OLD LIP TYPE

EDGE SEAL SEAL
Forward Clutch Apply Piston Center Seal
PU AmerIcan Motors Sales Corporation

ServIce Englnnrlng Dept. * 14250 Plymouth Rd. * DetroIt, MIch. 48232
Additional copies oF this bulletin are available through your zone office.
77-50
Subject: Improved Stick-Slip Correction Application: 1973-79 Jeep Vehicles File: CHASSIS
Procedure With Quadra-Trac T ransfer Case Transfer Case/ *
Quadra-Trac
No. 9-01 ian. 12, 1981
This bulletin supercedes Technical Bulletins Number 2, PROCEDURE;

7600 Series, Number 5, 7500 Series, Number 6, 7400
Series, and Number 13, 7300 Series, Group 18.000, 1 Inspect vehicle tires. ‘fires must all be same size,
dated February 9, 1976. Remove and destroy these type, make, arid tread design. .orrect if necessary.
bulletins and replace them with this current bulletin.
2 Check and correct tire inflation pressures If
The Quadra-Trac transfer case in some 1973-79 Jeep necessary. All tires must he inflated to recom
vehicles may develop a low frequency pulsating grunt mended pressures and not vary by more than 1/2 to
ing, or rasping noise that occurs when cornering at slow I psi 3.45 to 4.895 kl’a.
speed or when parking the vehicle. This noise may occur
if the Quadra-Trac differential brake cones tend to stick 3 Raise hood anti raise vehicle on hoist.
then release suddenly or release at different torque
values. This condition is referred to as stick-slip. 4 Check transfer case lubricant level. If level is low,
inspect for leaks and correct as necessary.
To counteract this condition, a new Quadra-Trac
lubricant has been developed to correct stick-slip. When 5 Inspect transfer ase vent. If transfer case is
the new lubricant is used, a transfer case remote vent equipped with remote vent tube that is routed into
kit must also be installed. Because water adversely engine compartment, proceed to step 8. If
affects performance of the new lubricant, the vent kit transfer case does not have remote vent tube, pro
must be used to prevent water entry and lubricant ceed to steps 6 and 7 for vent kit installation.
contamination.
6 On CJ models, install remote vent kit as follows:
Service correction involves checking tire pressures,
sites, and types, draining and refilling the transfer case a Clean vent area and remove and discard
with the following new lubricant, and installing a remote original vent tube fitting.
vent kit on the transfer case if required.
b Apply silicone sealant to threads of replace
NOTE! The new Quadra-Trac lubricant Ls ml ended for ment vent tube fitting and install fitting on
use in vehicles exhibiting stick-slip. Far vehicles that do transfer case.
not exhibit stick-slip, the current Quadra.Trac lubricant,
part number 5358652, remains the normal replacement c Cover straight end of vent tube with tape.
lubricant.
d Insert straight end of vent tube upward
The following parts are available and required. above crossmember and to rear of transfer
case. Rotate curved end of tube upward and
position it between dash panel and engine.
Description Quantity Part No. Group Remove tape from straight end of tube.
LUBRICANT, Quadra. e Cut and connect four-inch length of vent tube

Trac AR 8130444 18.500 hose to vent tube fitting and vent tube.
STRAP, Tie AR 3223227 3.165 CAUTION: The hose must be securely connected to the
KIT, Vent 1 8130445 18.500 fitting arid tube to prevent water from entering the
transfer case and contaminating the Lubricant.
Kit Contents:
Vent Tube 1 f Secure lower straight end of vent tube to
Vent Tube Clip 4 Quadra-Trac Emergency Drive vacuum tube
Vent Tube Fitting 1 using S-clip provided in kit and proceed to
Vent Tube Hose 1 step 8.

S.rvlc. Engineering Deportment * 14250 Plymouth Rood * Detroit, Michigan 48232
Additional copies of lhis bulletin are available through your zone Mice
77.51
7 On Cherokee, Wagoneer, and Truck models, install unit to drain completely. If transfer case is
remote vent kit as follows: equipped with reduction unit, loosen reduction unit
attaching bolts, pull unit forward and allow lubri
a Clean vent area and remove and discard cant to drain from reduction unit.
original vent tube fitting!
9 Install and tighten transfer case drain plug to 20
b Apply silicone sealant to threads of replace foot-pounds 27 N-rn torque. If equipped with
ment vent tube fitting and install fitting on reduction unit, seat unit in transfer case and
transfer case. tighten reduction unit attaching ixlts Tighten
3/8-16 bolts 20 foot-pounds 27 Nm torque.
c Lower vehicle. Tighten 5/16-18 bolts to 9 foot-pounds 12 N-m
torque.
d Cover straight end of vent tube with tape.
10 Fill transfer case and reduction unit, if equipped,
e Insert straight end of vent tube downward with new Quadra-Tnti- lubricant ‘I’ransfer ease
between engine and dash panel. Position requires two quarts 1.9 liters of lubricant.
lower straight end of tube to rear of transfer Reduction unit requires one pint, if equipped.
case and upper curved end next to vacuum
modulator vacuum tube. NOTE: Shake the Quiulru.Trar Lut’’ uiint con/Inner
vigorowdy before filling thi’ transfer ru,se. U i.s mi portent
f Secure upper curved end of vent tube to that the lubricant be mixer! thoroughly Imfore we.
vacuum modulator vacuum line using tie
strap.
11 Install and tighten transfer case fill plug to 20 loot-
g Close hood and raise vehicle. pounds 27 N-rn torque.
h Cut and connect four-inch length of vent hose 12 Lower vehicle.
to vent tube fitting and vent tuhe
13 On CJ models, secure upper curved end of vent
CAUTION: The hose must be securely connerted to the tube to vacuum modulator vw-uuni tube using tie
fitting and tube to prevent water from entering the strap and close hood.
transfer case and contaminating the lubricant.
14 Drive vehicle in circles both clockwise and
i Secure vent tube to transmission filler tube counterclockwise for approximately 15 minutes to
and Quadra-Trac Emergency Drive vacuum circulate lubricant throughout transfer ease.
tube using tie straps and proceed to step ifi.
8 Position drain pan under transfer case, remove CAUTION: Do not turn to or hold the steering wheel al
drain and fill plugs from transfer case and allow t/fr stop position uhen dn’iig the r-ehir/.r in runes.
The following standard servicing operations and work times will apply:
YEAR AND TIME

CODE NUM6ER tIVEL
1973-1979
STICK-SLIP, QIJADRA-TRAC - CORRECT 18.670 18395 Cke-Wag 0.6 6

Includes lubricant change and 15 minute Trk-CJ-7
driving time
With reduction unit - Add 0.2
VentKit-Install 18.670 A 0.3 6
9-122-flU
77-52
Subject: Quadra-Trac With Reduction Unit - Application: 1977 and 1978 Jeep File: CHASSIS
Disengages From High Range Vehicles With Quadra-Trac and Transfer Case!
Reduction Unit Quadra-Trac
Group 18.000
No. 8-01 May 16, 1978
Some 1977 and 1978 Jeep vehicles equipped with PROCEDURE

Quadra-Trac and the optional low range unit may
occasionally disengage from high range. This can be I Remove reduction unit as described in appropriate
caused by improperly shifting the low range unit from Technical Service Manual.
low range to high range or by a worn or otherwise
substandard direct drive sleeve. 2 Remove power takeoff cover.
Service correction involves verifying that the proper

shifting procedure as described in the Owner’s Manual
/
3 Position 11 16 inch, 1/2 inch drive deep well socket
in vise and clamp securely. Allow two inches of socket to
has been used. If the shifting procedures used are correct extend beyond top of vise.
and the Quadra-Trac disengages from high range, inspect
the reduction unit direct drive sleeve. If necessary, replace 4 Mount reduction unit on socket. Be sure socket
the direct drive sleeve. enters bore of sun gear Fig. 2. Reduction unit should be
supported by socket.
NOTE: To insure that a new direct drive sleeve will
improve the condition, compare it with Fig. I. 5 Move reduction unit control lever rearward to high
range position.
The following parts are available and required:
6 Remove snap ring and spacer from mainshaft
Description Quantity Part No. Group Fig. 3.
Sleeve, Direct Drive 8122689 18.615-17 7 Lift reduction unit housing upward and off gear
train Fig. 4.
Ring, Power Takeoff
Cover to Transfer 8 Slide direct drive sleeve off main shaft.
Case Cover Sealing I 8122406 18.515-3
NOTE: To insure that the new direct drive sleeve will
Gasket, Reduction improve the condition compare ii with Fig. I.
Unit to Power
Takeoff Housing 8122707 18.610-9 9 Install direct drive sleeve.
WORN, SUBSTANDARD OR TEETH
TEETH WITH A FLAT ON THE jWITHOUT A FLAT ON THE
END
END ARE ACCEPTABLE [E NOT ACCEPTABLE
I
r
MM
1 I
Fig. 1 Direct Drive Sleeve
1 I
OVER
‘I American Motors Sales Corporation

S.rvlc. Engins.rlng D.partm.nt * 14250 Plymouth Road * D.troit, Michigan 48232
77.53
Fig. 3 Main Shaft Snap Ring Removal -
Installation
Fig. 2 Mounting Reduction Unit on Socket
10 Align splines on assembled parts and install

housing. Be sure housing is seated firmly against direct
drive sleeve.
II Install rear spacer and snap ring. Be sure snap ring is

fully seated in snap ring groove.
NOTE: The snap ring is a select fit component which is

available in seven dfferent sizes and used to maintain
0.004-to 0.009 inch clearance between the spacer and
snap ring. Snap rings can be found in the current Parts
Catalog, Group 18.6 15-2.
12 Install power takeoff cover and gasket. Tighten

cover attaching bolts to 20 foot-pounds 27 N in torque.
13 Remove assembled unit from support socket.
14 Install reduction unit as described in appropriate

Technical Service Manual.
15 Check fluid level ofQuadra-Trac and reduction unit

and fill with Jeep Quadra-Trac Lube PN 8997212.
16 Road test vehicle to insure proper reduction unit Fig. 4 Housing Removal Installation
-
operation.

OPERATION SKILL
NUMBER LEVEL
CODE 77 78 -
REDUCTION UNIT, GEAR SLEEVE

REPLACE 18.735 18353 0.7 0.7 G
8-067-I Si
77.54
Subject: Quadra-True Drive Chain Replace- ApplicatIon: 1973 through 1977 File; Group 18.000
ment Wagoneer, Cherokee and Truck Models
and 1976 and 1977 0-7 Models With
Quadra-Trac Transfer Case
No.7-01 September 8.1977
This bulletin is being issued to provide additional Pinion mate shaft bore may be polished. Shaft should fit
information on replacement of the Quadra-Trac drive tightly in bores. Replacement is required if bores are
chain. When the drive chain is to be replaced, it is elongated or enlarged.
important that the Quadra-Trac unit be thoroughly Pinion shaft lockpin must fit tightly in case bore.
cleaned and the component parts inspected for excessive
Replacement is required if case bore is elongated or
wear. Abrasive contamination or worn components parts
enlarged or if lockpin is collapsed or otherwise damaged.
can result in excessive drive chain wear. Therefore, when
replacing the drive chain the Quadra-Trac unit must be * End Caps - Bearing and end thrust surfaces must be
removed from the vehicle, disassembled and all parts polished and smooth. Pitting, galling, scoring, or flat
thoroughly cleaned and inspected for damage or excessive spots indicate excessive wear and replacement is required.
wear.
* Needle Bearings Rollers must be secure in cage.
-
The following information is to be used as a guide for the Bearing should rotate smoothly. Rotation drag, high
cleaning and inspection of the components of the spots, chipping, scoring, galling, pitting, or discoloration
Quadra-Trac unit. For removal, disassembly, and indicate excessive wear and replacement is required.
installation procedures refer to the applicable Technical
Service Manual. * Thrust Washers Surfaces should be fiat and smooth.
-
Light scratches or a circular wear pattern are considered

CLEANING as normal and replacement is not required. If surfaces are
After disassmbling the Quadra-Trac and reduction unit warped, galled, or worn, replacement is required.
if equipped. wash all parts thoroughly in clean solvent. * Pinion Shaft -Shaft must be smooth, round, and
Be sure all lubricant, foreign matter, and metal particles straight and must fit tightly into case bore. A polished
are removed from each part. Keep side gears, brake cones, wear pattern is considered normal and no replacement is
preload springs, and thrust washers together as matched required. Galling, scoring, or metal pickup indicate
sets. Dry all parts except bearings with compressed air. excessive wear and replacement is required.
Bearings should be allowed to air dry.
* Side Gears and Pinlons-Teeth must have a smooth
INSPECTION uniform contact pattern. Thrust surfaces and splines may
All parts should be thoroughly inspected for excessive be highly polished or have slight tarnished spots. These
wear or damage. Worn or damaged parts should be are considered normal and replacement is not required.
replaced. The following standards have been established Replacement is required if teeth are chipped orcracked; if
and are to be used in determining the serviceability of the thrust surfaces or splines are galled or show measurable
component parts. wear.
* Brake Cones Spiral tapered braking surfaces will be
-
* Drive Sprocket - A polished wear pattern on the
sprocket teeth is normal. However, deep ridges and valleys polished. Very small, smooth score marks or original
on the teeth indicate excessive wear and replacement is machining marks are considered normal and replacement
required. Bearing surfaces should be polished and is not required. Rough score marks, rolling or
mushrooming of spirals are considered excessivewear and
smooth. Pitting, galling, scoring or flat spots indicate
replacement is required.
excessive wear and replacement is required. Drive
sprockets with chipped teeth or cracks must be replaced. * Preload Springs- Springs should be dished approxi
mately % inch and smooth. Light scratches or a circular
* Case Sprocket Tapered clutch and pinion gear thrust wear pattern are considered normal. Warping, galling, or
-
surfaces will be highly polished and may have small flatness is considered excessive wear and replacement is
smooth score marks or original machining marks. These required.
are considered normal. Replacement is required if rough
score marks, nicks, gouges, cracks, burrs, chipped teeth, Remember, before replacing the Quadra-Trac drive chain
or excessive wear is indicated. it is imperative that the unit be disassembled and all
pans thoroughly cleaned and inspected.

Service EngIneering Deportment * 14250 Plymouth Rood * Detroit. Michigan 48232
77.55
Subject: Rear Axle Housing Cower Service ApplicatIon: 1977-79 Cl Models File: CHASSIS
Axles-Propeller Shaft
No. 9-02 May IS, 1979
When performing a service operation that requires movement aligns cover, mark position for installation
removal of the rear axle housing cover, the cover should and proceed to step 5.
be aligned prior to installing it. -
3 Remove attaching bolts and rotate axle cover on
Servicing involves inspecting the cover to determine axle housing. Inspect bottom edge of axle housing, as
whether it extends below the bottom edge of the axle cover is rotated, to determine if cover no longer extends
housing and either repositioning or grinding the cover as beyond housing.
required. a If rotating eliminates condition, mark cover
position for installation and proceed to step 5.
b If rotating cover does not eliminate condition,
PROCEDURE scribe area of cover that extends below bottom edge of
axle housing.
I Position rear axle housing cover on axle housing 4 Remove cover and grind scribed area off cover using
with attaching bolts loosely installed, bench grinder. Remove all sharp edges from cover with
file after grinding.
2 Inspect rear axle cover for alignment as follows:
a If cover does not extend beyond bottom edge 5 Clean axle housing and housing cover mating
of rear axle housing, no realignment is required. Proceed surfaces throughly. Apply a thin bead of Jeep Gasket-in
to step 5. a-Tube or equivalent silicone sealer to housing and cover,
b If cover extends beyond bottom edge of rear or install a replacement gasket. Install and tighten cover
axle housing, realign cover by moving it upward. If bolts to 20 ft. lbs. 27 N.m torque.

OPERATION DESCRIPTION REPORTING
OPERATION - SkIa
MODEL -
CODE MU LEVEL
77 78 79
COVER, REAR AXLE - MODIFY 9.007 905! 83-93 0.1 0.1 0.1 G
9-073-093

Service Enginaring Deportment * 14250 Plymouth Rood e Detroit, Michigan 48232
Additional copies of this bulle fin are available through your zone office.
77-56
Subject: Lubrication - Double Cardan Application: AU 1976-1978 Models File: CHASSIS
Universal Joint Except CJ Models WftII Manual Axles Propeller Shafts
-
Transmission Group 9.000
No.8-01 April 10,1978
This bulletin is being released to emphasize the PROCEDURE

importance of properly lubricating the front propeller
shaft double cardan universal joint. Failure to lubricate 1 Raise vehicle and support so that front wheels are
this universal joint at the intervals outlined in the free to turn.
Mechanical Maintenance Schedule may result in
accelerated wear. Lubrication of the double cardan 2 Mark propeller shaft yoke and transfer case output
universal joint on Wagoneer, Cherokee, and Truck shaft yoke for assembly alignment reference.
models should occur every 15,000 miles under normal
service and 5,000 miles or 5 months under heavy duty 3 Disconnect front propeller shaft at transfer case.
service. On CJ-7 models, lubrication should occur every
5,000 miles under normal service and every 3,000 miles or 4 Push on propeller shaft until slip yoke at axle end of
3 months under heavy duty service. shaft is fully collapsed.
The double cardan universal joint is located at the 5 Rotate propeller shaft and flex universaljoints until
transfer case end of the front propeller shaft. The lubrication fitting for front universal joint spider is
construction which allows the double cardan joint to accessible.
operate smoothly also makes proper lubrication of its
components very important. The lubrication fittings are 6 Lubricate spider until grease just begins to appear
located in the spiders of the universaljoints and in the ball around bearing cap seals.
socket yoke see figure 1.
7 Repeat steps 5 and 6 for rear universal joint
It will be necessary to obtain an Alemite lubrication spider.
adapter, model num,er 6783, or equivalent to perform
the following procedure. 8 Rotate propeller shaft and flex universaljoints until
lubrication fitting for ball socket is accessible.
9 Lubricate ball socket until grease appears at vent

hole located on rear of ball socket yoke.
10 Position propeller shaft and connect to transfer

case.
Il Remove grease squeezed out of slip yoke vent bole

at axle end of propeller shaft.
12 Lubricate propeller shaft slip yoke until grease

appears at vent hole.
13 Lower vehicle.
The Standard Servicing Operations and work times as

Fig. 1 Double Cardan UniversaL Joint this bulletin.
&-033-093

Service Engineering Deportment e 14250 Plymouth Road e DetroIt, Michigan 48232
77-57
P’UJ.ep*

February 10, 1977
Subject: Front Propeller Shaft May Contact Starter ApplicatIon: 1977 Cherokee and Truck File: Group 9.000
Motor During Severe Off-Road Operation Models With Six-Cylinder Engine and Axle. Propeller
-
Cherokee, Wagoner and Truck Shafts

Model. With V-8 Engine .
On some of the subject vehicles, the front propeller shaft 4 Mount assembled windup bumper and spacers on
may come in contact with the forward end of the starter frame bracket and install replacement locknut. Tighten
motor during severe off-road operation. This condition is locknut to 24 foot-pounds torque.
caused by excessive front axle windup which allows the
propeller shaft to overtravel resulting in possible damage 5 Inspect position of starter motor brush cover band
to the starter motor, or propeller shaft, or both. retaining screw.
a If screw head is facing away from engine as shown
Service correction, on a complaint basis, involves the in illustration, proceed to step 6.
following: b If screw head is facing toward engine, remove
and reposition screw as shown in illustration.
* Six-cylinder models installing an additional front
-
axle wmdup bumper spacer part number 941411 and 6 Connect battery negative cable.
locknut part number 4487549. It may be also necessary
to reverse the position of the starter motor brush cover
band retaining screw.
* V-8 models if front axle windup bumper spacer is

-
missing install windup bumper spacer, part number

940304. It may also be necessary to cut off the end of
the starter motor brush cover band retaining screw.

Spacer, Windup
Bumper Six- - 1 941411 9.304
Cylinder
Spacer, Windup
Bumper V-8 - 1 940304 9.304
Locknut, 3/8-16 1 4487549 9.304
PROCEDURE
Brush Cover Band Retaining Screw Location - Six
Cylinder Models
Six-cylinder Model,
V-8 Models
1 Disconnect battery negative cable. 1 Remove front axle windup bumper retaining nut and
washer and remove bumper.
2 Remove front axle windup bumper retaining locknut
and washer and remove bumper and existing spacer. 2 Install ½-inch thick spacer on windup bumper.
Discard locknut and washer.
3 Mount assembled windup bumper and spacer on
3 Install existing spacer and %-inch thick spacer on frame bracket and install washer and nut. Tighten
windup bumper. locknut to 24 foot-pounds torque.
OVER
Service Engineering Dept. * 14250 Plymouth Rd. * Deiroft, Mich. 48232
77-cg
SPACER, FRONT AXLE HOUSING WIND

UP BUMPER-INSTALL aCE.
Includes reposItion starter motor brush WAG
cover band retaining screw-six-cylinder... P.086 11123 TRK 0.2 - - M
SERVICE No.TBI 7700 Series
P’I Jeep TECHNICAL

BULLETIN
6
Group: 9.000
7600 Series
Date: September 28, 1976
Subject: Front Axle Application 1976 and 1977 Cherokee and J-10 Truck Models
1976 Cherokees and J.1O trucks were equipped with Remember, wide wheels are not recommended for
a 0.38 inch thick tube wall front axle as standard use on vehicles with the thinner tube axle. If an
equipment. A heavier, 0.50 inch thick tube wall axle owner does install wide wheels on one of these
was used whenever these vehicles were ordered with vehicles, make sure you do not install a snow plow.
the wide wheel option.
In order to identify which vehicles have the heavier
For 1977, early model .1-10 trucks without the wide 0.50 inch thick tube wall axle, check the metal tag
wheel option will stifi be equipped with the 0.38 attached to the differential housing. The heavier
inch thick tube wall front axle. However late model tube wall axles will have numbers 5355015 or
.1-10 trucks will have the heavier 0.50 inch thick 5356607 stamped on the tag.
tube wall whether or not they are ordered with the
wide wheel option.

14250 Plymouth Road e Detroit, MichIgan 48232
Subject: Brakedrum and Rotor Repair vs Application: All 1976-79 Jeep Vehicles File: CHASSIS
Replacement Brakes-Wheels-Tires
Group 8.000
No.9-01 February 20. 1979
It is not necessary to replace drums or rotors if the 8 Install bearings and seal in rotor.
braking surface is rusted or lightly scored, and within
dimensional specifications. Instead of replacement. re 9 Install rotor on steering spindle and check runout
store surface finish maintaining dimensions within and thickness variation. Refer to Rotor Specifications.
allowable tolerances by using a brake lathe. Replace
ment is necessary only if drums or rotors have hard
spots or machining would cause the part to exceed
specified limits. Rotor Measurement
Because drum and rotor tolerances must he accurate 1 Measure rotor lateral face runout.
to ensure proper brake operation. correct service pro a Mount dial indicator on support stand or steer
cedures are very important. The specifications and pro ing spindle.
cedures for drum and rotor service are as follows. b Position indicator stylus so it contacts center
of rotor lining contact area and zero indicator.
ROTOR SERVICE c Turn rotor 360 degrees and note indicator
reading. Runout must not exceed limit stated in Rotor
Rotor Inspection Specifications.
dl Refinish rotor if runout exceeds stated limit.
I Raise and support front of vehicle. Replace rotor if runout is so severe that machining
would cause rotor to fall below minimum replace’
2 Remove front wheels. ment thickness specification. Refer to Rotor Specifi
cations.
31 Remove caliper do not disconnect brakeline. e If runout is within limits, proceed to step 2.
4 Inspect rotor braking surfaces. If surfaces are only NOTE: Excessive lateral runout will cause rotor
lightly rusted or scored. proceed to step 3. If surfaces wobble resulting in chatter. vibration, and pedal pulsa
are severely scored, cracked, chipped. excessively ion,
worn, or have hard spots a series of shiny or dark
colored spots. replace rotor.
2 Measure rotor thickness variation.
5 If rotor surfaces are only lightly scaled, rusted or a Measure variaüon using micrometer or two
scored, remove rotor, bearings and seal from rotor. dial indicators.
Clean rotor hub bearing surfaces and mount rotor in hi Take readings at four or more equally spaced
brake lathe. Clean surfaces using flat sanding discs points around rotor circumference and one inch 25
while rotor is turning in lathe. mm inward from outer edge of rotor.
c Thickness variation, from point-to-point, must
6 Remove rotor from lathe. not vary by more than limit stated in Rotor Specifica
ti on s.
7 Check rotor thickness at center of lining contact d Refinish rotor if thickness variation exceeds
area. Thickness must be larger than minimum replace stated limit. Replace rotor if machining will not correct
ment specification and provide sufficient stock for variation or if machining would cause rotor to fall
refinishing if necessary. If rotor is within limits, pro below minimum thickness specification.
ceed to next step. If rotor is less than minimum thick
ness specification or refinishing would leave it below NOTE: Excessive thickness variation will cause pedal
minimum thickness specification, replace rotor. pulsation and vibration wheti the brakes are applied.
OVER
P1
American Motors Sales Corporation
Service EngIneerIng Department . 14250 Plymouth Rood e DetroIt. Mlchigon 48232
Rotor Refinishing 1978 Models
Rotor refinishing should only be performed using Rotor Diameter:

equipment that will machine both of the rotor surfaces ci 11.7 in. 29.7 cm
simultaneously machining one side at a time can pro
duce a tapered rotor. The correct surface finish is 15 Cke, Wag. 3-10 Trk 12.0 in. 30.48 cm
to 80 microinches for Ci models; 20 to 60 microinches
for Cherokee, Wagoneer, and Truck models and must 3-20 Irk 12.5 in. 31.75 cm
not have tool marks grooves after machining.
Rotor Hub to Bore Runout All. 0.010 in. 0.254 mm
NOTE: If a rotor is glazed or highly polished, sanding
the rotor may not produce the required rotor finish. Rotor Lateral Runout All 0.005 in. iO.12 mm
It may be necessary to turn the rotor to meet the
finish requirements. Rotor Minimum Replacement Thickness:
Ci l.120inJ28.45mm
To ensure a correct surface finish, follow the lathe
manufacturer’s recommendations for feed and speed Cke, Wag, Irk 1.215 in. 30.86 mm
and either sharpen or replace dull cutting tool bits
before machining rotor. Rotor Thickness Variation All. 0.001 in. 0.02 mm
I Remove rotor from steering spindle. 1977 Models

2 Remove bearings and seal from rotor and clean Rotor Diameter:
bearing surfaces in rotor hub thoroughly. CJ ll.7in.29.7cm
3 Mount rotor in lathe according to manufacturer’s Cke. Wag, 3-10 Irk 12.0 in. 30.4S cm
instructions and install anti-chatter band.
3-20 Irk 12.5 in. 31.75 cm
4 Sharpen or replace cutting tool bits as necessary.
Rotor Hub Bore Runout All. .0.010 in. 0.254 mm
5 Machine rotor as necessary and according to lathe
manufacturer’s instructions only. Make two cuts if re Rotor Lateral Runout All 0.0003 in. 0.076 mm
quired and do not remove more than 0.007 inch 0.18
mm at a time. Rotor Minimum Replacement
Thickness All 1.125 in. 28.5 mm
CAUTION: Do not attempt to refinish rotor if ma
chining would cause the part to fall below the minimum Rotor Thickness Variation All. OAXXJS in. 0.013 wIn
replacement thickness specification for that rotor.
Refer to Rotor Specifications. 1976 Models
NOTE: If one disc brake assembly requires a new set Rotor Diameter:
of shoes, the shoes on the other assembly must be Cke, Wag. J-10 Irk 12.0 in. 30.48 cm
replaced to ensure even braking.
Rotor Hub Bore Runout All.. .0.010 in. 0.254 cm
ROTOR SPECIFICATIONS Rotor Lateral Runout All 0.003 in. 0.076 mm
1979 Models Rotor Minimum Replacement Thickness

All 1.125 in. 28.5 mm
Rotor Diameter:
Ci ll.7in.29.7cm Rotor Thickness Variation All 0.0005 mU .013 mm
Cke, Wag. J-lO Irk 12.0 in. 30.48 cm
BRAKEDRUM SERVICE
3-20 Irk 12.5 in. 31.75 cm
hspection and Measurement
I Raise and support vehicle.
Rotor Lateral Runout All, . - .0.005 in. 0.12 mm
2 Remove wheels.
Rotor Minimum Replacement Thickness:
Ci 0.815 in. 20.7 mm 3 Remove brakedrums.
Cke. Wag. Trk 1.215 in. 30.86 mm 4 Clean drums using soap and water solution. If
drums are grease or oil contaminated, clean drums with
Rotor Thickness Variation All. 0.001 in. 0.02 mm alcohol before cleaning with soap and water.
2
5 Inspect drums for cracks, severe scoring, distor- BRAKEDRUM SPECIFICATIONS
tia. or hard spots a series of shiny or dark colored
spots on contact surface. Replace drums that exhibit
these conditions. If drums appear in good condition. 1979 Models
proceed to next step.
- Maximum Drum Diameter:
6 Refer to Brakedrum Specifications then measure ci 10.060 in. 25.5 cm
drum inside diameter. If diameter is within limits and
refinishing would not create an oversize condition, pro- Cke. Wag. Trk 11.061 in. 28.09 cm
ceed to next step. If diameter exceeds limits or if drum
needs refinishing hut would exceed allowable size limits 3-20 Irk 12.064 in. 30.6 cm
after machining, replace drum.
Maximum Drum Radial Runout. 0.005 in. 0.12 mm
7 Mount drum in lathe according to lathe manu
fact ures instructions.
- . 1978 Models
8 Mount dial indicator on lathe so indicator stylus
contacts lining surface of drum; zero dial indicator. Maximum Drum Diameter:
CJ 10.060 in. 255 cm
9 Measure drum radial runout.
a Rotate drum 360 degrees and observe readings. Cke. Wag. Trk 11.060 in. 28.09 cm
h Move indicator stylus until readings have been
taken across entire contact surface of drum. 3-20 12.060 in. 30.6 cm
Ic Drum runout must not exceed 0.005 inch 10.12
mm total indicator reading at any point. Also note if Maximum Drum Radial Runout. 0.0005 in. 0.12 mm
indicator readings increase or decrease greatly as stylus
is moved across drum surface. Large changes may indi
cate tapered or hell-mouthed drum. 1977 Models
10 If drum is within limits and does not need refin- Maximum Drum Diameter:
ishing, install drum. If drum is not within limits or is Ci 10.064 in. 25.5 cm
lightly scored, refinish drum. Refer to Brakedrum Re
finishing. Cke. Wag, Trk 11.064 in. 28.09 cm
Brakedrum Refinishing J-20 Trk 12.064 in. 30.6 cm
I Sharpen or replace cutting tool hit if necessary. Maximum Drum Radial Runout. 0.X7 in. 0.18 mm
2 Install anti-chatter hand on drum
1976 Models
3 Machine drum according to lathe manufacturer
recommendations for feed and speed. Do not remove Maximum Drum Diameter:
more than 0.010 inch 0.25 mmof stock during any cut. Ci 10.060 in. 25.5 cm
4 Check drum radial runout again after completing Cke. Wag. Trk 11.064 in. 28.09 cm
machining operations.
J-20 12.064 in. 30.6cm
NOIE: When brake shoes are replaced on one wheel. $
they must also be replaced on the opposite wheel. Maximum Drum Radial Runout. 0.007 in. tO.18 mm
77-63
$ OPERATION DESCRIPTION REPORTING OPERATION - - - SKILL
CODE NIJMBER MODEL 76 77 78 79 LEVEL
SHOE SET. FRONT DISC BRAKE -REPLACE 8.152 8060 0.5 0.5 0.5 0.5 G
Disc Assembly-Clean A 0.1 0.1 0.1 0.! 6

Disc Assembly-Resurface One 8.163 B 0.5 0.5 0.5 0.5 P
Both 8.163 1.0 1.0 1.0 1.0 p

Includes clean, inspect and repack wheel hearings.
Material allowance for bearing lubricant is 50.30.
NOTE: Peter to the appropriate coin binations

listed or operation Brake Shoes. Four Wheels-
Replace 8050 as they apply.
BRAKE SHOES, TWO WHEELS REAR-

REPLACE 8.202 8020 0.8 0.8 0.8 0.8 G
Includes adjust parking brake.
Brake Drum-Reface Both 8.222 A 0.3 0.3 0.3 0.3 p

Rear Wheel Bearings- Repack Full Floating
Rear Axle 9.073 B 0.4 0.4 0.4 0.4 6
NOTE: Re/er to the appropriate combinations

listed for Operation Brake Shoes. Four Wheels -
Replace 800018050 a they apply.
BRAKE SHOES, DRUM BRAKE TWO

WHEELS FRONT-REPLACE 8.102 8010 83-93 0.7 0.7 6
Front Wheel Bearings-Repack 8.909 A 0.3 0.4 6

Remove, wash, inspect. repack. install new seals
and adjust.
Material allowance for bearing lubricant is $0.30.
Drum-Reface-Both 8.127 B 0.3 0,3 p

9-036-OIAIJ
7764
February 10, 1977
Subjeet:Posslble Brake Drag-Caused by Brake Application:1976and1977 Cl Models File: Group 8.000
Pedal Not Returning Fully When Released Equipped With Manual Drum
Brakes and Manual Transmission
Built Prior to YIN 37XXXXX042579
On some of the subject U models a possible brake drag 2 Loosen bolts attaching upper and lower halves of the
may occur and is caused by the brake pedal not returning toeboard plate.
fully when released. This condition may be the result of
the brake pedal rubbing against the steering column and 3 Pull steering column upward, maintain upward
keeping the master cylinder push rod from returning far pressure and tighten bolts attaching steering column
enough to relieve all the pressure in the brake system. mounting bracket to instrument panel. Tighten bolts to 20
foot-pounds torque.
Service correction involves loosening the steering column
attaching hardware and repositioning the column to cAI.rrloN: Bolts attaching column mounting bracket to
obtain clearance between the brake pedal and ignition the instrument panel must be tightened to the specified
switch, torque so the column mounting bracket capsules will
breakaway under impact, as designed.
PROCEDURE
4 Tighten toeboard plate bolts to 15 foot-pounds
1 Loosen bolts attaching steering column mounting torque.
bracket to instrument panel.
5 Check brake pedal-to-ignition switch clearance.
Readjust steering column if necessary.
The following operation and standard work time will apply.
CODE NUMBER 76 78 LEVEL
STEERING COLUMN-POSITION 10.956 10227 83-93 0.1 0,1 - 0
P1
AmerIcan Motors Sales CorporaUon
77-65
Subject: Power Steering Gear Repair vs Application: All 1977-79 Jeep File: CHASSIS
Replacement Vehicles Equip ped w ith Power Steering Steering and Suspension
1977 Group 10.000
Revised
No.9-01 January 16, 1979
This bulletin is being revised to correct the information in B. On page 11-57 under subtitle
step D under "1977 Jeep Technical Service Manual" "ASSEMBLY - STEERING GEAR HOUSING
and step F under "1979 Jeep Technical Service COMPONENTS," step 12 should be changed to read:
Manual." Please remove and discard DRB No. 9-01, Install end plug in rack piston. Tighten end plug to 75
Power Steering Gear Repair vs. Replacement, dated foot-pounds 102 N.m torque.
November 20, 1978.
C. On page 11-58 under the subtitle
The Warranty Administration Manual states that partial "WORMSHAFT BEARING PRELOAD," step 3
or complete overhaul of an assembly shall take
precedence over replacement of that assembly; except should be changed to read: Measure counterclockwise
when the sum total of replacement parts and labor costs one-half inch 13mm from first index mark and remark
housing. Refer to Figure I below.
at RFC values to repair the assembly would amount to
80 percent or more of the sum total parts and labor costs
at RFC values to replace the assembly. D. On page 11-58 under the subtitle
"PITMAN SHAFT OVERCENTER DRAG
TORQUE," step 1 should be changed to read: Loosen
The appropriate Jeep Technical Service Manuals state locknut, turn pitman shaft adjuster screw counterclock
that adjustment of the steering gear must be done with the wise until fully extended, then turn it back clockwise
gear assembly removed from the vehicle. one full turn. Step 7 should be changed to read: Tighten
pitman shaft adjusting screw locknut to 20 foot-pounds
On the other hand, the Standard Servicing Operations 27 N*m torque after adjusting overcenter drag torque.
Manual SSO has an operation and time for steering
gear adjustment performed with the gear assembly on
the vehicle.
In order to make the Jeep Technical Service Manuals and

the Standard Servicing Operations Manual correct and
to create continuity requires several changes. After these
changes have been made, dealers should have less
difficulty complying with requirements of the Warranty
Administration Manual. The following procedural
changes to the 1977-79 Jeep Technical Service Manuals
are necessary. Also, note the changes in the Standard
Servicing Operations Manual.
I. 1977 JEEP TECHNICAL SERVICE

MANUAL
A. On page 11-47 of the SERVICE Fig. 1 Indexing Gear Housing
DIAGNOSIS CHART under the heading
"CONDITION" and after subtitle "POOR RETURN
OF STEERING WHEEL TO CENTER," add step II. IL 1978 JEEP TECHNICAL SERVICE
MANUAL
Possible Cause Correction A. On page 2L-8 of the SERVICE
Ii Kink in Return Hose II Replace Return Hose "CONDITION," add step II to subtitle "POOR
OVER RETURN OF STEERING WHEEL TO CENTER."
P1 AmerIcan Motors Sales Corporation

Servlc. Enginnrlng D.portm.nt * 14250 Plymouth Rood * D&rolt, Michigan 48232
77-66
* Possible Cause Correction C. On page 2L-32 under the subtitle
II Kink in Return Hose II "STEERING GEAR ASSEMBLY AND
Replace Return Hose ADJUSTMENT," step 19 should be changed to
B. On page 2L-12, fig. 2L-7, View A, read: Install end plug in rack piston. Tighten end plug
information referring to the ball plug should read the to 75 foot-pounds 102 N. m torque.
as
shown in fig. 2.
D. On page 2L-34 under the subtitle "WORM
C. On page 2L-32 under subtitle "STEERING BEARING PRELOAD," step 3 should be changed to
GEAR ASSEMBLY AND ADJUSTMENT," step 19 read: Measure counterclockwise one-half inch 13mm
should be changed to read: Install end plug in rack from first index mark and remark housing. Refer to
piston. Tighten end plug to 75 foot-pounds 102 N m Figure I.
torque.
E, On page 2L-35 under the subtitle
D. On page 2L-34 under thesubtitle "WORM "PITMAN SHAFT OVERCENTER DRAG
BEARING PRELOAD," step 3 should be changed to TORQUE," step 1 should be changed to read: Loosen
read: Measure counterclockwise one-half inch 13mm locknut, turn pitman shaft adjuster screw counterclock
from first index mark and remark housing. Refer to wise until fully extended, then turn it back clockwise
fig. I. one full turn. Step 7 should be changed to read: Tighten
E. On page 2L-34 under subtitle "PITMAN 27 N.m torque after adjusting overcenter drag torque.
SHAFT OVERCENTER DRAG TORQUE," step 1
one should be changed to read: Loosen locknut, turn LV STANDARD SERVICING OPERATIONS
pitman shaft adjuster screw counterclockwise until fully MANUAL
extended, then turn it back clockwise one full turn. Step
7 should be changed to read: Tighten pitman shaft In the October 9, 1978, printing at the bottom of
adjusting screw locknut to 20 foot-pounds 27 N*m page 2-08-5 is the operation description GEAR, POWER
torque after adjusting overcenter drag torque fig. 2H- STEERING ADJUSTON-VEHICLE with operation
-
number 10290. DO NOT USE THIS OPERATION

III. 1979 JEEP TECHNICAL SERVICE NUMBER.
MANUAL
A. On page 2L-8 of the SERVICE
DIAGNOSIS CHART under the heading "CONDI
TION." add step Il to subtitle "POOR RETURN OF
STEERING WHEEL TO CENTER." Stepl I will read
as follows:
Possible Cause Correction
II Kink in Return Hose II Replace Hose
B. On page 2L-12, figure 2L-7, View A, the
information referring to the ball plug should read as
shown in fig. 2.
Seat ball in housing with blunt-nosed punch. Spray ball

area with Loctite solvent No. 75559, then dry with
compressed air. Cover ball with Loctite adhesive 290. Let
/
adhesive cure approximately two hours and reinstall Fig. 2 Revised Steering Gear Leak
housing in vehicle. Diagnosis and Corrective Action
View A
WARRANTV
OPERATION YEA R AND TI ME SKILL
NUM tEVEL
CODE
.IL_. 78 79
GEAR ASSEMBLY. POWER STEERING -
R & ft 10.500 10310 WAG-CKE-TRK 0.6 0.6 0.6 G

83-93 0.8 0.8 0.8
With snow plow Add- 0.1 0.1 0.1
Gear assembly Adjust
- 10.959 A 0.2 0.2 0.2 6
Gear assembly Replace
- 10.501 B 0.1 0.1 0.1 C
Gear assembly Overhaul
- 10.502 C 1.2 l.2 1.2 6
Adjuster Plug -Replace 10.555 D 0.3 0.3 0.3 C
Valve Body assembly Replace
- 10.615 E 0.5 0.5 0.5 6
NOTE: Combinations D and £ include adjust
ment. Use combination C only as a separate
operation.
- -
9-008-bA/iC
77-67
Subject: Rlvnut Replacement Application: 1977-1978 Cl Models File: CHASSIS
Equipped With Front Sta billz er Bar Steering and Suspension
Group 10.000
No. 8-03 August 25, 1978
A procedure has been developed to replace loose or

damaged Rivnuts used on 1977-1978 CJ Models
equipped with a front stabilizer bar.
Service correction involves removing the Rivnut and

/
installing a 3/8" x 1-I 2" SAF Grade 8 bolt and hardened
nut.
The following parts are available through local jobbers.

The quantities listed are required for each Rivnut
replaced.
3/8 - x 1-1/2 .‘ FROt4TOF

SAE Grade 8 VEHICLE
Bolt
3/8" x 1" O.D. Fig. 1

Flat Washer 2
4 Attach a 3/8" x 1-1/2" SAE grade 8 bolt with a
3/8 Lock 3/8" x 1" O.D. flat washer to wire and pull shank of bolt
Washer I through hole see Fig. 2.
3/8" Hardened NOTE: Leave wire attached to the bolt shank to help pull
Nut the bolt through the front stabilizer bar support bracket
during installation.
PROCEDURE
I Remove front stabilizer bar support bracket bolts
and pull stabilizer bar and bracket away from frame see
Fig. I.
2 Using a cold chisel and hammer, remove head of
damaged Rivnut by chiseling horizontally along bottom
of frame rail.
NOTE: When replacing the Rivnut closest to thefront of

the vehicle, partically remove the front stabilizer bar
support bracket spacer by tapping it with apunch toward
the center of the vehicle see Fig. 1,
3 Run mechanics wire up through hole where Rivnut

was located and out through elliptical hole located on top
of frame approximately 3" rearward of Rivnut hole see
Fig. 2.
FRONT OF
VEPICLE Fig. 2
I American Motors Sales Corporation
S.rvlc. Englnnring Dspartm.nt s 14250 Plymouth
Road * D.troit, Michigan 45232
Additional copies ot this bulletin are a"aiIable through your zone office.
_7_7 no
5 Placea3/8"x rO.D.flatwasherinspotfacedarea 7 /
of stabilize? bar support bolt hole in bracket and slide
support bracket over exposed threaded area of bolt. Use
wire which was attached to shank of bolt to help pull bolt
through stabilizer support bracket. Install a 3/8" lock
washer and hardened nut see Fig. 3.
6 /
Tighten nut to 3 ft. lbs. 41 Newton-meters torque.
NOTE: If bolt turns during tightening use a 1/2"
crowfoot adapter on the torque wrench and hold the
shank of bolt with a small pair of locking pliers.
Fig. 3
OPERATION DESCRIPTION REPORTING OPERATION - - SKILL
CODE NUMBER MODEL 77 78 - LEVEL
RIVNUT,STARILIZERBAR 10.260 10189 83-93 C

One or Two Replace
- 0.5 0.5
Three Add 0.1 0.1
All Add 0.1 0.1
8-I03-IOJ
7 7-69
fljep*

Subject: Sport Steering Wheel Skirt Application; 1977-1978 Jeep Vehicles File CHASSIS
Replacement Equipped With Sport Steering Wheel Steering, Suspension
No. 8-02 July 10, 1978
A replacement procedure has been developed for the 6 Color coat replacement skin following procedures
sport steering wheel skirt used on 1977-1978 vehicles outlined in 1978 Jeep Technical Service Manual, Metal
equipped with the sport steering wheel option. Repair and Painting. Page 3B-3, Volume 3.
The sport steering wheel skirt is available through the 7 Install new skirt with three retaining screws that
current Parts Catalog under Group No. 10.283-1 and can hold center horn button receiver insulator.
be installed as follows:
8 Align steering shaft and steering wheel marks, and
install wheel on shaft.
PROCEDURE
9 Install plate, horn button receiver and bushing with
three screws.
I Disconnect battery negative cable.
N OTE: The horn button receiver cup has a notch cut in it
2 Remove center horn button by lifting it up and which must be indexed to the 12 o’clock position when
pulling it out. installing.
3 Remove steering wheel nut and washer. 10 Install washer and nut and tighten nut to 25 foot
pounds 34 N/ M torque.
NOTE: Check for alignment marks on steering shaft and
steering wheeL Paint alignment marks on shaft and wheel CAUTION: If for any reason a new steering shaft nut
V none are present. must be used, inspect and identfv the shaft nut thread
type before installing the replacement nut. Metric shafts
4 Remove three horn button receiver retaining have an identifying groove in the shaft steering wheel
screws, remove receiver and plate. Use steering wheel splines and Metric nuts are color-coded blue for
puller J-2 1232 to remove steering wheel. ident/ication.
CAUTION: Do not hammer on the end of the shaft. II Install center-type horn button by indexing
Hammering could shear or loosen the plastic retainers projection on rubber retaining ring with notch in cup and
which maintain rigidity of the energy-absorbing feature pushing cup down to engage ring.
of the column.
12 Connect battery negative cable.
5 Remove steering wheel skirt by removing three
retaining screws that hold center horn button receiver 13 Reset clock if equipped.
insulator.

OPERATION DESCRIPrION OPERATION SKILL
REPORTING MODEL -
NUMBER LEVEL
CODE 77 78
SKIRT, STEERING WHEEL, SPORT -
REPLACE 10.280 10251 03 0.3 M

S.rvlcs Enginnring D.partmsnt * 14250 Plymouth Road * Dtrot, MichIgan 45232
Additional copies ot lh,s bulletin are available through your zone office.
77-70
flJeep

March 21, 1977
Subject: Momentary Delay In Powr Steering Application: All 1975, 1976 and 1977 PIle: Group 10,000
AssIst During Cold Start-Up Models With Power Steering
Some owners of 1975, 1976 and 1977 Jeep vehicles 7 Install replacement 0-rings in oil ring grooves and
equipped with power steering may complain of a lubricate with power steering fluid.
momentary delay in power steering assist during cold
start-up and drive-away. The owner may report that the 8 Lubricate replacement seal rings with power steering
condition occurs when making a right turn and when the fluid and install in oil ring grooves over 0-rings.
ambient temperature is between 25 to 45 degrees NOTE: The teflon seal rings mc’ be slightly distorted, this
Fahrenheit. condition is normal and straightening is not required. The
sea’ rings will straighten themselves during operation of
I/ic steering gear.
Service correction, on a complaint basis, involves
replacing the valve body 0-rings and seal rings using the CAUTION: Before installing valve body be sure stub
following kit. This kit contains green colored seal rings shaft-to-worm gear 0-ring is properly positioned. Replace
which are the only ones that should be used. O’ring if damaged.
NOTE: Do not use old repair kit 3204833 containing 9 Align notch in lower edge of valve body with drive pin
white or tan colored seal rings. These rings do not provide in pinion shaft and install valve body in housing.
an adequate seoi.
NOTE: Be sure drive lags on pinion shaft engagefully into
Description Quantity Part No. Group slots ill stub shaft cap. When valve body is correctly
installed, fluid return hole in housing will be visable. if
Kit, Power Steering Gear I 8127720 10.625 ho/c is not visable, pinion shaft is not seated, spool valve
Valve Ring and Seal locating pins are misaligned or valve body stub shaft
locating pills are misaligned. Correct as necessary.
PROCEDURE CAUTION: Do not press on stub shaft to seat valve body.
Press directly in: valve hotly au/v.
I Remove steering gear as outlined in appropriate
Technical Service Manual. 10 Install adjuster plug in housing using Spanner Tool
J7o24. Tighten plug until fully bottomed in housing.
2 Place steering gear assembly in a vise equipped with II Adjust thrust bearing preloacl as follows:
protective jaws. a Using spanner hole in adjuster plug for referente,
mark plug and housing.
3 Remove adjuster plug locknut. b Measure back counterclockwise 3/16 to 1/4 inch
from spanner hole reference mark and make a second
4 Remove adjuster plug using Spanner Tool J-7624. mark on housing.
c Back adjuster plug off to second mark.
5 Remove valve body assembly by pulling straight up on 12 Install adjuster plug locknut and tighten to
stub shaft. approximately 80 foot-pounds torque.
6 Carefully cut and remove seal rings and 0-rings from 13 Install steering gear as outlined in appropriate
valve body. Technical Service Manual.

SEALS, STEERING GEAR

VALVE BODY-REPLACE 10.615 10.345 83-93 1.2 1.2 1.2 6
Includes R & R Steering Gear. WAG-CKE
-TRK 1.0 1.0 1.0 0
With snow plow - Add 0.1 0.1 0.1 0
ServIce EngIneerIng Dept. * 14250 Plymouth Rd. * Detroit, Mich. 48232
Additional copies of this bulletin are available through your zone office
77-11
fljeep.

Subject: Transmission Shift Cover Contacting Application: 1916, 1977, and 1978 File: BODY
Floorpan Cherokee and Truck Models With 4- Body General
Speed Transmission
No. 8-01 December 16,1977
The transmission shift tower may contact the floorpan on 5 Remove a piece of floorpan large enough to provide
the subject vehicles causing a noise similar to gear rattle a one inch I’ clearance between floorpan and tower.
to be transmitted into the passenger compartment. This Cutting operations may be done using an air chisel or by
interference problem will normally occur where the tower drilling a series of closely spaced holes and cutting with a
portion of the shift cover extends through the opening sharp cold chisel Fig. 1.
provided in the floorpan for the shift lever.
6 Slide shift lever boot down into position and secure
Service correction involves providing clearance between to floorpan with retainers.
the shift tower and floorpan by removing a piece of the
floorpan at the contact point.
NOTE Before proceeding with any transmission repairs

involving a rattling type noise on the subject vehicles, it is
advised that the vehicle be inspected for the described
interference problem.
PROCEDURE
1 Using large screwdriver, disengage shift lever boot

retainers from floorpan.
2 Slide boot up shift lever.

3 Check tower and floorpan for actual contact or for
signs of contact such as chipped paint or shiny metal.
4 If contact between floorpan and tower is not evident

proceed with diagnostic procedures to isolate cause of
noise. If contact is evident proceed to step 5. rIg.

OPERATION SKILL -
FOUR-SPEED TRANSMISSION TO CKE

FLOORPAN CLEARANCE INSPECT. - - 20.005 20.125 TRK 0.1 0.1 0.I G
Cut floorpan to provide clearance ... 20.005 A 0.1 0.1 0.1 C
8-025- BSJ
Ti American Motors Sales Corporation

S.rvlc. Engineering D.partm.nt * 14250 Plymouth Road * D.trolt, Michigan 48232
Add,t,onaI copies of this bulletin are available through your zone office.
77-72
April 6, 1977
ApplicatIon: 1976 and 1977 0-7 File: Body
..oose Models With Hardtop Enclosure Section
On some 1976 and 1977 CJ-7 models with a hardtop

enclosure the body-to-rear wheelhouse strainer may pull
loose from the body panel.
Service correction involves removing and rewelding the

strainer, repairing the body sheet metal, and painting as
necessary.
PROCEDURE
2 Remove seat belt retractor.
3 Remove drivers seat and track assembly. Body-to-Rear Wheelhouse Strainer

4 Loosen wiring harness from body stays and move it
aside.
5 Fold back carpet, if equipped. 11 Spot prime and color coat body side panel, strainer,
and wheelhouse panel as necessary.
6 Loosen roll bar, if equipped, and slide rearward to
gain access to strainerto-wheelhouse spot welds. 12 Tighten wiring harness to body stays.
7 Remove strainer by chiseling welds from wheelhouse 13 Slide roll bar forward, if equipped, and tighten bolts
panel and body side panel. to 25 foot-pounds torque.
8 Grind welds from body side panel and strainer. 14 Reposition carpet, if equipped.
Straighten body side panel and strainer as required.
15 Install drivers seat and track assembly. Tighten nuts
9 Position strainer on outer body side panel and weld in and bolts to 15 foot-pounds torque.
place.
16 Install seat belt retractor. Tighten bolts to 45
NOTE: Make sure outer body panel is flat and straight. foot-pounds torque.
10 Spot weld strainer to wheelhouse panel. 17 Connect battery negative cable.
The following operation and standard work times will apply.

OPERATION DESCRIPTION REPORTING OPERATION MODEL - Skill.
STRAINER, BODY-TO-REAR
WHEELHOUSE REWELD
- 20.125 20073 93 1.6 1.6 - G
Does not include spot prime and

color coat. Refer to Paint Section of
appropriate $50 manual.

77-73
flJeep

February 24, 1977
Subject: Water Leak Amund Llftgate Hinges - Application: 1977 0-7 Models File: Body Section
Caused by Loose Hinges With Hardtop Enclosure Built
-
Prior to yIN J7XXXXXOS3BS9
Some owners of 1977 0-7 models may complain of water PROCEDURE

leaks around the liftgate hinges. This condition may be
caused by the hardtop portion of the iiftgate hinges being
loose. The hinges may be loose as a result of the screws 1 Remove hinge-to-top attaching screws.
bottoming against the tapping plate preventing them
from fitting properly against the top. 2 Position shims between hinge and top.
Service correction involves removing the hinge-to-top 3 Install screws.

attaching screws and installing the following shims
between the hinge and the top. 4 Check Liftgate operation.

Shim, Liftgate 2 8128568 28.572

CODE NUMBED 77 78 79 LEVEL
SHIM,LIFTGATE HINGE-INSTALL 3L031 23335 93 02 - - M

Service EngineerIng Dept. * 14250 Plymouth Rd. * Detroit, Mich. 48232
77-74
SERVICE No. TB 2 7700 Series
P1 Jeep TECHNICAL
BULLETIN
11
Group: Body Section

Date: November 4, 1976
7600 Series
Subject: Seized or Binding Windshield, Door, or Tailgate Hinges Caused by Rust or Corrosion -1976
-
and 1977 CJ-5 and 11-7 Models Built Prior to YIN J7XXXXXO14S1O
Windshield, door, or tailgate hinges on some of the tailgate and door hinges have a stainless steel hinge
subject vehicles may bind or become seized due to pin. The tailgate hinges also have an oil hole for
rust or corrosion as a result of the hinges not being improved lubrication.
properly lubricated during scheduled maintenance
services. When hinge replacement is necessary, on vehicles
built prior to J7XXXXXO1451O, order the appro
To eliminate this condition improved hinges are priate parts. The following parts will be available
being installed in production. The new windshield from your Parts Distribution Center the week of
hinges are zinc phosphate coated and have an oil November 29, 1976. Do not order parts before this
hole for improve lubrication. On 11-7 models the date
Description Model Quantity Part No. Group
Hinge, Windshield - R.H. CJ-5 w/o Metal End. 11-7 1 5462424 25.005
Hinge, Windshield - L.H. CJ-5 w/o Metal End. 11-7 1 5462425 25.005
Hinge, Windshield - R.H. CJ-5 w/Metal End. 1 5462426 2&005
Hinge, Windshield - LH. CJ-5 w/Metal End. 1 5462427 2&005
Hinge, Tailgate - L.H. & R.H. CJ-7 1 5462416 23.006
Hinge, Door - R.H. CJ-7 1 5462412 23.015
Hinge, Door - L.H. CJ-7 1 5462413 23.015
NOTE: Windshield, door and tailgate hinges should be lubricated with Lubriplate Part Number 5555 or equi
valent every 15,000 miles for nonnal driving and every 5,000 for heavy duty driving.
PROCEDURES 5 Position replacement hinges on windshield

frame and body and install attaching screw using
Windshield Hinge Replacement-CJ-5 and CJ-7 Ton Bit Tool J-25359.
1 Remove hinges attaching screws using Ton

Bit Tool J-25359. Tailgate Hinge Replacement CJ-7
2 Clean replacement hinges in suitable solvent 1 Remove hinge attaching screws using Ton Bit
and dry with compressed air. Tool J-25359.
3 Color coat replacement hinges to match body 2 Clean replacement hinges in suitable solvent
using Jeep exterior spray paint. and dry with compressed air.
4 Lubricate replacement hinges with Lubriplate 3 Color coat replacement hinges to match body
part number 5555, or equivalent. using Jeep exterior spray paint.
Service Publications Department. American Motors Sales Corporation

77-75
4 Lubricate replacement hinges with Lubriplate 3 Clean replacement hinges in suitable solvent
part number 5555, or equivalent, and dry with compressed air.
5 Position replacement hinges on body and tail- 4 Color coat replacement hinges to match body
gate and install attaching screws using Ton Bit using Jeep exterior spray paint.
Tool 1-25359.
5 Lubricate replacement binges with Lubriplate
part number 5555, or equivalent.
6 Position replacement hinges on door, align

Door Hinge Replacement-CJ-7
with wax pencil outhne and install screws using
Ton Bit Tool 3-25359,
1 Mark outline of existing hinges on body and
door with a wax pencil.
I? Position replacement hinges on body, align
with wax pencil outline and install screws using
2 Remove hinge-to-body and hinge-to-door screws Ton Bit Tool J-25359.
using Ton Bit Tool 1-25359 and remove hinges.
8 Check door alignment. Adjust as necessary.
NOTE: Upper hinge is part of windshield hinge
assembly. Be sure to support windshield frame be- The Standard Servicing Operations and work times
fore removing hinge and check alignment after as published in the current 850 Manual are not
installation, affected by this bulletin.
77-76
Subject: Moisture Entering Parking and
Application: 1976-80 Cd Models File: BODY
Front Directional Signal Lamp Assembly
Body Electrical
No. 80.2 Dec. 7, 1979

Some 1976.80 CJ models may have moisture entering MOUNTING
the parking and front directional signal lamp assem GASKET
bly through the wire harness entrance into the upper
side of the lamp housing.
Service correction involves repositioning the lamp

housing and replacing the lens gasket or the lamp
assembly if necessary.
The following parts are available if required:

cat
LAMP, Assembly
Parking and Front
Directional Signal AR 5461340 3.292 LAMP LENS
HOUSING
BEZEL ASSEMBLY
GASKET, Directional
LENS
Lamp Mounting GASKET
and Parking AR 991400 3.292
Lamp Assembly and Gaskets
PROCEDURE
4 Remove two screws that attach lens and gasket
1 Remove park and turn signal lamp assemblies to lamp housing. Separate lens from lamp housing
from grille panel and inspect mounting gasket for any and gasket. Rotate housing and gaskets 180° so
distortion. Replace gasket if distorted. wires exit from bottom of housing and assemble
2 Inspect internal bulb sockets for corrosion. lens to housing see illustration.
a If corrosion is not present, then continue Install assembly with new mounting gasket if
5
procedure on existing assemblies. required to grille panel being careful not to strip
b If corrosion is present, obtain replacement screws.
lamp and continue procedure.
3 Apply chassis lubricant or dielectric compound, NOTE: Use locally procured oversized mounting
8127445, to bulb socket to prevent corrosion. screws if required.
COST OPERATION YEAR AND TIME SKILL

OPERATION DEScRIPTIoN MODEL 16-80 LEVEL
CODE NUMBER
LAMP ASSEMBLIES, PARK AND FRONT

DIRECTIONAL SIGNAL- INSPECT
AND/OR REPOSITION 3.292 3403 CJ 0.1 G
Replace One or both 3.292 A Cd 0.1 G

SO-032-BSA
P1 AmerIca’ Motors Sales Corporation

Servic. Englnnrlng Dspartm.nt . 14250 Plymouth Road * D.trolt, Michigan 48232
Subject: Tailgate Glass Defogger Wire Repair ApplicatIon: 1977-79 Wagoneer and File: BODY
Cherokee with Tailgat e Glass Repair Body Electrical
No. 9-01 June 7. 1979
If during a tailgate glass repair or during a tailgate glass

defogger repair, if either the feed or ground wire for the
defogger is found to be broken or chafed adjacent to the
tailgate glass lower channel, it can be repaired.
Service correction involves removing any excess tailgate

glass-to-channel sealer that would interfere with the
correct routing of the feed or ground wires, soldering
the broken wire, covering the soldering joint with heat
shrinkable tubing and securing the repaired wires to the
lower glass channel with a nylon strap.
The following parts are available and required: Fig. 2 Trimming Channel Sealer
Description Quantity Part No. Group No. 4 Clean both ends of wires where cut or broken.
KIT, Rear 5 Trim insulation from feed or ground wires to

I 8129876 3.774
Window expose approximately 1,14 inch of bare wire.
Defogger
6 Slide heat shrinkable tubing over feed or ground
wires.
PROCEDURE NOTE: Use 60/4Osolderor equivalent such as Eutec Rod
/578 for this solder joint.
I Remove tailgate glass and channel assembly as
outlined in appropriate Jeep Technical Service Manual. 7 Solder feed or ground wires to braided strap
keeping joint as small as possible. & sure solderjoint is as
2 If wires requiring repair is not broken, remove close as possible to glass.
nylon strap and cut wires adjacent to tailgate glass
lower channel see fig. I. 8 Slide heat shrinkable tubing over the solder joints
see fig. 3.
WIRE
WIRE
Fig. I Defogger Wire Interference
Fig. 3 Tailgate Glass With Defogger Wire In
3 Remove any excess channel sealer that protrudes Position
from end of channel sec fig. 2.
9 Shrink tubing with low heat soldering gun.
OVER
S.rvlc. Enginoring Dspartm.nt * 14250 Plymouth Road * Detroit, MIchigan 48232
Additional copies of this bulletin are available through your zone of
ice
10 Secure feed or ground wires with nylon strap to II Install tailgate glass and channel assembly as
inside of square 1oop located on channel, outlined in appropriate Technical Service Manual.

OPERATION
OPERATION DESCRIPTION REPORTING MOOEL - -
NUMBER
CODE 77 78 79
GLASS, TAILGATE R&R
- 25.127 25150 WAG-CKE 0.4 0.4 0.4 C
Replace 25.127 A 0.l 0.1 0.1 C
Wire, Defogger Repair
-
Oneside 3.807 K 0.1 0.1 0.1 C.

9-0146- BSJ
77.79
Subject: Windshield Wiper Motor Disassembly Application: 1974,1975, 1976, 1977, and File: BODY
and Assembly Procedure Supplementary 1978 Jeep Wagoneer, Cherokee, and Body Electrical
Technical Service Manual Information Truck Models Group 3.000
No. 8.06 March 31,1978
This bulletin is being issued to supplement the listed 5 Remove wiper motor-to-dash panel mounting
model-year Technical Service Manual procedures screws and remove motor.
pertaining to windshield wiper motor disassembly and
assembly. The supplementary information includes the 6 Clamp crank arm in vise and loosen crank arm
following: retaining nut, remove nut and arm from motor.
1 An additional Troubleshooting in Vehicle diagnosis 7 Remove seal cap, retaining clip, and end plate
procedure for worn-out wiper motor gears. washer.
2 Wiper motor disassembly and assembly which 8 Punch out gear box cover retaining rivets and
includes wiper motor gear replacement. remove cover and gear train.
3 Standard Servicing Operations update. NOTE: Mark ground strap location for reassembly.
9 Repack cover with a waterproof grease, part
DIAGNOSIS PROCEDURE number 8991416 or equivalent.
When the windshield wiper motor gear wear-out is 10 Install gear and pinion over terminal board shaft.
suspected, check under the dash at the motor to insure the
linkage is properly attached. If the linkage is intact, turn Il Install gear and shaft in gear train cover.
the ignition to the on position, then turn the wiper motor
on and listen for the noise of the motor running. If the 12 Install washer and retaining clip.
wiper motor runs, but does not move the linkage, gear
replacement is the recommended repair. If the wiper 13 Install seal cap and crank arm on shaft. Do not
motor does not run, refer to the Troubleshooting secure arm.
Procedures in the appropriate Technical Service Manual.
14 Make sure motor linkage is in Park position. Line
The following parts are listed and available through the crank arm up with the identification marks on cover see
Parts Catalog; however, the current supply of Drive Gear illustration.
Kits is exhausted. Do not order parts until after March
27, 1978.
Description
Drive Gear Kit
Quantity
1
DISASSEMBLY AND
ASSEMBLY PROCEDURE
Part No.
941916
Group
22.031
a USE THIS SET OF
INDEX MARKS TO
LOCATE CRANK ARM
I Disconnect battery ground cable.
2 Manually place the wiper arms in Park position on

windshield.
3 Disconnect wiper drive link from crank under

instrument panel.
4 Disconnect motor wires at motor under hood. OVER CRANK ARM ALIGNMENT

S.rvic. Englnnrlng D.portm.nt . 14250 Plymouth Road * DetroIt, MichIgan 40232
778O
15 Place gear train cover over dowel pins and secure 18 Connect motor wires to motor.
cover. & sure cover is located properly over locating
dowel pins. 19 Connect wiper drive link to motor crank.
16 Clamp crank arm in vise and secure crank arm nut. 20 Connect battery ground wire.
17 Position motor on dash panel and install mounting

screw

OPERATION - SKILL
OPERATION DESCRIPTION REPORTING MODEL - - -
NUMBER 74 75 76 77 78 LEVEL
CODE
MOTOR, WINDSHIELD WIPER- R&R 22.027 22010 WAG- 3 .3 .3 .3 .3 C

eKE
TRK
GearSet-Replace B .3 .3 .3 3 3 G
8O3S8Si
77-81
Subject Hectrie Tailgato Window Regulator App&atlsts 1974, 1975, 1976, 1977 FIle: BODY
Pinion Gear Shaft Lose and 1978 Wagoaser and Cheekee Both ElectrIcal 1977 and
ModeS Wills Electric Tafipto Window Prior Group 3.000
No. 8.04 October 13, 1977
If the electrically operated tailgate window, on one of the WARNING: Regulatorspring tension MUST be retained
above vehicles, is inoperative and the problem is caused as before removing motor and drive unit from regulator.
a result of a loose pinion gear shaft on the window
regulator, it is no longer necessary to replace the window 7 Install a 1/4 inch by 1 inch screw, with flat washer,
regulator. between the sector gear teeth Fig. 1.
Efkctive repairs can be made, providing the gear teeth are 8 Remove motor attaching screws and slide motor
not damaged, by restaking and welding the pinion gear from under regulator.
shaft in accordance with the following procedure.
9 Remove regulator attaching screw and regulator. If
PROCEDURE attaching screws are not accessible, proceed as follows:
a Graspregulatorarm asfaroutboardas possible.
b Push downward on arm until sector gear holes
1 Lower tailgate window. align with attaching screw.
c Hold regulator arm down and insert screw
2 Open tailgate. between sector gear teeth.
d Remove regulator attaching screws and
3 Remove tailgate carpet and access cover. regulator.
4 Remove retainers attaching regulator arms to 10 Clean regulator in solvent and dry with compressed
channel. air.
5 Disengage regulator ann pins from channel, 11 Wire brush area around pinion gear shaft.
6 Support window glass in raised position. 12 Stake pinion gear shaft in position.
SECTOR GEAR 13 Tack weld pinion gear shaft in three places Fig. 2.
WELD
3 PLAcES
Fig. I Locking EI.ctric Operated Window Fig. 2 PinIon Gear Shaft W.ldm.nt
Regulator Geara OVER
S.rvlc. Engineering Department * 34250 Plymouth Road * Detroit. MIchIgan 48232
77-82
14 Clean welded area using a wire brush. 20 Engage regulator arm pins to channel.
15 Paint welded area using black AMC/Jeep spray 21 Install retainers attaching regulator arm to channel.
paint, part number 8990636, or equivalent
22 Install tailgate window.
16 Lubricate regulator pinion gears and sector gears
with Lubriplate Multi-Purpose grease, or equivalent. 23 Install tailgate access cover and carpet.
17 Install regulator in tailgate. 24 Close tailgate.
18 Install regulator motor. 25 Raise tailgate window and check for proper
operation.
19 Remove screw from between sector gear teeth.
REGULATOR. ELECTRICAL TAILGATE

WINDOW REPAIR
-
8OO 6.BSJ
77.33
Application: 1974, 1975, 1976, 1977, File: BODY
otor and 1978 Wagoeea and IleTokee Body ElectrIcal 1977 and
Models With Eiretrically Operated Prior Group 3.000
Tailgate Window
No. 8.03 October 13, 1977
If the electrically operated tailgate window, on one of the

above vehicles, is inoperative and the problem is caused as
a result of a broken electrical connector on the motor, it is
no longer necessary to replace the motor.
Effective repairs can be made by cutting the female

connector from the wires, installing two quick connect
terminals and filling the connector cavity on the motor
with a sealer. The following parts will be required.

Sealer
Gasket-in-a-Tube AR 8993317 15,260
Terminal 1/4 Inch

Quick Connect 2
FILL CAVITY
PROCEDURE WITH %ALER
TAN WIRE
1 Lower tailgate window.
2 Open tailgate.
BROWN WIRE
3 Remove tailgate carpet and access cover.
4 Raise tailgate window, using safety switch. Electric Tollgate Window Motor
5 Loosen window regulator screw.
6 Remove motor from window regulator.
13 Fill motor connector cavity with Gasket-in-a-Tube
7 Disconnect female connector from motor, Sealer, part number 8993317, or equivalent see
illustration.
8 Cut off wires at female connector.
14 Install motor on window regulator.
9 Strip ends of both wires.
15 Tighten window regulator screw.
10 Attach 1/4 inch quick connect female terminal to
each wire. 16 Install tailgate access cover and carpet.
11 Connect tan wire to upper motor terminal see 17 Lower tailgate window, using safety switch.
illustration.
18 Close tailgate.
12 Connect brown wire to lower motor terminal see
Check tailgate window fir proper operation.
illustration. OVER 19
Service Englnnrlng Deportment e 14250 Plymouth Road e DetroIt, MIchIgan 48232
Additional copies of this bulletin are available thi’ough your zone office.
77.34
OPERATION OESCRIPTION Pt R AT ION MODEL SKILL
REPORTING NUMBER r
CODE
-
4 75 I 76 77 I 78 LEVEL
MOTOR,
- REPAIR
TAILGATE WINDOW
23.310 23391 WAG- 0.6 0.6
Ij 0.6
I
0.6 I 0.6 G
CRE
-
I I
7-O$3-BSJ
77-85
Subjeet: cracked Headlamp Bulb ApplicatIon: 1977 and 1978 Q5 and File: BODY
0-7 Models BuIlt Between VINs Body Electrical
37XXXXX1Q8715andJ8XXXXXO13665 1977 Group Body Section
No. 8-01 September27, 1977
If a sealed beam headlamp unit is reported to be cracked 8 Mm headlamps.

on a CS-S or built check to
be sure that the lamp was positioned in the shell properly. 9 Install headlamp door.
When replacing the unit, make sure that the shell lances
align properly with the bosses on the lamp. If an
interference between one of the shell lances and the lamp
bosses is encountered, correct the condition as outlined in
the ibilowing procedure.
PROCEDURE
1 Remove headlamp door.
2 Remove headlamp retaining ring.
3 Remove and discard cracked bulb.
4 Position replacement bulb in shell and check for

proper alignment.
LANCED AREA 3
5 File lanced area of shell that interferes with bosses of REWORK AS NECESSARY
bulb see Illustration.
6 Install headlamp bulb.
7 install headlamp retaining ring.

OPERATION DESCRIPTION REPORTING OPERATION SKILL
MODEL
CODE NUMBER 77 LEVEL
78 79
SHELL. HEADLAMP - REWORK 3.245 3373 8393 0.2 0.2 - M
Both Heodiomps Add-
0.1 0.1 -
Includes aiming headlarnps

8-002-B Si
Fl American Motors SSes Corporation

Service EngIneering Deportment e 14250 Plymouth Rood * DetroIt, MIchIgan 43232
- Additional copies of this bulletin are available through your zone office.
77-86
April 21, 1977
Subject: Off-Road DrivIng Lamp KIt - Installation Application: 1977 J-10 Truck File: Group 3.000
and Aiming Procedures Models With Golden Eagle Trim Electrical
Package .
This bulletin is being issued to provide the necessary

instructions for installing and aiming the off-road driving
lamp kit used on J-10 truck models with the Golden Eagle
trim package.
The following off-road driving lamp kit will be shipped

directly from the manufacturer to the dealer for
installation on the vehicle.
Description Quantity Part No Group
Kit, Off-Road
Driving Lamp 8997207 15.162
Each kit contains:
Description Qty. Description Qty Fig. 1 Off-Road Driving Lamp Kit Installed
Lamp, 12 volt 2 -Bushing, 2 PROCEDURE

with Cover Strain Relief
-Switch, Rocker 1 Iitallatkn
Kit, Wiring
Consisting of: - Bracket, Switch I 1 Position driving lamps on roll bar mounting brackets
and tighten nuts Fig. 1.
- Wire, Black -
-Screw, Bracket 2
6 inches 2 Attach end of 25 ft. yellow wire terminal end to a
- Connector, snake wire.
- Wire, Red - 3-Way Butt 1
18 inches NOTE: A suitable snake wire can be fabricated by
6 joining the ends of3 & 4 lengths of welding rod together.
-Tie, Cable
-Wire, Brown -
Holder, Fuse
12 inches
-
3 Insert snake wire with yellow wire attached into
bottom left corner of pick-up box and feed through stake
-Fuse, 20 AMP 1 box section and into roll bar, Continue snaking wire
-Wire, Yellow -
6 inches through roll bar until end of wire reaches access hole in
-Terminal, underside of roll bar at right hand lamp Fig. 2.
Spade Female
- Wire. Yellow -
25 feet 4 Remove snake wire and attach terminal end of yellow

- Instruction Sheet I wire to right hand lamp.
NOTE: For missing or damaged items contact the kit 5 Insert bushing in right hand access hole of roll bar.
manufacturer direct:
6 Pull a loop of wire from left hand access hole in roil
bar.
CHIlE Lights EFPE Company
-
33195 Harper Street 7 Cut wire loop and strip ‘Ii inch of insulation from
St. Clair Shores, Michigan 48082 each end Fig. 3.
OVER

Service Engineering Dept. * 14250 Plymouth-Rd. * DetroIt, MIch. 48232
Additional copies of this bulletin are available through your zone of/ice.
77-87
___
FIg. 2 Roll Bar Access Hole L. H. Shown
8 Connect terminal end of 6 inch yellow wire to left

hand lamp.
9 Strip ‘I. inch of insulation from other end of 6 inch

yellow wire.
10 Insert both ends of yellow wire from roll bar and 6

inch yellow wire from lamp into 3-way butt connector and
crimp securely.
FIg. 3 Roll Bar Wire Routing
11 Puch 3-way connector andwires into left hand access
hole in roll bar.
20 Attach one end of 6 inch black wire to negative -
12 Insert strain reliefbushing into left hand access hole. terminal of rocker switch. Attach other end to steering
column collar trim screw or other suitable ground.
13 Route yellow wire extending from pick-up box along
inner side of left frame rail to engine compartment. 21 Route yellow wire from lamps to rocker switch and
cut off excess.
14 Route wire up dash panel firewall and through
22 Strip ¼ inch of insulation from yellow wire, install
heater vacuum control hose grommet into passenger
compartment. female spade terminal and crimp.
15 Drill a % inch diameter hole in lower instrument

-
panel 2-½ to 3 inches left of fresh air vent knob.
- -
--
16 Install fuse holder Fig. 4.
17 Drill two 1/8 inch holes under instrument panel,

below fuse holder. Use rocker switch as template.
NOTE: On vehicles equipped with air conditioning locate

switch holes left of discharge duct.
18 Install rocker switch Fig, 4.
19 Attachoneendofl2inch brown wire to positive

fptenninal of rocker switch. Attach other end to straight
side terminal of fuse holder.
FIg. 4 Fuse Holder and Switch Location
page 2
77-88
23 Attach female spade terminal to remaining terminal 2 Remove lamp covers.
on rocker switch.
3 Loosen lamp attaching bolts. Turn ignition switch
24 Attach one end of 18 inch long red wire to fuse block and lamp switch on, adjust beams as follows:
terminal above "transmission kickdown" fuse. Attach
other end to center terminal of fuse holder.
a Horizontal distance between light beams on
wall should be same as distance between lamps on roll bar.
25 Secure all loose wire using cable ties.
b Vertical height of light beams on wall should be
26 Install 20 amp fuse in fuse holder, remove lamp 1 inch less than installed height of lamps on roll bar.
covets and check lamp operation.
4 Tighten lamp attaching bolts.
NOTES Lamps are switched through ignition switch and
will only operate when ignition switch is in on position. 5 Turn off ignition switch and lamp switch,
Mining lamps 6 Install lamp covers.
1 Position vehicle on a flat level surface, facing and NOTE On vehicles sold in California the fuse must be
approximately 25 feet from a wall. removed from the fuse holder for street use.

WARAANTY YEAR AND TIME
OPERATION DESCRIPTION REPORTINC OPERATION MODEL SKILL
CODE NUMOR 77 78 79 LEVEL
LAMPS, OFF-ROAD DRIVING-

INSTALL 15.162 15.659 TRK 1.0 - - G
Includes aiming lamps
page 3
77-89
Revised
January 14. 1977
Subject: Application: File: Group l5.00ö1
Citizens Band CE Mobile Radio and Antenna 1976 and 1977 MOdels
Diagnosis Procedures
Warranty Reporting Codes have recently been assigned to more susceptible to damage. If a loading coil is broken,
cover the Standard Servicing Operations of this bulletin. it is the same as operating without an antenna and may
This bulletin is being revised to include the WRC seriously damage the radio.
information. Remove and discard ORB 7-03, dated
December 23. 1976, File: Service General and file this * The use of twin antennas should be avoided unless they
revised bulletin in Group 15.000 of your 1977 ORB are installed at their designed separation. Twin
binder. antennas designed to operate at an 8 foot separation
will result in reduced performance if mounted at a S
This bulletin is to provide information for the diagnosis of foot separation. When installing twin antennas, the
citizens band mobile radios and antennas. coaxial cable to each antenna must be of equal length.
CE RADIO INSTALLATION INFORMATION
There arc many different manufacturers of CR radios, * Re sure the antenna base has a good ground. This is
always use manufacturers instructions when installing a necessary to shield the antenna from vehicle induced
Cli radio. 1-loweven the following general information noise interference. For magnetic base antennas, the
should be helpiul for a good trouble free installation. coaxial cable shielding provides the ground through the
radio chassis. If the antenna has a threaded base, coat
e A Cli radio should not be located in direct line with
the threads of the adapter or mast with a silicone
heater duct, it must have sufficient circulating air to
prevent heat build-up. electrical grease. AMC part number 8127445 or equiv
alent. Antennas should be installed as vertically as
a CR radios require a current supply of at least 1.5 possible.
amperes and a minimum of 12 volts. Maximum voltage
should not exceed 16 volts for circuitry protection. The * A CB antenna cannot be tested the same as an AM or
power supply should be taken from a source that has FM antenna. Most CR antennas have a shunt to
voltage available with the key in the accessory position. ground. Due to the costly equipment necessary to check
e When splicing leads, be sure to solder connections. If a Cli antenna, it is suggested that a known good
antenna be used as a check against a suspected
the power supply lead must cross an alternator lead,
cross the alternator lead at a right angle. defective antenna.
e Do not use wire smaller than 18 gauge stranded copper * Do not allow the coaxial cable to become crushed.
wire. Never use solid wire. Route cable underneath scuff plates rather than under
Current protection for the radio is an in-line 2 ampere the carpet.
fuse. Do not bypass the in-line fuse.
USING A VSWR VOLTAGE STANDING WAVE
e SomeCB radios do not have a ground wire and must be RATIO METER
grounded through the mounting bracket. Do not use
coaxial cable shielding for radio chassis ground. An
When installing a radio or antenna, a VSWR meter must
extra ground wire is recommended to prevent loss of
ground due to a loose mounting bracket or a poor be used. If the antenna is relocated on- the vehicle, a
antenna ground. VSWR check should be performed.
WARNING: Do not key operate the microphone VSWR is a measurement of the magnetic fields which
until the antenna has been connected to the radia reflect back into the antenna, this causes an increase in
the VSWR reading. Besides limiting the range of the
CE ANTENNA INSTALLATION INFORMATION transmitter, this also causes a heat build-up which can
damage the transmitter circuitry. A perfect VSWR read
Receiving and transmitting range of a CR radio is affected ing is 1.0. Any reading between 1.0 and 1.5 is excellent. A
by the antenna height- The higher the antenna, the longer reading above 2 is excessive and may require antenna
the range. The following rules apply generally to the relocation or height adjustment. VSWR readings can vary
various types of antennas available. depending upon atmospheric conditions. VSWR can also
vary with respect to surrounding objects that affect
. A top loaded antenna may provide a greater range but is reflection or conductivity.
over

ServIce Engineering Dept. * 14250 Plymouth Rd. * DetroIt, Mlcti- 48232
Additional copies of this bulletin are available through yow zone office.
77-90
upon atmospheric conditions. VSWR can also vary climatic conditions. Move vehicle to a different loca
with respect to surrounding objects that affect tion and retest
reflection or conductivity.
NOTE: Although you are not talking while checking
TUNING THE ANTENNA VSWR, a carrier signal is being transmitted which
Use of a VSWR meter is required and a 50 ohm can wipe out another persons transmission. Try to
dummy load is recommended, pick a time when the channel is not in use to check
VS WR.
The antenna wavelength should be adjusted for
each channel for peak performance. As this is im 9 If ground and cable connections are good,
practical, a channel near the middle of the 23 chan antenna must be adjusted up or down to achieve
nels is selected for optimum performance this is a VSWR of 1.5 or less. Some antennas have a ball
also adequate for the remaining channels. If the which may be moved up or down the mast or mast
majority of transmitting is on one particular channel, may be moved up or down in the mounting base.
the antenna should be adjusted for that channel. A socket head screw is used to secure ball or mast
Trim the antenna as follows: in position.
1 Disconnect coaxial cable from radio. 10 To determine if an antenna should be moved up

or down, use a VSWR meter:
2 Connect a jumper coaxial cable from radio to a Turn to channel 23, calibrate meter, and
TXWR connection on VSWR meter Refer to illus record reading.
tration. Jumper should not exceed 18 inches. b Turn to channel 1, calibrate meter, and
record reading. Compare two readings.
c If VSWR is best at rjinjjel 1, shorten the
antenna. If VSWR is best at channel 23, lengthen
antenna.
11 Move antenna or ball in proper direction 1/8

inch at a time until lowest VSWR reading is ob
tained. Each lime antenna length is changed, the
VSWR meter must be recalibrated,
NOTE; VSWR meter can only be calibrated in

Voltage Standing Wave Ratio Meter forward position.
When checking VSWR on different channels, meter

3 Connect a 50 ohm dummy load to VSWR meter
antenna connection. Radio will not transmit with must be recalibrated for each channel.
a dummy load. 12 If VSWR reading cannot be brought below 2,
4 Turn radio on and turn selector try moving antenna to another location an inch
chel 12.
or two may be enough. If another antenna is tried,
5 Move VSWR switch to forward position and key previous antenna must be removed as closeness of
mike. Calibrate meter to "set" position while keying two antennas has a great effect even if one antenna
mike. As soon as meter is calibrated to "set" posi- is not connected.
tion, release mike key. RADIO DIAGNOSIS
6 Move VSWR switch to reverse position and key Refer to Troubleshooting Guide
mike again. Observe meter and release key, needle 1 Obtain information from owner on complaint.
should barely move. If meter indicates more than Visually inspect antenna and cable for damage.
.01 VSWR, there is a problem in jumper harness
or meter. 2 Turn radio on. Dial light must light. If no light,
check for voltage at power supply.
7 Remove dummy load and connect antenna cable
tOVSWR meter. 3 Disconnect antenna from radio. Connect VSWR
meter to radio. Connect 50 ohm dummy load to
CAUTION: Do not talk into mike while making
VSWR meter or reconnect antenna to VSWR meter.
VSWR readings.
8 Move VSWR switch to forward position and WARNING: If a defective antenna is suspected;
recalibrate meter. Move VSWR switch to reverse make transmission time extremely short when
position and read meter, Meter should indicate 1.5 checking VSWR.
or less. If reading is 1.5 or less, remove VSWR meter, 4 Key mike. If needle on VSWR meter does not
connect antenna cable to radio and installation is move meter switch in forward position, radio is
complete. If a reading greater than 1.5 is indicated, defective and must be removed for service. Wiggle
recheck cable connections including antenna mount. mike cord while keying mike to be sure problem
A reading of 2 is not harmful and could be due to is not in mike cord.
Page 2
7791
RADIO AND ANTENNA TROUBLE SHOOTING GUIDE
CONDITION POSSIBLE CAUSE CORRECTION
Radio does not transmit 1. Power supply open 1. Check fuse and point of supply
or receive
2. Chassis not grounded 2. Add ground wire, check mount
connections, ground wire termination
3. Fuse blown 3- Check for proper size fuse 2 amp
4. Volume control knob fully 4. Read operating instructions
counterclockwise
Dial lights-little or 1. Antenna system disconnected 1. Check all connections. Install test
no noise from speaker antenna and recheck
2. Squelch knob too far clockwise 2. Read operating instructions
- 3. Object broken or lodged in external 3. Remove object
PA speaker
Cannot transmit 1. Defective antenna 1. Install test antenna and retest
2. Damaged antenna cable 2. Repair or replace cable. Check cable
routing
3. Defective microphone 3. If microphone is not detachable -
remove radio for service. Install test

microphone if mike is detachable
4. Panel meter shows no movement 4. Remove radio for service
5. PA*CB switch in PA 5- Move switch to CB position
Dial light does not 1. Defective bulb 1. Replace bulb
light- Radio functions
normally
Can receive but cuts 1. Poor connection to power supply 1. Check fuse connection. Wiggle wires.
in and out. Dial lights Splices may require resoldering. Wires
flickers. may require rerouting
Receiving only very 1. Poor antenna match 1. Check VSWR. Check for corroded
nearby stations antenna lead
2. Defective radio 2. Check with known good radio
connected to original antenna
S-meter moves 1. Squelch turned up too high 1. Read operating instructions
2. Defective speaker 2. Remove radio for service
Does not transmit, 1. Damaged mike or mike cord 1. If mike cord is not detachable,
receiver does not cut remove radio for service
out when mike is keyed If detachable-replace mike
Transmits a carrier 1. Defective mike 1. Replace mike
but no modulation
One or more channels 1. Dirty channel selector switch 1. Remove radio from chassis, spray
not operating switch with TV switch cleaner
2. Crystals or oscillator defective 2. Remove radio for service
Fuse blows when 1. Defective radio 1. Remove radio for service
transmitting 2. Radio not grounded and antenna 2. Add ground wire to radio chassis.
has lost its ground Tighten antenna mount
Squeal when 1. Loose wire in mike or cord 1. Repair mike or remove radio for
transmitting service
2. Improper use of power mIke 2. Use less power
Page 3
7792
5 Attempt radio contact with another unit. If 6 Remove YSWR meter and connect antenna to
VSWR meter did not show any problem but recep radio.
tion or transmission is unsatisfactory, install a Antenna R & R
known good test antenna and check radio operation.
1 Remove defective antenna and replace with new
antenna. Route antenna cable away from areas where
NOTE: Do not test VSWR with two antennas close
to each other as it affects VSWR even if one antenna it will be stepped on, pinched or constantly flexed.
Where cable is routed through doors or hatches be
is not connecteeL
sure there is sufficient soft rubber stripping to
encompass the cable without crushing it.
6 If operation is still unsatisfactory-replace
radio or antenna or both as required.
2 Apply a good electrical grease such as part
number 8127445, to all connections that are screwed
Microphone Replacement-Kraco Model Radios together on the antenna.
Kraco radios have a microphone which is attached 3 Check VSWR of new antenna and trim to channel
to the radio with a quick disconnect coupling. If 12 or channel most often used by owner.
depressing the mike button key has no effect or if
wiggling the cord causes intermittent transmission, 4 Remove VSWR meter and connect antenna to
this is a sign of a microphone or mike cord problem. radio.
1 Disconnect mike assembly from radio. CHECKING FOR SHORTED OR OPEN
2 Install replacement mike assembly. COAXIAL CABLE
3 Test radio operation by making contact with An ohmmeter with a capability of reading 1 ohm or
another radio operator. less is required.
PROCEDURE Test F01 Short

RadioR&R
1 Disconnect the cable at each end.
1 Disconnect antenna at radio.
2 Calibrate the ohnuneter.
2 Remove original radio. If radio disconnects at
fuse connection, tape fuse to a location where it 3 Touch one ohmmeter prod to the coaxial center
cannot short out. terminal and the other prod to the vehicle body. If
the ohmmeter shows any continuity, the cable is
3 Fill out radio repair tag completely and attach shorted and must be repaired or replaced.
it to the radio.
Test for Open
NOTEt If possible, ship radio back to repair facility
1 Disconnect cable at each end.
in its original container. Refer to Guarantee Admini
2 Calibrate ohmmeter.
stration Manual for authorized service outlet
addresses or to the card included with new nzdio. I3 Connect one ohmmeter prod to each end of the
cable at the center terminal. The ohmmeter should
4 Install replacement radio. indicate 1 ohm or less. If no reading is obtained,
5 Connect VSWR meter between radio and antenna the cable is open and must be replaced. If
and check and adjust VSWR to 1.5 or less on channel more than one ohm is indicated, check for corrosion
12 or on channel most used by owner. or damaged cable.

CB RADIO ANDIOR ANTENNA -CHECK 3007 0.1 0.1 - 6

Radio-Replace 15.315 A 0.2 0.2 - 0
Antenna-Replace 15.025 B 0.3 0.3 - 0
RadloandAntenna-Replace - C 0.4 0.4 - G
MicrupbonsKiaca-Replace 15.315 0 0.1 0.1 - 0
NOTE: Do not use comhination D in conjunction

with combination A orC.
Page 4
77-93
VU Jeep TECHNICAL
BULLETIN
Gup:13.
Date: November 3, 1976
Subject: Air Conditioning System Not Cooling-Caused by Obstruction in Suction Hose-Late 1976 Models
and Early 1977 Models Built Prior to VIN J7XXXXXOI5O8O-Equipped With Air Conditioning
The air conditioning system on some late model 2 Lower evaporator assembly.
1976 and early model 1977 Jeep vehicles may not
cool properly because of a rubber shipping plug in 3 Disconnect suction hose from evaporator.
the suction hose. The plug should have been removed
before the suction hose was attached to the evapo- 4 Check inside of hose for obstruction using a
rator. If the suction hose is obstructed and you piece of wire.
check the system pressure, your gauges will indicate
a low suction low side pressure and a high head NOTE: Be sure to check the hose carefully as rubber
high side pressure. shipping plug may have been forced into hose as
much as stx inches from connector.
To correct this condition, disconnect the suction
hose from the evaporator and remove the rubber 5 Remove plug from hose.
shipping plug.
6 Connect suction hose to evaporator.
PROCEDURE 7 Charge system refer to appropriate Technical

Service Manual.
1 Discharge system refer to appropriate Technical
Service Manual. 8 Check air conditioning operation.
The following standard servicing operation and work time will apply:

PUJO,SUCTIONHOSE-REMOVE 13.440 13119 0.3 - - 6

77-94
Subject: Seat Cover Button Replacement Application: 1977 and 197$ Jeep File; BODY
Models With Sen Cover Buttons Instrument Panels -
Seat Assemblies
No. 8-01 April 25, 1978
In the event that a seat button has been pulled from a seat Wagoneer - Cherokee Rear Seat Back
cover, it is not necessary to replace the seat cover when
only a seat button and retainer are required. The seat I Fold rear seat back down.
buttons can be found in Group 29.367-1 and the retainers
in Group 29.367-2 of the current Parts Catalog. The 2 Remove necessary hog rings from bottom edge of
procedures for replacing seat cover buttons are as seat cover to allow positioning of seat button retainer.
follows:
3 Slide seat button retainer into position and insert
seat button stem through seat cover and retainer.
SEAT BUTTON
REPLACEMENT PROCEDURES 4 Pull seat cover back to installed position and install
hog rings.
CJ-5 and CJ-7 Individual Seat Back and
Wqoneer Seat Back-Bench Seat 5 Return seat back to upright position.
I Remove front seat per appropriate Technical Truck Seat Back - Bench Seat
Service Manual.
I Remove seat back.
2 Remove hog nngs from bottom of trim to loosen
seat cover, 2 Remove necessary hog rings from bottom edge of
seat cover to allow positioning of seat button retainer.
3 Pull loose cover forward.
4 Starting at bottom edge of seat cover, slide seat seat button stem through seat covet and retainer.
button retainer up into position between cover and seat.
Push button stem through seat cover hole and seat button 4 Pull seat cover back to installed position and install
retainer, hog rings.
5 Pull loose cover back to installed position and 5 Install seat back.
install hog rings.
Truck Seat Cushion - Bench Seat
6 Install front seat per appropnate Technical Service
Manual. I Remove seat per appropriate Technical Service
Manual.
Cherokee Truck Individual Front Seat Back
-
2 Remove necessary hog rings from rear edge of seat

1 Unzip front seat back zipper to loosen cover, cover to allow positioning of seat cover and retainer.
2 Pull loose cover forward. 3 Slide seat button retainer into position and insert
seat button stem through stat cover and retainer.
3 Starting at bottom edge of seat cover, slide seat
button retainer up Into position between seat cover and 4 Pull seat cover back to installed position and install
seat. Push button stem through seat cover and seat hog rings.
button retainer.
5 Install seat per appropriate Technical Service
4 Pull seat cover back to installed position and close Manual.
zipper.
OVER
TI Amencan Motors Sales Corporation

Service EnginnTlng Department * 14250 Plymouth Road * Detroit, Michigan 48232
77.95
. WARRANTY YEAR AND TIME
OPERATION SKILL
NUMBER LEVEL
CODE 77 78
BUTTON, SEAT TRIM INSTALL
- 29.367 29037 CJ-15 .3 .3 6
Each Back Panel Front
- 16-17 .2 .2
25-45-46 .3 .3
Each Back Panel - Rear 15-16-
17-IS .3 .3
25-45-46 .4 .4
Each Seat Cushion 25-45-46 .3 .3
S.059-RSA/J
77-96
Tijeec,

Subject: Cracks or Tears in Door Exterior Application: 1976 and 1977 CJ-7 File: BODY SECTION
Sheet Metal Models With Hardtop Enclosure
No. 7-01 October 24, 1977
A crack or tear in the door exterior sheet metal, below the 12 Remove fixed ventilator window assembly as
fixed ventilator window, may develop on 1976 and 1977 follows:
CJ-7 models with hardtop enclosures. This condition a Insert a pointed tool between weatherstrip and
may be caused by broken welds on the inner and outer upper forward corner of door frame.
door panel flanges. b Force tool downward until window assembly
separates from door frame.
Service correction on a complaint basis involves c Slide window assembly rearward past door
disassembling the door, rewelding the flanges and panel flanges. Pull outward and downward to remove.
refinishing the door sheet metal as necessary.
13 Align and clamp inner and outer door panel flanges.
PROCEDURE 14 Tack weld flanges together.
IS Drill two 1/4 inch holes partially through outer

Remove door assist handle. flange.
2 Remove window regulator handle. 16 Weld drilled holes and original spot welds.
3 Remove door trim panel and water dam paper. NOTE: Drilled holes should be welded as shallow as
possible to avoid distortion of flanges.
4 Lower door glass.
17 Repair cracked or torn door outer sheet metal as
5 Remove regulator arm guide. follows:
a Tack weld crack or tear. Space welds 1/2 inch
6 Remove inner and outer glass weatherstrips. apart, over entire length. Flatten tack welds using a body
spoon and hammer.
7 Remove division bar attaching screws. b Weld entire length of crack or tear. Use a body
spoon and hammer to relieve distortion.
8 Remove door glass channel felt. Pry channel out at c Grind welded area using a body grinder with a 24
forward leading edge using a pick or other pointed tool. grit sanding disc.
Pull channel out and back toward rear curved radius of
window frame; then lift channel straight up and out of NOTE: Grind welded surface lightly, heavy or excessive
door. grinding may impair weld strength.
9 Remove division bar. Tap bar rearward using a 18 Strip paint back to original contour using a body
rubber mallet. Pull back inner lower edge of weatherstrip grinder with 24 grit sanding disc.
to allow clearance of division bar bracket.
19 Apply body filler to affected area, fill all depressions
10 Remove weatherstrip felt channel from division and flow filler to original contour.
bar.
NOTE: Mix body filler and hardener according to
II Remove door window glass. manufacturers instructions.
OVER
ServIce EngIneerIng Department * 14250 Plymouth Road e DetroIt, Michigan 48232
Additional copes of this bulletin are available through your zone office.
cHANNa
GLASS
DIVISION BAR
WEATHERSTRIP
C.J-7 Front Door
2
20 Grind affected area using a body grinder with a 50 NOTE: Do not allow paint to flash or set-up between
grit disc. Grinder should be operated at low speed. coals as an orange peel or rough surface will result.
21 Sand filler to contour using 40 or 60 grit sandpaper 38 Remove masking after paint has become tacky and
on a hand file board. Sand outer areas gradually working allow paint to dry.
to center.
39 Apply a light coating of Silicon Lubricant, part
22 Finish-sand area using 80 grit sandpaper on a hand number 8992881 or equivalent, to fixed ventilator
file board. window weatherstrip to ease installation.
23 Featheredge paint break line around affected NOTE: It will be necessary to sea:front edge of weather-
area using 180 grit sandpaper. strip into door frame; then seat the glass into the
weatherstrip.
24 Finish-sand area using 220 or 240 grit sandpaper.
40 Install fixed ventilator window in door. Slide
25 Wash door with a mild detergent and water. Rinse window over door panel flanges and into door frame.
thoroughly. Apply pressure to upper rear of window until weatherseal
is bottomed in door frame.
26 Clean painted area with DuPont Prep-Sol Wax and
Grease Remover, or equivalent. 41 Install door window glass.
27 Prepare affected area using DuPont Metal 42 Install division bar.
Conditioner, or equivalent.
NOTE: & careful during installation that division bar
28 Mask penmeter of outer door panel, bracket does not tear inner edge of window weatherstrip.
29 Mix primer-surfacer according to manufacturer’s

instructions, 43 Install division bar weatherstrip felt channel.
30 Paint affected area. Allow a slight overlap onto NOTE: If weatherstrip binds, raise door glass as high a,
original paint. possible and slip lower end ofweatherstrip out ofdivision
bar and attach to lower edge of door glass. Lower glass
31 Remove masking. until upper edge of weatherstrip is aligned with upper
edge of division bar.
32 Wet sand primed surface using 220 grit, then 400
grit sandpaper. 44 Install division bar attaching screws.
33 Clean entire door with a mild detergent and water.
Rinse thoroughly and dry with a soft cloth. 45 Install door glass channel. Raise door glass and
attach end of channel to glass. Lower glass and position
upper portion of channel.
34 Mask perimeter of outer door panel,
35 Clean surface with wax and grease remover. 46 Install inner and outer glass weatherstrips.
36 Mix paint, DuPont Centari acrylic enamel or 47 Install regulator ann guide to door glass.
equivalent, according to manufacturer’s instructions.
48 Install water dam paper and trim panel.
37 Spray one medium wet coat at 65 lbs. gun pressure
followed by a full wet coat. Compare paint match with 49 Install window regulator handle.
adjacent body panels.
50 Install door assist handle.
a If paint is too light, reduce air pressure to 35 lbs.
darkens color and apply mist coats as necessary.
b If paint is too dark, increase air pressure to 75 51 Raise door glass.
lbs. lightens color and apply several dust coats holding
spray gun about 18 inches from surface. 52 Clean windows.
77.99
The following operation and standard work time will appir
WMRANTY YEAR AND TIME SKILL
REPORTING OPATION
coot NUMBER 76 77 78 LEVEL
DOOR, HARDTOP ENCLOSURE-

REPAIR 23.001 23007 93 3.0 3.0 - C
Paint and Material Allowance $3.75
7.070-BSJ
NOTE: In accordance with the Warranty Administration Manual "A II paint repairs during the new vehicle warranty period
require prior work approval by the zone service representative’
77-100
PUJeep

January 13, 1977
Subject: Application: File:
Whitco Top Loose at Front Former-Caused 1976-1977 CJ Models Built Prior Body Section
by Insufficient Stitching at Front Edge of Top to YIN J7XXXXXO354S4
or Screws Loose in Front Former
On some of the subject vehicles equipped with a EXISTING STITCHED

FABRIC TOP AREAS
Whitco fabric top one or both of the following con
ditions may occur.
The front edge of the fabric top may twist out of

the front former. This condition is caused by insuf
ficient stitching of the fabric to the top front rail.
The screws attaching the front former to the wind

shield may become loose. This condition is caused
by improper screws being used to attach the former.
Service correction, on a complaint basis, involves FRONT FORMER

WINDSHIELD
one or both of the following: FRAME
0R1018
* Removing the top and stitching the fabric to the

3 Inspect front former attaching screws, if loose
top front rail in two additional locations.
proceed to Front Former Repair Procedure.
* Removing the improper screws and installing the
4 Install top.
proper size screws or, if holes are damaged drill
ing new holes in the former and installing larger
screws.
Front Former Repair
The following screws may be required for attaching
the front former to the windshield frame. Order 1 Remove front edge of top from front former.
screw part number G162003 if screw holes are not
distorted. If screw holes are distorted order screw 2 Remove front former-to-windshield frame attach
part number 4004710. ing screws and front former.
Description Quantity Part No. Group 3 Check screw holes in windshield frame.
a If screw holes are not distorted, ream holes
Screw, Self-tapping As 0162003 17.660 using a No. 20 drill bit.
No. 12-11 x 1/2 Required 14 If screw holes are distorted, measure 1 inch
inch from each existing hole and drill a new hole using a
No. 7 drill bit.
Screw, Self-drilling 7 4004710 26.077
No. 10-16 x 9/16 4 Position front former on windshield frame.
inch
5 Install front former-to-windshield frame screws.
PROCEDURE
a If existing holes were enlarged. use No. 12-11
Fabric Repair x 1/2 inch self-tapping screws.
1 Remove top. b If new holes were drilled, use No. 10-16 x
9/16 inch self-driffing screws.
2 Stitch fabric to top front rail at two additional
locations as shown in illustration. 6 Install front edge of top in front former.
over
Additional copies at this bulletin are available through your zone office.
77-101
The following Standard Servicing Operations and work times will apply.

OPERATION DESCRIPTION REPORI1NG OPERATION MODEL. SKILL
CODE 76 77 78 LEVEL
FORMER,TOP.-INSPECT 20.230 20501 83-93 0.1 0.1 - M

Former-Repair, Enlarge or Relocate
Screw Holes A 0.2 0.2 - M
,, lnl
1 Jeeps

December 21,1976
Some owners of 1976 and 1977 Wagoneers and Chero

kees may complain of a sag in the rear headlining.
This condition is caused by the headlining not fully
seating into the retainer mouldings.
Service correction, on a complaint basis, involves

repositioning the headlining in the retainer mould
ings and installing two coat hooks for additional
support. The following parts, as applicable, will be
required.
Screw, Tapping 2 4002099 29.010
Hook, Coat 2 3678791 27.130

Black
2 3675832 27.130
Blue 60866
2 5455151 27.130 Correcting Rear Headlining Sag

Buff 4 Install rear opening header moulding and end
2 3675833 27.130 caps.
Green
5 Measure back 13 inches from headlining retainer
and up 1-1/8 inches from bottom of .1-moulding on
PROCEDURE both sides and mark position on headlining.
6 Install headlining retainer moulding.
1 Remove rear opening header end caps and 7 Drill a 7/64-inch hole i-inch deep on both sides
moulding see Mustration. at positions marked in step 5. Drill through head
lining and into roof rail.
2 Remove headlining retainer moulding by grasp
ing center and pulling downward. CAUTION: Do not exceed .1 inch depth as damage
to the outer roof panel could result.
3 Position headlining in J-mouldings. Allow 1/8
inch gap between forward edge of rear headlining 8 Position coat hooks and install tapping screws.
and retainer. Do not overtighten.

REPORTING OPERATION SKILL
OPERATION DESCRIPTION CODE NUMBER MODEL 76 77 78 LEVEL
HEADLININ6. REAR REPOSITION MD

B
-
INSTALL COAT HOOKS 29.015 29123 Wag.-tke. 0.4 0.4 -

77-103
TECHNICAL Group: Body Section

BULLETIN Date: September 28, 1976
Subject: Paint Information -AU 1977 Jeep Vehicles
Attached are Ditzler and DuPont color charts for If additional information is required, contact your
all 1977 Paint colors. Color names and code num Zone Service Manager, Service Representative, or
bers are included in each chart. use the toll-free Denier TEKLINE.
Attachments 2

1977 AMERICAN MOTORS CORPORATION
GREMUN * HORNET
MATADOR * PACER
JEEP
AUTOMOTIVE REFINISH COLORS

Mtr. Code LUCITE CEPITARI DULVX Mir. Code WTI CENIASI® OOLU1 MI,. Code LUCfli CENTMI DULUX
and Color CODE CODE CODE and Color CODE CODE CODE and Color CODE CODE CODE
G7 6V 7M
Alpine White Sunshine Yellow Golden Ginger Met.
43499L 43499* 434990 44119W 44119*H 44119D

J2
Brandreine Met.
lB
Mocha Brown Met.
I Lime Green
7c 7W
Autumn Red Met. Captain Blue Net.
447931* 44193AW 44793DM 44191L11 44191*11 44197011

6D 7D 7?
Sand Tan Powder Blue Tawny Orange
441111 44111* 441110 44192L11 44192*11 44192DI1 44199114 44194* 4419$DH
6J 7K lz
Silver Frost Met. Midnight Blue Met. Sun Orange
441131 44113* 441130 44193131 44193*11 44193DH 44199L11 44199*11 441990H

7L
Loden Green Mel.
441161M 44116kV 44116DM 44194W 44194*11 44194D11

6R
Brilliant Blue
44111W 44117*11 44117D
INTERIOR COLORS
43611L White Flat 435101 Tan Flat 43$12L11 Berry Flat 43602LH Blue Hat
99L Black Flat 44807LH Ok. Tan Flat
UJCIIS kryhc Lucqeer. CLNTMOI Oaylic entoil end OIJLIJO Eeamot are RegisterS Irademaihe p1 the Do Pant Couipa.y.
Setfina shown we sehiect he change wItty Fernrolatiees are utilized.
Color thipe r610doced ant paper caneal Is, caeoiderat totally accurate color nIches te Iillw car maker, ot.erdarthor Os Poet nuntertal Page 1
77Aflç
AMERICAN MOTORS CORPORATION
PRIOR YEARS COLOR INFORMATION
1974
MIr. PaiM Incite CSair Dolor ljfrPajid Locite Contari Outer
Code Color Code__- Cede Code Code Celot Code Code Code
Al Stow kThite 52131 521.3* 52130 PS Medium Ian Met. 42849LH 428494K 42849014
DY TransAm Red 54t8LM 54084W 54080K P9 Copper Met. 428501M 428504W 428500K
ElA Diamond Blue Mel. 55861 5586* 55S6D 61 Light Green Met. 42851L 42851* 428510
E6 Fawt Beige 55191 5519* 55190 62 Medium Green Met. 42852111 42852*11 428520H
£9 Mellow Yellow 55221M 5522AW 5522D 63 Dark Green Met. 428531K 42853411 42853011
P2 Mane Blue 55241 5524AM 5524014 64 Plum Met. 428541M 428544W 42854DM
P4 Daisy Yellow 155261H 552MM 5526011 65 Warm Silrer Met, 428551 428554 42855D
PS Vineyard Maroon Met. ] 55701M 55704W 5570DM 65 Orange 42856111 42856411 42856011
PS Medium Blue Met. J42841LK 42847AH 42847DH P1 Block 991 994 93005
El Dark Blue Met. j_ 42848111 42848AH 428480K 1 ]
1975
Mtr.Paint
Code Color
Lojcltr
Code
Cenit.ro
Code
Doter
Cod.
Nlr.Paii.t
Cod.
I Color
Incite
Cod.
CentarF
Code
Dolor
Code
DY Trans. Am. Red 54081W 54084W 5408011 114 Dark Cocoa Met. 43503LK 435034W 43503DH
ES Fawn Beige 55191 55194 55190 115 Green Apple 435041 43504AH 43504014
9 Mellow Yellow 5522LM 55224W 55220 ItS Golden Jade Met. 43505111 43505AM 43505DH
P9 Copper Met. 428501W 428504W 428500K H? Aztec Copper Met. 435061H 43506AM 43506DM
63 Dark Green Met. 428531W 42853411 42853DH 118 Jjulumn Red Met. 435071M 435074W 43507DM
I Stenna Orange 42856LK g56AH 42856DH 149 [ Slrer Dawn Met. 43508L 43508A 435080
G7[ Alpine White 434991 434994 434990 J2 Brandywine Met. 435101M 435104W 43510DM
Blue 17 43533DH
I Pastel 43500L 435004 435000 Ivory Green 435331 435334
69
HJ
]
Medium Blue Met.
Deep Blue Met.
435011
435251
435014
435254
435010
435250 P1
Caramel Tan
Black
43534111 1ISUT
994
435340
93005
991
1976
Hr. Palut Incit? Centad- Dolor Mtr.Paiail Lucite Centan Doles
Code Color Code Code Code Code Color Code Code Code
66 ,naDran_ 428561K 42856414 42856011 6C EvergreenMet. 44110L11 44110411 44110DH
Cl AlpineWtlite 434991 434994 434990 60 Sandlan 441111 441114 441110
69 Medium BlueMet 43501L 435014 435010 SE Burnished Bronze Met. 44I121K 44112411 441120K
114 Dark Cocoa Met. 43503111 435034W 435030K Si Silver Frost Met 441131. 441134 441130
H Golden Jade Met. 43505111 435054M 43505014 54 Limefire Met. 441 141M 441 1MM 44114DM
HI Aztec Copper Met. 435061K 435064M 43506DM V Firecracker Red 441 161M 441160W
.!.
NI Autumn Red Met. 435071M 435074* 43507DM 63 Brilliant Blue 441171H 44117AKi 441170
32 Brandywine Met. 43510LM 435104W 43510DM ST Nautical Blue Met. 441181W 441184K 441180K
Fl Black 99L 99* 93-005 GM SunshoneVellow 44119LK 441194K 441190
5* Marine Aqua Met. 441081H 441084H 44I08DK 7P Lime Green 11I3F
SB Seaspray Green 441091 441094 44109011 I
1977 BACK PANEL & SIDE STRIPES COLORS

GREMLIN X
I Nt g.CodePaint Color
Stock
lejniber
Hr. Pale
Code Color
Stock
Number
I
Pt Black 991 75891 Gold 43669LH
L 67 White 434991 77832 Berry 448061W
AMERICAN MOTORS CORPORATE COLORS

70R80 Red 442361K 708*2 Blue 430091K
70831 Yflaite 557691 P1 Black 991
77-106
1977 AMERICAN MOTORS
INDEX r GREMLIN- HORNET-MATADOR
No. 16 INDUSTRIES PACER-JEEP
tCIFY: 001 For DURACRYL® acrylic TaCquier * DAR For DEISTAR® acrylic erlimel * DOE For DITZCO® alkyd enamel
Paint Code & Price Codes Paint Code & Price Codes Paint Code & Price Codes Paint Code & Price Codes
DDL OAR DQE DDL DAR DOE DDL OAR DOE 001 OAR DOE
2702 - 2696
Alpine Whine 7D Powder Blue
33160 -- - 2901 --
PewterGray Poly 6R 7W Captain Blue Poly
2714 SC SC 0 2827 SC_ - 2898 2902

Sunshine Yellow e7L Loden Green Poly Tawny Orange
Brandywine Pomy 6V
2895 SC D 2899 H_ SC 2903

Mocha Brown Poly 7M Golden Ginger Poly 7Z Sun Orange
9000, 9300 Also a Jeep color

P1 Classic Black *Jeep color only
Bumper mcccl Between

2822 0 2992 KY Bumper and Radiator
6J Silver Frost Poly *7C Autumn Red Poly 73R58 Satin Gray
33075
ENGINE ENAMEL AMERICAN MOTORS 1976-77 JEEP

Blue 14688 CORPORATE COLORS
73.R.87 CHEROKEE WAGON
PAINT DITZLER EXTERIOR COLOR
CODE COLOR NAME CODE
75-R100J FLAT BLACK -9425
Trunk Spatter 70- P82 Corporate Blue 14083
Finish-Gray 70- P80 Corporate Red 71865
70R25DSI 768 70. P81 Corporate White 0887 HOOD SCOPE AND BLACKOUT
P-I Corporate Black 9000 AREAS - Low Gloss Black 9381
73-R-45 Argont Gray
33023 Splash Panel
PLASTIC GRILLE COLORS ACCENT COLORS
VINYL PAINT COLOR DITZLER
BACK PANEL - GREMLIN X
PAINT COLOR DITZLER UCY CODE NAME CODE
CODE NAME CODE CODE 75-11-77 Tan Poly ‘Touring P1<9" 24100
DITZLER Black 9399 120 74.R.24 Copper "Cassini" 24007
PAINT 70-RI
COLOR NAME CODE Semi Gloss 71-2-76 Bright Silver DOE-8568
CODE
Black 9000 Balance of colors are eflerior body colors 75-11-83 "Jeep" Gas Cap Argent DOE 8568
P1
07 White 2702
75-R-91 Gold 24150 1977 JEEP FLEET COLORS AMC - 1977 VINYL ROOF COLORS
77-R-32 Berry 7221 4
PAINT DITZLER COLOR NAME UCV NUMBER
CODE COLOR NAME CODE Black 120
1977 JEEP FA Transport Yellow 80020 White 2-383
FB Omaha Orange 60281 Dark Blue 2-I 78
VINYL ROOF COLORS FC Federal Gray G.S.A Brown 2-47 7
AND ROOF COLORS Gray Spec-1644D 31817 Buff 2-290
FE Forest Green 44586 Tan 2-413
TEXTURED Fh Olive Drab Spec X-24087 42955 Dark Red 2-202
COLOR UCV DtTZL ER
NAME NUMBER CODE
1977 JEEP
Black 120 9405 . Reduce with DX-1 507
White 2-130 0845 Texture Additive IN TWO-TONE COMBINATIONS THE
Levi Blue 2176 FIRST TWO DIGtTS INDICATE THE
Levi Tan 2-214 UPPER COLOR, THE NEXT TWO DIGITS
THE LOWER COLOR
OVER
1977 AMERICAN MOTORS INTERIOR COLOR IN FORMATION
LOW GLOSS OR FLAT COLORS

used on: Instrument panel, console area, etc.
DITZLEFI VINYL
OlA UCV
PAINT CODE COLOR NAME NUMBER NUMBER
15-R5 Metal While 0B94 2-175
75-R29 Plastic
73-1127 Metal Black 9399 120

15-1123 IPlaslic
15.112 IMelal Blue 14736 2-144

75-1126 Plastic
75-114 Metal Tan 24055 2-214

75-R28 Plastic
15-1145 IMelaIl Berry Maroonl 50937 2-202

75-1151 Plastic
76-1146 Oark Tan 24331 2-478

76’R47 Used on Instrument Panel and Speaker Grill of he Pacer
Above colors must be oversprayed with UCV-69
SEMI-GLOSS OR MEDIUM GLOSS COLORS

Used on: Body shell nlerlor paris, such as garnish mouldings. lower steering column. etc.
DITZLER VINYL
DmA UCV
PAINT CODE COLOR NAME NUMBER NUMBER
75-P9 White WB100 183
12-1150 Black 9391 120
75-116 Blue Dark Blue 14808 2-268

Light Blue 2-453
75-118 Tan Dark Tan 24133 2-425

Light Tan 2-205
75-R46 Berry Maroon Crimson Pacer 50938 2-202
Strap Blue 2-103

Strap Brown 2-257
Strap Berry 2-202
Strap Black 120
Strap White 153
JEEP - INTERIOR COLORS

DITZLEP VINYL
DIA UCV
COLOR NAME CODE NUMBER
Black 9390 120
While 0894 183
Blue 14735 Levi Blue 2-144
Tan 24055 2-417
Berry Maroon 50931 2-202
Service Technical Letter File: Service General
No.9-10 July 24, 19791
Subject Information
Replacement of Watershield Paper- In some instances when removing the door trim
1977-79 Cherokee-Wagoneer--Truck panel and watershield paper, the paper becomes
Models damaged and must be replaced to prevent water
leaks -
Watershield paper and adhesive will be available

as a replacement part after August 20, 1979.
Part numbers are as follows:
Description Qt Part No. Gropp
Paper, Watershield 1 5464553 23.012

Rear Door, Left

Rear Door, Right

Front Doar,Left
Paper, Watershielrd 1 5464556 23.012

Front Door, Right
Adhesive Quantity 1 3624805 23.012

Sufficient for
One Door
The Standard Servicing Operations and work times

as published in the current 550 Manual are not
affected by this bulletin.

Additional copies of this letter are available through your zone office.
77-109
Service Technical Letter
OF INTEREST TO: File: Service General
LI Dealer Principal Service Writer
X Service Manager Mechanic No. 9-06 March 30, 1979
Subject Information
Frozen Door Handle Pushbutton Ice may accumulate on the outside door handle
Repair - 1978-79 Cherokee, pushbutton on the subject vehicles making it
Wagoneer, and Truck Models inoperative. The following outlines the service
correction for this condition.
Thaw any ice that has accumulated on the push

button mechanism. Depress the button and spray a
liberal amount of WD-40 penetrating lubricant, or
equivalent, past the button using the small plastic
spray tube. Repeat the operation on all door
pushbuttons and allow 15 minutes to dry. After
drying, repeat the above procedure using AMC/Jeep
Silicone Lubricant 8993542 or equivalent.
Bronze Tone Tint Damage - CJ-7 CAUTION: If an aftermarket heated grid rear
GQlden Eagle window defogger is installed on a bronze tone
rear window, it will cause damage to the tint of
the glass. Such installations are not approved.
Tire Size Capacity of Rear Swing- Tires larger than the 9-15 LT Tracker must not be
Out Spare Tire Carrier-’- 1976-79 mounted on the swing-out spare tire carriers. The
CJ-5 and CJ-7 Models carrier may be damaged if larger than specified
tires are installed.

Additional copies of this letter are available through your zone of/ice.
77. 110
9 Dealer Principal X Service Writer
Service Manager Mechanic No. 9-05 March 3, 1979
Subject Information
Compression Pressure Specification The compression pressure specifications for

Update - 1977-79 Six- and Eight- 1977-79 six- and-eight--cylinder engines have been
Cylinder Engines updated. The pressure specifications for both
six- and eight-cylinder engines are now 120 to
150 psi with a maximum allowable pressure
variation between cylinders of 30 psi.
The updated specifications should be noted in the

1977-79 Jeep Technical Service Manuals,
Roof Rack Moan - 1979 Wagoneer and A roof rack moan may be produced by the front end
Cherokee Models rail of the roof rack. The moaning noise can be
eliminated by positioning the front end rail over
the center stanchion with the large diameter of
the end rail toward the front of the vehicle.
NOTE: The roof rack moan is very similar to an

axle noise. Be sure not to misdiagnose the noise.

77-111
1 Jeep,

D Dealer PrincIpal Service Writer
X Service Manager Mechanic No.9-03 November 16.1978
Subject Information
Automatic Transmission Clutch and The chart used in the 1976 through 1979 Jeep
Band Application Chart Technical Service Manuals is incomplete. The
chart should have shown that the Lo Clutch
Roller is also applied in 2-range first gear.
Correct the chart by inserting the necessary
indicator dot as shown in the illustration.
CLUTCH BAND APPLICATION

-
Pk 11 123
0 UT
12
FORWARDCLVTCH * * S S S S
DIRECT CLUTCH S S
FRONT BANS *
INTERMEDIATE CLUTCH * ® 5
INTEIIMEFJIATE ROLLER 5 - 5 -
ItAlIANS S -
LOCLUTCH ROLLER S S
@01 BUT NO EFFECT
/
Lpiace dot here,
Service Technical Letter No. 9-02, Eliminate the subject and information in the
dated October 2, 1978 All 1979
- subject Service Technical Letter regarding blade-
Jeep Models - Starter Solenoid type starter solenoid terminals. Jeep vehicles
With Blade Terminals have stud-type starter solenoid terminals only.

Additional copies a/this letter are available through your zone offlea
77. 112
9 Dealer Principal j Service Writer
Service Manager Mechanic j No. 8-05 June 23, 1978
Subject Information
Canvas Top Installation CJ-7

- Prior to installing a canvas top on a CJ-7 model
Models Which Previously had a that has had a factory installed hardtop and a
Factory Installed Hardtop and Roll rollbar, check the hole in the top-center of the
bar roilbar for burrs. This hole is drilled in the
rolibar for use in attaching the rubber bumper
used on 0-7 models that have the hardtop option.
Remove the burrs as necessary to eliminate the
possibility of contact with the canvas top
material.
Brake Master Cylinder Push Rod Master cylinder push rod retainers are available
Retainer - 1977-1978 Cl Models as an individual part part number 8129287,
With Manual Disc Brakes group 8.054. It is not necessary to order a
master cylinder push rod to obtain a push rod
retainer. -
Batteries in CJ Models Built CI models built after May 16, 1978 have a nylon
After May 16, 1978 strap around the battery and battery tray. This
strap is installed for transportation tie-down
only. It may he left on or removed, but is not a
necessary part after the vehicle has reached its
original destination.
Valve Train Noise - V-8 Engines On some V-S engines, the valve rocker arm may
contact the spring retainer if the keepers sink toc
far into the retainer. To validate this condition
remove the retainer and inspect the bottom surface
for flaring. however; the presence of tooling
marks on the retainer surface will not affect the
operation or the durability of the retainer.

77.11
Service Technical Letter Icont’dJ
Subject Information
Engine Oil Filters All CJ Models

- The short engine oil filter, part number 8993146
Equipped With 6-Cylinder Engines 4.25" long, must be used on CJ models equipped
with a 6-cylinder engine. If the long engine
filter is used, part number 8991072 5.44" long,
it is then possible for the oil filter to contact
the engine support bracket or frame rail under
extreme torque loads. This may result in damage
to the oil fitter causing a lossof oil and possibli
engine damage.
1978 Jeep Technical Service Manual, A typographical error exists in the Model 2100
Volume I Correction - Model 2100 - Carburetor Specifications chart on page 13-Si,
2V Carburetor Volume I, of the 1978 Jeep Technical Service
Manual. The dimensions given under the heading
Float Level Dry setting are 0.555 inch with the
OK Range given as 0.493 to 0.617 inch. The Float
Level Dry setting should be 0.500 inch and the
OK Range should read 0.484 to 0.516.
1978, 6-Cylinder Engine Exhaust If a 1978, 6-cylinder exhaust manifold is received

Manifold - Two Center Lower as a replacement part part number 8125075 and ti:
Attaching holes May Not Line Up two center holes do not line up with the cylinder
With Cylinder Head llole’ head holes, enlarge the holes with a 29/64 inch
drill.
77A14
OF INTEREST TO: File: Service General -
fl Dealer Principal Service Writer

Service Manager Mechanic No. 8.02 November IS, 1977
Subject Information
Typographical Error 1977

- The dimensional thickness of the direct clutch
Technical Service Manual, page flat steel plates, referenced in the note
7-50 and 1978 Technical Service immediately following step 9 should be changed
Manual, page 2C-53 from 0.0195 to 0.0915.
Battery Post Contamination - The battery posts on some low mileage vehicles
All Models or service batteries may develop a condition,
referred to as "black post". If a no-start
condition is encountered, or when a new
battery is put into service, clean the battery
posts with a cylindrical wire brush and apply
a thin coat of grease.
Correction of Rear Wheel Cylinder The rear wheel cylinder dimension for CJ
Diameter - 1976 Technical models listed in the "Brake Size and Application
Service Manual, page 9-41 and Chart" is incorrect. Please change this
1977 Technical Service Manual, dimension from 15/16 inch to 7/8 inch.
page 9-47.

Additional copies olthis letter are available through your zone off/ca
77-115
Dealer Principal Eli Service Writer
0 Service Manager Q Mechanic No. 7.08 July 19, 1977
Subject Information
Replacement Parts For 0ff-Road Reference: DRB 7-04, Group 3.000 dated April 21,
Driving Lamp Kit 1977 J-10 Truck
- 1977.
t.bdels With Golden Eagle Trim Part numbers have been assigned to the components
Package- of the off-road driving lamp kit Parts Catalog
Information Bulletin, dated April 1977, Group 3.246:
Repair or replacement parts should be ordered in
the normal manner from your Parts Distribution
Center.
Automatic Transmission-to-Quadra During the 1977 model year production three differ
Trac Installation All Models
- ent methods were used to seal the Quadra-Trac unit
With Automatic Transmission and to the transmission.
Quadra-Trac - 1. One gasket without a sealer.
2. Two gaskets coated with Permatex No. 3.
3. Loctite sealer No. 504 without a gasket.
Regardless of model year or method originally used,
when installing the Quadra-Trac unit use one gasket
part number 998315 and coat both sides with Perma
tex No. 3.
Possible Gear Clash in Second and On some of the subject vehicles a gear clash grind.
Third Gear Caused by Worn Inserts
- ing noise between second and third gear may be
in Synchronizer 1977 CJ Model
- encountered. This condition may be caused as a
With T-15O Transmission Built - result of the inserts in the second-third synchro
Between VIN J7XXXXX1O6233 and nizer being worn and may not occur until after
VIN J7XXXXXIO9229. 4,000-to-6,000 miles of use. Service correction,
in complaint cases, involves removing the trans
mission, removing the second-third synchronizer,
and installing new inserts. Refer to your 1977
Technical Service Manual, Section 6, Manual Trans
mission, for servicing procedures.

Sirvics Engineering Department e 14250 Plymouth Rood * Detroit, Michigan 48232
77116
ServiceTechnical Letter Icont’dI
Subject Information
Quadra-Trac Front Cover-to-Case The Quadra-Trac front cover-to-case gasket square

Gasket - All Models With Quadra- rubber seal ring is no longer being used in
Trac. production. The gasket has been replaced by a
sealant compound. The gasket groove in the front
cover has also been eliminated. When installing
the front case cover, with or without machine
groove, do not install a gasket. Apply a 1/16 inch
bead of sealant compound Gasket-in-a-Tube, part
number 8993317 around the gasket surface of the
cover.
77.117
Service Technical Letter No. 7-07
LII Dealer Principal [KI Service Writer
Date: May 19, 1977
[] Service Manager [J Mechanic
Subject Information
Vibrations -Mechanical and Vibrations are usually either mechanical felt in

Audible - All Jeep Vehicles seat, steering wheel, etc. or audible heard,
seems to completely surround the observer Oc -
casionally, a vehicle will have mechanical and

audible vibrations. Whenever either situation
exists and your normal diagnostic efforts, such
as visual inspection for damaged components, tire!
wheel/prop shaft runout and balance, etc., have
not revealed the cause, call your local zone ser
vice office for supplemental diagnostic assistance
before making any major component changes or re
pairs.
Crankshaft Pilot Bushing - All All service replacement engines, short blocks,
Models and replacement crankshafts are shipped with a
sleeve in the end of the crankshaft. This sleeve
is for use on all automatic transmission applica
tions. A 7/8 inch and 5/8 inch long bushing is
also shipped loose with each engine, short block
and crankshaft. On applications with a Borg
Warner manual transmission, remove the existing
sleeve from the crankshaft and install the 7/8
inch long bushing. On applications with a T15O
manual transmission remove the existing sleeve
from the crankshaft and install the 5/8 inch long
bushing.
Cruise Command Control Regulators When a problem with the Cruise Command Control
All 1977 Models Equipped With system is encountered, before replacing the regu
Cruise Command lator, apply the diagnosis guide on pages 3-94
and 3-95 of your 1977 Technical Service Manual.
Over

Service Engineering Dept. * 14250 Piymouth Rd. * Detroit, Mich. 48232
77-118
Subject Information
Front Exhaust Pipe-to-Exhaust The hex nuts, part number 5351688 six-cylinder
Manifold Attaching Nuts All - and V-B, used to attach the front exhaust pipe
1977 Models to the exhaust manifold have a locking feature
which is destroyed when the nuts are removed.
Whenever the nuts are removed for any reason, new
nuts must be installed to assure proper torque re
tention.
Painted Bumpers - 1977 Cherokee The painted bumper sections on some 1977 model
and Truck Models vehicles may peel due to a dechroming process at
the factory. When this condition is encountered
replace the affected sections
Golden Eagle Intermix Paint For- We erred. The intermix paint formula listed in
mulas 1977 CJ and Truck Models
- Service Technical Letter No. 7-05, dated April 7,
With Golden Eagle Trim Package 1977 incorrectly listed the code number of the
red intermix as DMA 333 it should have been DMA383.
The following charts list the Ditzler and DuPont

intermix paint formulas for the paint Color Code
7E Oak Leaf Brown.
Ditzler Code No. DDL24443 Lacquer DuPont Code No. 45101W Lacquer
Color Code No. Pint quart Gallon Color Code No. Pint Quzirt Gallon
White DMA311 10.0 20.0 80.0 Yellow 452L 7.5 14.3 58.0
Black DMA3SB 79.0 158.0 632.0 White 401L 25.0 49.5 199.0
Yellow DMA329 112.0 224.0 896.0 Black 4061 65.0 129.0 517.5
Red 0MA383 184.0 368.0 1,472.0 Pon Orange 4351 119.0 237.0 949 0
.
Yellow DMA384 524.0 1,048.0 4,192.0 Binder-A 450L 294.5 588.0 23S2.0
Balancer-A 4801 436.5 872. 5 3,489.0
Ditzler Code No. 0AR24443 Acryllic Enamel DuPont Code No. 4SlOIA Acryllic Enamel
Color Code No Pint Quart Gallon Color Code No. Pint Quart Gallon
White D?&40l - 10.0 40.0 Drier 7588 - 45.0 180.0

Black 0MR490 -. 2S0.0 1,000.0 Green 741A - 57.5 231.0
Red DMR477 - 732.0 2,928.0 Moly Orange 733A - 103.5 413.0
Yellow DMR486 - 944.0 3,775.0 Yellow 732A - 230.5 923.0
Katalyst Drn495 - 964.0 3,856.0 U.S. Black 705A - 900.5 3,602.5
Clear DMR499 - 1,050.0 4,200.0
ITheel Color - Gold - Ditzler Code No. 23674
77119
________________________________________________

April 21, 1977
Subject: Golden Eagle Trim Package Application; 1977 3-10 Truck Model I I File: Service
General
The new Golden Eagle trim package previously * Tan vinyl bucket seats with armrest
introduced for the 1977 CJ-5 and CJ-7 models is now
available for the 1977 1-10 truck model. This new trim * Cigar lighter
package includes:
Full carpeting
* Special Oakleaf Brown exterior color * Tan sports steering wheel
* Chrome front bumper * Engineturned instrument panel overlay
* Cherokee grille
* Off-road driving lamps - rollbar mounted
* Special decals
The ott-road driving lamps will be shipped separately and
* Unique Golden Eagle striping are to be installed by the dealer. Installation and
adjustment procedures are included with the lamps. A
Diagnosis and Repair Bulletin covering the installation
* Rear step bumper
and adjustment procedure wilt also be issued.
* Pick-up box mounted roilbar
Alt other servicing procedures remain as outlined in your
1977 Technical Service Manual. The Oakleaf Brown paint
* Tubular steel grille brush guard
is an acryiic enamel and the paint code number is 7E.
Paint intermix formulas are available from your local
* 8-inch spoked steel wheels, painted gold
DuPont or Ditzler supplier. In the event your local
supplier has not received the intermix formula, refer to
* 10-15 Tracker A-T tires
Service Technical Letter7-0S, File: Service General, dated
April 6, 1977.

77-120
Service Technical Letter No. 7-05
Date:.April 7, 1977
Service Manager Mechanic
Subject Information
Wheel Lug Studs Off Center in Rear A few.rear axle shafts have the wheel lug stud
Axle Shaft Flange -1976 and 1977 holes drilled slightly off-center in the flange.
Wagoneer and Cherokee Models This condition can cause what appears to be ex
cessive tire/wheel/drum runout. Field fix is to
replace rear axle shaft.
Quadra-Trac Chain Tension When measuring chain tension, it is imperative that

Measurement the shoulder of the tool touches the machined sur
face that surrounds the hole in the case. In some
instances, the hole in the case is not threaded
deeply enough to permit correct installation of
the tool if only "hand-tightening" is used. In
such cases, use a 1/4-18 NPT National Taper Pipe
Thread tap and thread the case about 1 to 1-1/2
turns deeper. Coat the tap with grease to capture
any aluminum chips that are generated.
In addition, be sure that the park brakes are off,

that the transmission and reduction unit are in
neutral and that all four wheels are free to turn
not resting on floor, hoist, etc..
Golden Eagle Intermix Paint Formula The intermix paint formula for Oak Leaf Brown,
1977 CJ Models With Oak Leaf Brown, Code 7E, is available to Ditzler jobbers through
Code 7E their warehouse or by the salesmen. However, if
you cannot obtain the paint from a Ditzlet dealer,
give him the following codes and intermix formula.
INTERMIX PAINT FORMULA
Color: Oak Leaf Brown Color Code No. 7E
Ditzler Code No. DDL24443
Ditzler Parts Per

Color Code No, Pint Quart Gallon
White DMA311 10 20 80
Black DMA3S8 79 158 632
Yellow DMA329 112 224 896
Red DMA333 184 368 1,472
Yellow DMA3S4 524 1,048 4,192

77-121
ServiceTechnical Letter No.7-04
j Dealer Principal j Service Writer
Date: March 17, 1977
N] Service Manager Mechanic
Subject Information
Cooling System Thermostat Revision A 195 degree thermostat has been substituted for
use in all applications requiring a 205 degree
thermostat. The 195 degree thermostat does not
affect defroster performance and is in compliance
with the National Traffic and Motor Vehicle Safety
Act.
Rear Seat Retaining Strap 1977

- On vehicles where the rear seat retaining strap
Wagoneer and Cherokee Models is not used regularly it may be necessary to pre
stretch the strap before using. To stretch the
strap simply grasp the end firmly with both hands
and pull steadily.
Relubable Propeller Shaft Slip- The lubrication interval for the propeller shaft
joints and Spiders - 1977 CJ slip-joints and spiders on 1977 CJ models should
Models be every 5,000 miles for vehicles in normal use
and every 3,000 miles for vehicles in heavy duty
use. Use AMC/Jeep All Purpose Lubricant Lithium
base or equivalent.
This change should be noted on page B-7 of your

1977 Jeep Technical Service Manual.

Service Engineorino Dept. * 14250 Plymouth Rd. * Detroit, MIch. 48232
77-122
ri Jeeps

March 10. 1977
Subject; New Golden Eagle Trim Package ApplIcation: 1977 0-5 and 0.7 File: Service
Models General
A new body trim package, the Golden Eagle, has been * flared fenders
introduced for the 1977 0-5 and CJ-7 models. This new * Black rocker panel mouldings
trim package includes:
* Rear mounted spare tire with lock swing-out on CJ-7
* Special Oakleaf Brown exterior color
* Convenience group
* Special decals
* Decor group
* Unique Golden Eagle striping * Roll bar
* Tan Levi’s soft top * Clock and tachometer
* Tan Levi’s interior front bucket seats
Servicing procedures remain as outlined in your 1977
* Rear bench seat
Technical Service Manual. The Oakleaf Brown paint is an
* Full carpeting acrylic enamel and the paint code number is 7E. Paint
* 8-inch spoked steel wheels, painted gold intermix formulas are available from your local DuPont or
* 9-15 Tracker A-T tires Ditzler supplier.

ServiceTechnical Letter No.7-02
Dealer Principal Service Writer
Date: December 23, 1976
Service Manager Mechanic
Subject Information
Improved Design Batteries - All 1977 Jeep vehicles are presently being
All 1977 Models equipped with an improved design battery. These
new batteries have less antimony in the grid
material and the mudrests in the bottom of the
cells have been lowered, resulting in a potential
ly longer lasting battery. To achieve the poten
tial long life of these batteries, it is necessary
that the negative battery cable be disconnected on
all vehicles in stock.
Revised Procedure for Storage and As a result of the improved battery, and discon
Protection of New Vehicles necting the cable as mentioned above, it is no
I longer necessary to start and run vehicles in
storage every 15 days as specified in Section 8
of the Warranty Administration Manual.
Warn Lock-0-Matic Hub Installation On some of the subject vehicles the tapped hole
1977 Cherokee and J-10 Truck Models in the end of the axle shaft for attaching the
Built Between VINs J7XXXXXO2I43S body assembly of the Warn hub was omitted. If
and J7XXXXXO31794 hubs are to be installed on one of these vehicles
and it does not have a tapped hole in the end of
the axle shaft it will be necessary to replace
the axle shaft. Do not attempt to drill and tap
the axle shaft -
Touch-up Spray Paint Identification If the color coded cap of an aerosol can of
touch-up spray paint is misplaced or lost the
paint color can be identified by the 4 digit nunt
ber on the bottom of the can. This 4 digit num
ber is the last 4 digits of the paint color part
number. To locate the paint color, simply add
899 in front of the 4 digits on the bottom of the
can and look up the part number. Example: the
4 digit number on the can is 2788, add 899 and
look up part number 8992788 Trans-AM Red.
[ over

Subject Information
Jeep Vehicles With Snow Plow/Winch The snow plow blade/winch blocks the air flow in
Overheating at Highway Speeds the radiator and the tenipatrol does not receive
the proper heat input to activate the fan. To
correct this condition disconnect the tempatrol
bi-metal spring and turn it counterclockwise ap
proximately 90 degrees to provide positive fan
engagement. Reconnect the bi-metal spring when
the plow blade/winch is not on the vehicle.
VI *meñcaiss
SSes Corpomfion
14250 Plymouth Road
Detroit, Michigan 48232
August 31, 1976
To All Jeep Dealers
Subject: Product Servicing Information
FILE UNDER: Service General 77-1 in 7700 Series and 76-6 in 7600 Series Jeep TB
Binders
This letter contains Jeep vehicle servicing information about selected items that
can be covered in condensed form. Six copies are provided. Be sure your service
manager gets two copies he should file them under Service General in his 7700
Series and 7600 Series Jeep TB binders and that all your service and sales people
are aware of its contents.
Technical bulletins with complete servicing procedures and SSO information will
continue as the standard method of conveying information about items requiring more
thorough coverage.
AUTOM&TIC TRANSMISSION - MANUAL SHAFT HEX NUT - EARLY 1977 MODELS WITH ALTFOMA.TIC
TRANSMISSION
Some early 1977 vehicles with automatic transmissions have a 3/8-16 inch
hex nut P/N 6124829 attaching the detent lever to the manual shaft in
stead of the specified metric MlO x 1.5 hex nut P/N G11500424. Trans
missions using the 3/8-16 hex nut are identified by a letter "E" painted
on the case near the manual shaft.
REAR AXLE AND BRAKE APPLICATION - EARLY CHEROKEE, WAGONEER AND TRUCK MODELS
Some early 1977 Cherokee, Wagoneer and Truck models were built with 1976
rear axles and brakes. Vehicles so equipped can be identified by one of
the following part numbers stamped on a metal tag attached to the differ
ential housing cover.
PART NUMBERS
5356008 5356014 5356018 5356051

5356010 5356017 5356050 5356053
Sincerely,
CLut 4.CLLL
Curtis E. Todd
Manager, Diagnosis & Repair Procedures
CET:rcg
77 1#
Subject: Six-Cylinder Camshaft Application: 1977-80 Jeep Vehicles File: POW ER PLANT
Pm Breakage With Six-Cylinder Engines Engines
No. 80-3 Feb. 4, 1980
service replacement lal-t. c Remove air conditioning condenser attach
ing bolts and move condenser up and out
Service correction involves replacmg a broken of way
camshaft pin with a new spring pin.

Descnption Quantity Part No. Group
PIN, Spring and chain.

ment.
coolant in a clean container. 1. Center punch pm.
3 Remove fan and shroud.
3. Insert G448423 screw into drilled pin
arid carefully puli pin from camshaft.
radiator. prevent metal chips from entering the pan.

b Disconnect and remove alternator, until it is seated.

Service Engineering Department * 14250 Plymouth Road * Detroit, Michigan 48232
78-1
CAUTION: If the camshaft moves rearward, repo- light film of AMC Perfect Seal, or equivalent, on out-
sition the tool wedged against the camshaft so that side diameter of seal.
14 Install camshaft gear and timing chain, Tighten cover. Turn bolt until tool bottoms against cover.
camshaft gear bolt to 50 foot-pounds 68 Nm
108 N-rn torque.
pounds 22 N-rn torque and connect fuel lines. bolt torque value is reached, the damper can be held
wedging a bar between them, Rotate the bar until it
17 Position oil pan tab gaskets on oil pan and use contacts the frame member to prevent the damper
sides of timing case cover gasket with sealer. Apply
1/8-inch 3 mm bead of sealer to joint formed at 24 If equipped with air conditioning:
oil pan and cylinder block. a Install air conditioning belt intermediate
pulley.
19 Position timing case cover on engine. Place 26 Install radiator. Connect radiator hoses, trans
screws.

pounds 9 N’m torque and 5/16-18 oil pan screws
toll foot-pounds 15N-m torque.
24 N-m torque.
YEAR AND TIME

OPERATION DESCRIPTION MODEL -
CODE NUMUER LEVEL
is ig so
PIN, SPRING CAMSHAFF GEAR

DRIVE- REPLACE 1.040 1163 6-Cyl. 1.7 1.7 1.7 1.7 G
With Air Conditioning- Add 0.3 0.3 0.3 0.3
80-044-0MM
78-2
Subject: Oil Leakage at Cylinder Head Cover Application: All 1976-1978 Jeep File: POWER PLANT
or Oil Pan Gasket Surface Models Engines
Group 1.000
No. 8-03 July 11, 1978
If oil leaks occur at either the cylinder head cover or oil Procedures for sealing cylinder head covers and oil pans
pan gasket surfaces of the subject vehicles, two methods are published in the appropriate Jeep Technical Service
of sealing may be used. A room temperature vulcanizing Manual. The following chart lists the engine, model,
RTV adhesive such as Gasket-in-a Tube, part number year, Teehnicl Service Manual and page number of the
8993317, or equivalent may be used in place of a gasket; procedures applying to the vehicles involved.
or a gasket coated on both sides with a quick drying
adhesive such as AMC part number 8127960, or
equivalent may be used.
Year and Technical Service Manual Page Number
Engine/Model *976 1977 1975
6 Cyl. Engine
CJ-5 & 7
Cyl. Head Cover lA-c 1977 Jeep IA-9 18-16. Volume I
Technical Service
Manual
Oil Pan IA-21 IA-22 18-21. Volume I

Cherokee
Cyl. Head Cover IA-9 1977 Jeep IA-9 18-16. Volume I
Technical Service
Manual
Oil Pan IA-21 IA-22 18-21. Volume I

Truck
Cyl. Head Cover IA-9 1977 Jeep IA-9 lB-lb. Volume I
Technical Service
Manual
Oil Pan IA-2I lA-22 18-21, Volume I
8-Cyl. Engine
CJ-5 & 7
Cyl. Head Cover lB-I I 18-12 10-51. Volume I
Oil Pan 18-24 18-25 18-56, Volume I

Wagoneer
CyL Head Cover I B-Il 18-12 I B-51, Volume I
Oil Pan 18-24 I B-25 I B-Sb, Volume I

Cherokee
Cyl. Head Cover lB-I I 18-12 18-51, Volume I
Oil Pan IB-24 18-25 18-56, Volume I

Truck
Cyl. Head Cover I B-Il ID-I? I B-SI, Volume I
Oil Pan 18-24 18-25 18-56, Volume I
OVER
P1 Ameñcan Motors Sales Corporation
Additional copies of this bulletin are available through your zone otlice
78-3
WARRANTY YEA R AND I ME
OPERATION SKILL
NUMBER LEVEL
COD 76 77 78
COVER, CYL. HEAD - RESEAL WITH

RTV 6 Cyl. 1.072 1011 6 Cyl. 0.5 0.5 0.5 6
8 Cyl. One 8 Cyl. 0.5 0.5 0.5
Both 8 Cyl. 0.7 0.7 0.7
Oil Pan - Reseal With RTV 6 Cyl. 1.152 A 6 Cyl. 0.8 0.8 0.8 6
8 Cyl. 8 Cyl. 0.8 0.8 0.8
PAN, 6 OR S CYL ENGINE OIL - RESEAI,
WITH RTV 1,152 lOl3 6 Cyl. 0.9 0.9 0.9 6
8 Cyl. 0.9 0.9 0.9
78-4
Subject: V-S Engine Oil Pressure - New Oil Application: 1977-1978 V-S Engines in File: POWER PLANT
Pressure Reli ef Spring Vehicles With Oil Pressure Gauges Engines
2.
No. 8-V July 3, 1978
Some 1977-1978 V-8 engines may have oil pressure gauge

readings that are within specifications but less than what
is normal for V-8 engines. This condition may be the
result of a weak pressure relief spring in the oil pump.
Service correction involves replacing the weak spring

with a new replacement spring.
The following part is available and may be requireth
Spring, Engine Oil

Pump Release Valve I 3233994 1.176
PROCEDURE CAP
RELIEF
VALVE
I Check oil level. SPRING GASKET
2 Remove oil pressure relief valve spring by removing

retaining cap from cover see illustration.
Pressure Relief Valve Assembly
3 Measure free length, if less than 3.25 inches
82.55 mm, replace spring. 6 Assemble relief valve, spring, and retaining cap
back into cover.
4 Check the operation of relief valve by sliding poppet
valve back and forth. It should move freely. 7 Torque retainer cap to 28 foot pounds 38 newton-
meters torque.
5 If the spring length is 3.25 inches and poppet is free,
check oil pump gear clearance as outlined in appropriate 8 Start engine and check oil pressure and check for oil
Jeep Technical Service Manual. leaks.
The Standard Servicing Operations and work times as published in the current SSO Manual are not affected by this bulletin.
g-097.OIA/J

Service Englnnring Deportment e 14250 Plymouth Rood e Detroit, Michigan 48232
78-5
Subject: V-S Engine Oil Consumption-Intake Application: All 1978 V-S Engines File: POWER PLANT
Manifold Gasket Engines
No. 5-01 June 30, 1978
Some 1978 V-8 engines may have an oil consumption rate

of 2 or more quarts per thousand miles at highway
speeds. This may be caused by the intake manifold gasket
locating dowels being too long and bottoming out in the
cylinder head counter bores.
Service correction involves checking for external oil
leaks, verifying the engine condition i.e., compression
test and/or cylinder leakage test, and confirming the oil
consumption rate. If after checking these items, the cause
of the oil consumption is not apparent replace the intake
manifold gasket.
PROCEDURE
I Check for external engine oil leaks.
2 Verify engine condition i.e. compression test Fig. 1 Intake Manifold Gasket Locating Dowel
and/or cylinder leakage and repair as necessary.
3 Confirm rate of engine oil consumption. 6 Inspect new intake manifold gasket for proper
dowel length which should be between .090 and .110 inch
Fig. I.
4 Remove intake manifold as outlined in 1978 Jeep
Technical Service ‘Manual, Volume I, page lB-50. 7 Install intake manifold as outlined in the 1978 Jeep
Technical Service Manual, Volume I, page IB-50.
5 Inspect existing intake manifold gasket dowels to
confirm cause of oil consumption.
8-098-OiA/J

Service Engineering Deportment e 14250 Plymouth Road * Detroit, Michigan 48232
Additional copies 01 this bulletin we available through your lone office.
78-6
Subject: Radiator Coolant Overflow ApplIcation: 1978 Cherokee, Wagoneer, File: POWER PLANT
and Thick MOdels With Air Condition- Cooling
ing or Heavy Duty Cooling.
No. 8-01 October 20, 1977
Some 1978 Cherokee, Wagoneer and Truck models PROCEDURE

with air or heavy duty cooling may
experience a radiator coolant overflow. This condition 1 Install coolant recovery bottle on front wheelhouse
may be caused by the absence of a coolant recovery bottle panel.
and the installation of a closed system radiator cap.
2 Install hose from radiator filler neck into coolant
Service correction involves the installation of a coolant recovery bottle and secure with hose clamp.
recovery bottle. The following parts will be required:
NOTE: Hose should be submerged into bottle so end is
Description Quantity Part No. Group below ADD mark,
Bottle, coolant 3 Fill radiator.

Recovery 1 5358025 2.025
4 Check coolant recovery bottle at normal operating
Screw 2 4005466 14.801 temperature. Coolant should be between FULL and ADD
marks on bottle, Acid coolant to recovery bottle as
Clamp, Hose 1 3223128 2.025 necessary.

OPERATION SKILL
OPERATION DESCRIPTION REPOR1ING LEVEL
17
BOTTLE, COOLANT RECOVERY CKE
INStALL 2.971 2009 WAG- - 0.2 - M
IRK
s.3-O2J

ServIce Engineering Department e 14250 Plymouth Road e Detroit, MIchigan 48232
78-7
This bulletin is being issued to revise the ammeter circuit

illustration for Cherokee, Wagoneer, and Truck models
on page JL-43, Volume I of the 1978 Technical Service
Manual and on page 1 L-45 of the 1979 Technical Service
Manual. The revised circuit illustration is shown in figure
I. In addition, the wiring diagram for Cherokee,
Wagoneer, and Truck models on page W-5 in the 1979
Technical Service Manual has also been revised to
identify splice "B" as shown in figure 2.
AMMETER
YELLOW
I RED
DASH
CONNECTOR
J55
90293
Fig. I Ammeter Circuit - Cherokee -
Wagoner Truck Models

-
Fig. 2 Wiring Diagram W-S Cherokee
- -
Wagoneer Truck -
9056-SQJ
P1 American Motors Saks Corporation

Service Engineering Department e 14250 Plymouth Road * Detroit. MichIgan 48232
78-8
Subject: Altitude Performance Application: 1968-80 Jeep File: POWER PLANT
No. 50.7 Nov. 10, 1951
formance adjustments for 1968-80 .Jeep vehicles re control label, part number EF 8130457, to the engine
quired under a newly established Federal standard. The compartment dash panel. Di, not attach the label to any
adjustments are intended to improve driveability per-for component that can be readily removed from the
manee as well as emissions performance at altitudes vehicle.
other than that for which the vehicles were origuialty
certified.
Any Jeep vehicle that has been so adjusted must have a that were sold for principal use at altitudes below 4,0l0
These unique labels are available in a kit., part number engine compartment to identify these vehicles.
Distribution Services On 1968-80 Jeep v-hides originally sold for operation at
37200 Amrhein Road altitudes above 4,101 feet that are being operated below
Livonia, Michigan 48150 4,000 feet, the ignition timing! as shown on the vehicle
emission control hibel located in the engine compart
The adjustment procedures and unique labels must be ment or specified in the apropriate Jeep lbchnucal Ser
ment or specified in the appropriate Jeep Technical 8cr.
vice manual should be advanced 5° not to exceed 150 These adjustments apply only to 1968-80 Jeep vehicles
total advance. The engine idle speed should be reset ac that were sold for principal use at altitudes above 4,000
St-11444A/i

Service Engineering Department * 14250 Plymouth Rood * Detroit, Michigan 48232
Additional copies of this bulletin are available through your lone office.
Subject: Rough or High Engine Idle Speed or Application: 1976-78 Cherokee, File: POWER PLANT
Dieseing When Warm Engine is Shut Off Wagoner, or Truck Models Equipped Fuel and Exhaust Systems
with 360 or 401 CID Engine and 4V
Carburetor
. No.$$ June 19, 1979
Some of the subject vehicles may have a rough idle, high 5 Remove accelerator pump link.
idle speed, or may diesel when shut off after the engine
reaches normal operating temperature. These conditions 6 Install new accelerator pump link into lower
may be the result of worn accelerator pump linkage or forward hole of throttle lever see illustration.
the secondary throttle plates not closing completely.
NOTE: There are two types of throttle levers in use, a
Service correction involves replacing the accelerator two-hole and a three-hole lever. The lower, forward hole
pump link and installing a secondary throttle plate helper is the only hole used on Jeep applications.
spring.
7 Install new accelerator pump link-to-throttle lever
The following parts are required and will be available retainer.
after August 6, 1979. Do not order parts before this date. 8 Install nylon nut on accelerator pump link. Adjust
nut until notch in accelerator pump arm is in position
Description Quantity Part No. Group No.
recorded in step 2.
KIT, Secondary NOTE: If the nylon nut on the accelerator pump
Throttle Repair 8132560 4.001 appeared to have been tampered with prior to removal.
refer to the Metering Rod Carrier Stroke Adjustment in
Kit Contents: the applicable Technical Service Manual to correctly
position nylon nut.
SPRING, Secondary
Helper 9 Remove air horn cover screw located above primary
throttle shaft on accelerator pump side of carburetor.
WASHER, Spring Install washer on screw and start screw in hole. Hook one
end of helper spring around screw and tighten screw see
LINK, Accelerator illustration.
Pump
10 Hook other end of helper spring between secondary
RETAINER throttle link rod retainer and primary linkage see
illustration.
PROCEDURE
CAUTION: Prior to starling engine check the carburetor
I Allow throttle to return to closed position. linkage for proper operation and be sure secondary
throttle plates are closing completely.
NØTE: The fast idle screw should not contact thefast idle
cam and the throttle solenoid should not be energized. 11 Spray choke and linkage cleaner 8993549 on both
ends of secondary shaft to clean shaft.
2 Observe position of notch in accelerator pump arm.
Measure distance between notch and index mark cast in 12 Hold choke open and operate carburetor linkage to
air horn see illustration. Record this dimension. wide open throttle position several times to ensure proper
operation.
3 Remove nylon nut from accelerator pump link.
13 Adjust curb idle speed.
4 Remove acceleratqr pump link-to-throttle lever
retainer.
OVER

ServIce Engineering Deportment e 14250 Plymouth Rood e Detroit, Michigan 48232
Add,t,ona? copies ot this bulletin are available through your zone ottjce.
ACCELERATOR .J I C-’TzC -J
PUMP ARM
NOTCH
SPRING
WASHER
HELPER
SPRING
ACCELERATOR
PUMP LINK
SECONDARY
HELPER
SPRING
SECONDARY THROTTLE
LINK ROD RETAINER
SECONDARY
THROTTLE
UNK ROD

OPERATION - SKILL
NUMBER LEVEL
CODE 76 77 78
KIT, CARBURETOR - INSTALL 4.006 4039 WAG-CKE-TRK 0.3 0.3 0.3 6
9-090-04 J
78-11
Subject: Left Rear Quarter Panel Rattle Application: 1978-79 Wagoneer and File: POWER PLANT
Cherokee Models Fuel & Exhaust Systems
No. 9-04 May 19, 1979
Some 1978-79 Wagoneer or Cherokee models may have a 3 Remove inside rear quarter panel trim.
rattle in the left rear quarter panel area.
4 Cut insulation into strips approximately 2 inches x
This may be caused by movement of internal check ball 9½ inches save any remaining for repair on another
and ramp inside the rollover check valve, vehicle.
Service correction involves wrapping the exterior of the 5 Completely wrap rollover valve with two insulation
rollover check valve with vinyl insulation, strips.
The following part is available and required: NOTE: Upon completion of the wrapping operation, be
sure the rollover valve female fitting is perpendicular to
Description Quantity Part No. Group No. the floorpan of the vehicle.
INSULATION 1 3693126 13.440 6 Install quarter panel trim.
7 InstaH spare tire carrier and tire if equipped.

PROCEDURE
8 Close tailgate.
I Open tailgate.
2 If equipped with inside-mounted spare, remove

spare from carrier and remove carrier.

OPERATION SKILL
NUMBER S’" LEVEL
VALVE, ROLLOVER - INSULATE 4.165 4201 CKE-WAG 0.2 0.2 G

Insidemountcdsparetire-R&R 4.165 A 0.2 0.2 G
9-079.B Si

ServIce EngIneering Department e 14250 Plymouth Road e Detroit, Michigan 48232
Additional copies of this bulletin ate available through your zone office.
78-12
Subject Emission Components Application: All 1976-1978 Jeep Models flit: POWER PLANT
Fuel and Exhaust System
Group 4.000
No. 8-07 April 23, 1979
The following charts reflect emission components using e Engine CD

the information found on the "Vehicle Emission ControL e Engine Family
Information Label" located in the engine compartment. e Evaporative Family 1978 CJ models only or
These charts identify the latest emission control devices carburetor type Jeep Heavy Duty
used on the applicable models. Correct part numbers are
also identified for certain devices with multiple d Determine from the V.E.C.J.L. the certification
applications. area i.e:, 49S = 49 State, Alt = High Altitude, Cal =
To use the charts: Califorma. Use this information to locate the correct
box in the third column on the chart.
a Select the chart with the correct model year heading
e Determine what transmission the vehicle has and
i.e., 1978 Jeep, etc.
use this information to select the correct box in the fourth
column of the chart.
b Locate the model in the first column of the chart.
c Open the hood and find "Vehicle Emission Control 1 The above information aligns aCTOSS the chart. The
remainder of the information should be used to check the
Information Label" V.E.C.l.L. or Jeep Heavy-Duty vehicle for correct component application.
Emission Control Label. Record the following
information for use in the second column on the chart.
LEGEND
Vehicle Emission Control Information Label VECIL Trans. Transmission Type
Engine CD Man = 3- or 4-speed Manual
Engine Family M4 4-Speed Manual
Evaporative Family 1978 models only M3 3-Speed Manual
A = Automatic
Jeep Heavy-Duty Application Carburetor Number Number on Tag Attached to
Engine CID Carburetor
Carburetor Type:
IV One Venturi Distributor Number Number on Tag Attached to
2V Two Venturi Distributor
4V Four Venturi
EUR Valve Number: Number on Face of Diaphragm
Housing
e = On All Models Specified
- z Not Applicable EGR Code Number or Letter Adjacent to Valve
Number
V.E.C3.L. = Vehicle Emission Control Information
EGR CTO Temp Nominal Temperature at Which
Label
CTO Switches
115°F Valve = Part Number 3228288; Optional with
Area 49S r 49 State, Alt = High Altitude, Cal
3225912
Calif otnia
OVER
Service EngineerIng Department e 14250 Plymouth Rood e DetroIt, MIchIgan 48232
78-13
DP Dashpot
160°F Valve = Part Number 3228894; Optional with
3226361. 3229449
TM = Throttle Modulator
AG Air Guard
+ Pre-Catalytic Converter
Cat. Cony. Catalytic Converter
TVS = Thermal Vacuum Switch

0 = Nominal Temperature for EGR CTO Switches
SVV Solenoid Vacuum Valve

3 = EGR Back-Pressure Transducer 3229120; Orifice
Plate 3233536
Positive Crankcase Ventilation Nominal Temperature for Spark cro Switches

PCV = Dr
TAC Type Thermostatically Controlled Air Cleaner

V = Vacuum
M = Mechanical
0= Delay Valve
Anti-diesel Solenoid in PCV Line

Spark CTO Type
Warm-up + Pellet type
1600 F Valve Standard Switch. Part Number
3216448; Optional with 3229450 Dr Delay Valve in Vacuum Line Between Manifold
220° F Valve = Heavy-Duty Switch, Part Number Vacuum and Diverter Valve
5358881
Spark CTO Temp. Nominal Temperature at which
CTO Switch Starts to Open
0= Optional Switch 535SR80 Used on Heavy-Duty
Cooling Package
Special Air Pump Pulley and Diverter

NLV = Nonlinear Valve
Includes Vacuum Check Valve
TCS Transmission Controlled Spark
CVTC = Carburetor Vented to Canister
FTVC = Fuel Tank Vapor Control
TS Throttle Solenoid
EC Electric Choke
1978 JEEP
IGI sp.ti
VICIt Ti.... .b 1 AG PCV TAC ECS CVTC VTVC U K OP TM

MS.l A,..
N,.mb.i N..mbe, Numb., C.d.
b .. .. -
Cm. 7 232 495 M3 7730 3232434 323W 89

I-I I 115’, * - . V I60 * . S - - -
El-I
C. 7 232 ALl M3 7231 3232434 3230113
I-IC A Il5’F * * * V I60F * * --
T - -
CJ5. 7 258 495 MAN 7230 323244 3230184

.1 3544.1. I Il5’ * - * V l60’F * . . --
I. I-I
cm, 7 238 19$ MAN 7230 3232431 3230177
I-I 409l.. I II5’F * * V l0F * . . --
8-I-I
Ci. 251 49S A 7228 3232434 3230179
IT I 115’F * , V 1O’F * * --
E.I-I
CTh. 258 ALT MAN 7231 3232431 3730191
I-IC I 1151 * * * v ic * * S -
8-1-I
CTh. 7 258 CAL MAN 7230 3232434 3230119
I-Tc A II5’f * * * V S
8.14
78-14
1978 JEEP Cont’d.
68 Spoil.
Model VECIL Ar., Trans Carb Disi GA Valve 61 CTO AG Ca’ cv IAC do TCS CVTC FIVC U C
Number Nun,bet Number Cod. Con, Ten,Pq OP TM
TCnIPC YIP.
Ci, 7 238 CAL A 7701 3232434 3230175 - -
I-IC 115°F
B . 5 5 V 160°F * 5 C
E-I-1
Cm, 304 495 A3 8DM? 3231340 3730192
UI-I 3544,1.’ LI I5’I 5 V
5 C C S
E-4-T
Ci5,7 304 495 M3 80M2 3231340 323088
li-I 1409A,.Iej 115°f * .
0 . V . -
.4-1
Ci, 7 304 495 A BOA? 3230443 3230189
I-I A s
ISfl S * V - - * S S - - -
E.4-T
CJ5,7 304 ALT M3 8DM24 3231340 3230194
Il-I W 115°F . 5 C V 60°F - S S - S -
8-4-1
Ci,? 304 ALT A BOA2A 3230443 3230191
llT r 115°f * 60°F
S 5 V 5 e 5
E-4-T
05.7 304 CAL M3 SOM2C 3231340 3223980
Il-IC c/a Red 115°F * S
E-4-T ® V S S S - S S
Ci. 7 304 CAL A 8OAtIC 3231340 3230839 -

III 1 115°F . C V 160°F 5 5 5 5 5
8-4-1
C
258
Cherokee 495 MAN & A 8107 3232434 3218739 Blue 160°f S V 60°F
I,uck I-HO
2V C
360 *
Cherokee MAN 8RHA2C 3230443 3219052 None 160°f * V 160°f . .. *
Truck Ill-HO
C j
2V
Cherokee 360 19$ A oRHA2 3231341 3219052
WogOneer 111-140 None 60°F 5 - S V l60..-., -
Truck 2V -.....
Cheroke. 360 CAL A BRHA2C 323374 3233596

Wugonee, Ill-lID All 115F * e S V 220°F - S S S
Truck 2V -
30 -
Cherokee 4 M4 61NM4 3230443 3219052 None 140°F . S V 160°F
Ill-HO
Truck
Cherokee
v C .......... -
360 495 A OTHA4 3231311 329052

Wagon,., Ill-HO None 60°F 5 . v 160°F -
C C
-
Truck v -
Ch.rokee 40’ A OTNA4 3231341 3219052 None 160°f I * V 60°F - - = =

Wogoneer NI-HO
Truck 4V C
1977 JEEP
68 Spot1
Carb
68 68 CTO Cal TAC CTO
Model VECIL Ae.o Irons Valve AG PCv TCS CVTC FTVC T5 C OP TM
Number Number Code Temp. Con, lype Temp.
- -
Number
-
I - ---
232 M3 322979 323084

CJS.7 754 L 115°F M 160°F -
-r 3.54 Axle * - * - - -
CJ5, 7 232
I-i
495 M3
4.09 AsIc
7154 322979 3230179 F 115°f
**
-ir -- - ::
CJS, 7 232
I-IC
ALT M3 710 322979 323083 - K 115°F
* . --
"-
: -- ::
CJ5, 7 258 495 MAN 7154 3229719 323084 1 115°F 160°F
I-I 354A.le * -
- M * - - -
05, 7 258 195 MAN 7154 327979 373079 F 115°F 160°F - - -

S C M - S * e
l-T 4.09 4.1.
Ci. 7 258
I-I
495 A 7151 3239719 3230190 j° 115°F 160°F - : :::
CJ. 7 258
I-IC
ALT A 711 322979 3230192 ti 115°F --- - - ::
Cm.? 258
I-IC
CAL N 7154 3229’19 3230186 N 115°F
. . 160°F
: 7 7 : :::
Ci. 7 258
I-IC
CAL A
3.54Asde
753 322979
.
3230186 14 115°f
. 5 C Ak
160°F
::
Ci.? 258
I-IC
*TZ A
4.09 kde
7153 3229719 3230846 *0 115°F
* S
160°F
S S S S ---
-
CTh. 7 304 495 M3 6DM2 3228264 3230188 0 115°F V
Ci, 7
Il-I
304 495 6DA2J 323093 V
S 5 5
n . t L.fl
A 3228263 13°F
* 5 5 V 5
Il-I - --
1977 JEEP Cont’d.
-
GA ‘Ga - - - - - --
Cotb- Did. GA CTO Cat- tIC CTO
Medal VICIL ACSO hone Valve AG PCV TCS CVTC flVC TS C OP TM
Numb., Numb., Cod. Temp0 Csav TYP.
Number TernsPc - - - - -
CJ5,? 304 ° M3 YOM2A 3228264 3230194 w 15°F 5 5 5 v ac., S - S

8.1
304 ALT A 7OA2A 3230191 I 115°f 5 S v 160°F 5 S 5 5
Ci.? 377826] *
8.1
CJS.? 3223980 S
CAL Mi 60M2J 3228264 Red ll$eF S S v 160°F S S - - -
I-IC c/a
**
Ci? 304 CAL 5

Il-I A aDA? 3228264 3230186 N 115°F S S a V 60°f - - -
258 - - - -
Cherokee 49$ MAN & A 8107 3229719 3218739 Blue 601 S Ak 60°F
I-HO
Truck TI
Cherokee 360
495 MAN 6ANM2 372826] 3219052 None 60°F 5 5 V 60°f - - - - - e
UI-HO
° ch
2V
-
Cherokee 340
- - - -
Wogoneer Ill-HO 495 A 68NA2 3728265 321 9’T5? f-lore 160°F 5 V 160°f
Iruck 2V
5
0 - - - - -
Che,okee 360 371095

Frock Ill-HO 495 ‘4 6THM4 3278763 No-p ‘6°f * * , 60°, - - - -5
4V -
Cherokee 360 3219052
None * e aO°f S
C
495 A 160°F - - - -
WOgonser Ill-HO 61H44 3228265 ‘
-
T,uck
Chero.ee 401
3719052
Wogoneer Ill-MD 495 A orHA. 3228265 Not,r 60°F 5 5 Ion’; - - - -- --
;
Iruck LV
Che,okee 5
IV-HO CAL M4 aTHM4 3228263 3230261 t IoQf S 5 °°° S - -
-
Truck
IV --
Cherokee 360
Wogonee, IV-HD CAL A 6INA4C 3228265 323C?61 160.1 . . . f- 60’F
- 5 - - -
Truck IV - --
Cherokee 401
Wogoneer IV-HO CAL A 5 5 V 160°F 5 5 - -
61HA4C 3228265 3230261 1 1601 - e
Iruck 4V
-- 0,l,cePloIe 3225145/ Bockpressurefronsducer 3229120
1976 JEEP
- - -___-
rCt0 5- - --
Model Are. Trans Caib DisI GA VoI.e GA lock PrnsurS Cal IAC CTO
VICIL AG PCV ICS DV FTVC T S C TM
Numb., Number Numb., Cede Tronsduce, Ce,,, Type
T’c - -
CJ5 1 232 495 M] 1109 3727331 3773980 Red 3278838 IIYF

I-I Orl,cePIoIe - 5 Ak - - - S - - -
3 22 5242
015 7 258 495 MAN 7109 3227331 3273980 Red 3228838 115°F - - -
I-I Or,hceplo.e - - S f-V - S - -
3225242 - - -
CJS I 258 CAL MAN 7084 3777331 3723980 Red 3228836 1151
I-IC Or,l,cePlole S S S M - S - -
322665?
CJ? 238 495 A 7083 3777331 3273980 Red 3229838 115°F
l-T 0r.f,cePIoe S f-k - - 5 - - -
3225144
-
C7 258 CAL A 7085 3777331 3273980 Red 3228836 115°F 60°f
I-IC Or,l,cePlole S S S M 5 - 5 -
322 59 56
Cm? 304 495 Ak] 60M2 3228284 3771980 Red 3229117 HS°f -- -
Il-I Or,l,ceplore S S 5 V - 5 - -
32 283 38
CU 304 495 A 60A2J 3228263 3223980 Red 3229118 15°F - - - -
n-i 0,,hcePloIe
* V - - - s s - -
3275145
05 7 304 CAL M3 60M2J 3228264 3273980 Red 3229120 115°F 160°f - - -
Il-IC Or,I,cePIoIe S S S V S S --
3225956
7R1R
1976 JEEP Cont’d.
--
GA Spark
Model VICIL Area Irons Corb Ott GA Valve GA Bock Pressure CW AG
c0 PCV TAC CIO ICS DV FTVC TS C TM
Number Numbs, Number Code Transducer Temp Can, lype Ternp,
- - - - ‘i-i -- --
CJ7 304 CAL A 60A2i 3228764 3223980 Red 3229119 115°F 60°F
H-I OrrIrcePicIe S
S S S V - 5 5 --
3225956
Chsrokee 495 MAN 7018 322733
I-HO 3228739 B1ue 160°F M 160°F -
-
--
- -
--
-
Truck
IV
259
Chsrokso 495 A 7088 3227331 3228739 Blue 160°F 140°F
I-HO 5 M - - -
Truck
lv - - - - - -
360
Cherokee 495 MAN 68KM? 3228263 3229052 None 160°F 160°F -
Truck
Ill-HO - v -
2V -
Ch.rolsee 360 495 A 69HA7 3228265 3729052 None 160°F 160°F

Wogoneer Ill-HO S
- - S V - - -. --
Truck ?V
Chsrokee 493 A&&N 6THMI 3228263 3229052 None 160°F 160°F

Ill-HO V - - - *
Truck
4V - - - -
Cherokee 360 495 A 6THA4 3228265 3229052 f-lone 160°F 60°F

Wogoneer Ill-HO V -
Truck 4V
Cherokee
rIll-HO -
CAL MAN 6THMI 3228265 3223981 Vellorr 3223407 160°f 160°F
Truck
Che,okSs
v - .S. -2. .t !_
360 CAL A 6THAIC 3228265 3223981 Yelloo 3223407 160°f 160°F
Wogoneer Ill-HO V 5 - -
Truck 4V - - - -
Cherokee 40 495 3228265 3225952 None

A 6THA4
Wogonser Ill-HO 160°F 5 5 V 160°F -. -
Truck IV -
Cherokee 401 CAL A 6THA4 3228265 3775951 Block 3223407

Wogoneer Ill-HO 60°f 5 5 V 160°f °
Truck IV - - - -
9.009-04AJ
78-17
Subject: Gas Tank Sending Unit Application: 1975-1978 Cherokee and File: POWER PLANT
Wagoneer Fuel and Exhant System
Group 4.000
No. 8-06 May 9, 1978
The fuel gauge in some 1975-1978 Cherokees and REPAIR PROCEDURES

Wagoneers may indicate 3/4 full when the tank is known
to be full. This condition may be the result of inaccuracy 1 Remove fuel tank, as described in appropriate
in the fuel tank sending unit. Technical Service Manual.
the vehicle, removing the sending unit from the fuel tank,
and reshaping the sending unit lever arm to correspond 3 Check sending unit with an ohmmeter for
with the attached template. continuity through resistor for normal resistance change
as lever is moved through its full arc of travel.
Before proceeding to the repair procedure, verify the a If sending unit is electrically faulty, replace it.
accuracy of the fuel gauge by using the DARS Charts on b If sending unit is electrically sound, proceed to
page IL-8, Volume 1 of the 1978 Technical Service step 4.
Manual. If the tests indicate inaccuracy in the sending
unit, proceed to the repair procedure. If the tests indicate 4 Reshape sending unit lever to attached template.
inaccuracy in the fuel gauge, refer to the appropriate
model/year Technical Service Manual for the correct 5 Install sending unit in tank.
replacement procedure.
6 Install fuel tank as described in appropriate
NOTE: Theproceduresfound in the DARS Charts on Technical Service Manual.
page 1L4 of the 1978 Technical Service Manual are
applicable to 1975-1978 vehicles.

WMRANTY YEAR AND TIME
- 0 PE R All C N SKILL
OPERATION DESCRIPTION R[PORTING MODEL -
NUMBER - L Vt
CODE 76 77 78
SENDING UNIT, FUEL TANK - DIAGNOSIS 3.614 4197 CKE-WAG 0.2 0.2 0.2 G
Sending Unit, Remove, Adjust, and Install.
- . . - 3414 A CKE-WAG 0.9 0.9 0.9 C
With Skid Plate ADD
- 0.3 0.3 03
Sending Unit, Replace

- 3.614 B CKE-WAG 0.9 0.9 0.9 G
With Skid Plate ADD
- 0.3 0.3 0.3
NOTE: Combination A and B cannot be used

together. Both include drain, R&R and refillfuel
tank as required
8-069-043

Savic. Engineering Dsp@rtm.nt . 14250 Plymouth Road * D.trolt, Michigan 48232
Add,tion& copies of this bulletin are available through your zone office-
78-18
1975-1978 Cherokee and Wagoneer
Sending Unit Template
78-19
Subject: Inability to Obtain W.O.T. or Actuate Appiication:tI978 Wagoneer, Cherokee,
- Filet POWER PLANT
the Choke Unloader and Truck Models Fuel and Exhaust Systems
No. 8-05 April20,1978
Some owners of 1978 Wagoneer, Cherokee, and Truck

models may find it difficult to obtain wide open throttle
or release the choke by depressing the throttle pedal. This
may be the result of inadequate throttle travel.
Service correction involves inspecting for wide open

throttle and unloader actuation, and correcting the
throttle travel in accordance with the following
inspection and repair procedures.
INSPECTION
1 Position drop light for proper visual inspection of

throttle linkage travel. Fig. 2 360 2-V
2 Push throttle pedal down to wide open throttle

position.
3 Observe position of carburetor linkage in

relationship to throttle stop see figures I, 2, and 3.
Fig. 3 360/401 4-v
4 If carburetor linkage contacts throttle stop, throttle

linkage geometry is correct. Proceed to stepS. If linkage
does not contact throttle stop, proceed to Repair
Procedure.
5 Remove drop light and return vehicle to owner.

Fig. 1 258 2_V
OVER

Ssrvic. Engineering D.portni.nt * 14250 Plymouth Road * Dtroit, Michigan 48232
78-20
REPAIR PROCEDURE
I Have helper hold accelerator pedal to floor.
2 Measure distance between throttle linkage and

carburetor stop and record measurement.
3 Remove three throttle pedal retaining screws.
4 Disconnect throttle cable from pedal bellcrank.
5 Remove bellcrank assembly from vehicle.
6 Place bellcrank in vise using wood or suitable

material to protect bellcrank.
CAUTION: The vise must have protective material on

the jaws to prevent damage to the accelerator belicrank
pivot surface.
7 Bend accelerator bellcrank as shown in figure 4,

distance recorded in step 2.
CAUTION: Do not bend more than the required

amount as this would strain the linkage at wide open
throttle.
8 Remove bellcrank from vise.
9 Position bellcrank with inner and outer brackets on Fig. 4

firewall of vehicle.
NOTE: Position throttle belicrank on firewallside ofthe II Connect throttle cable to bellcrank.
kickdown switch lever on automatic transmission
equipped vehicles. 12 Check for wide open throttle.
tO Install three bellcrank retaining screws. I 3 If required repeat steps 2 through 12.

OPERAT ION MODEL SKILL
OPERATION DESCRIPTION REPORTING NUMBER 78 LEVEL
CODE
LINKAGE, THROTTLE - INSPECT.. 4.050 4735 WA& .1 0

CKE
TRK
Belicrank - Adjust A .2 C
L028-04J
78.21
Subject: Cold, Hard Starting Application: 1978 Cherokee and Truck File: POWER PLANT
Models With 258 CID Engine and 2V Fuel and Exhaust Systems
Carburetor
No. 8-04 December 21.1977
Some owners of 1978 Cherokee and Truck models with 6 Open throttle valve setting to place fast idle screw on
258 CID engine and 2V carburetor may complain of a high step of cam.
cold, hard starting problem.
7 Pull diaphragm against stop using tool No. J23738
Service correction involves replacing the choke housing or any vacuum source which holds at least 19 inches of
baffle plate restrictor and changing the initial choke valve mercury Hg.
clearance, fast idle cam setting, and the choke cover
setting. The following part will be required. 8 Measure clearance between choke plate and air
horn wall. Refer to Carburetor, Service Specifications
Descnpt.on Quantity Part No. Group Chart.
Plate, Baffle I 8129399 4.001 9 Adjust initial choke valve clearance.
Restrictor a Open throttle slightly and place fast idle screw
NOTE: Parts for this bulletin will be available the week on second step of cam to obtain the new fast idle cam
of January 30, 1978. Do not order parts before this date. position.
b Measure and adjust distance between choke
plate and air horn wall. Refer to Carburetor Service
PROCEDURE Specification Chart.
I Remove air cleaner. NOTE: Adjust clearance by bending fast idle cam link
down to increase measure or up to decrease
2 Remove choke cover, measurement.
3 Remove choke heat inlet baffle restrictor plate. 10 Loosen choke housing cover screw and set to index.
4 Install replacement choke heat inlet baffle restrictor II Tighten choke housing retaining screws.
plate.
12 Install air cleaner.
5 Install choke cover, turn 1/4 turn rich and tighten
one retaining screw. 13 Verify problem has been corrected.
Carburator Service Specifications Chart

Aumat4c
Initial Mc&.r.tor
Flat Fat idi. Choke Ccqer Fast Ide’
L.vsl Piston Gap Choke Valve
-ace
Cam Setting s.ut,. DImensions
usi Notchea Rich c,,, Cholie
Nfler PC°’ ‘ tkHeadst
Set OK St OX Set OK Set OK Set OK Set OK S.f OK ID
To Rang. To Rang. To Range TO Range To Rang. To Rang. To Range
0.218 0.025 0.135 0.095 1/2 NR 0.420 1650

Manual T
8107 0.25 to 0.040 to 0.150 to 0.110 to INDEX to 0.440 to 0.280 1700 to
Automatic 1/2 I’lL 1750
0.282 0.055 0l 0.125 0.460
49 State
‘Hot with TCS Solenoid and EGR dsccnn.cted
OVER
VU Amedcai Motors Sales Corporation

* 14250 Plymouth Rood * D.trolt. Michigan 48232
S.rvle* Englnnrlng D.pcrtmat
78-22
OPERAT ION SKILL
NUMBER LEVEL
CODE 77 I 78 79
PLATE, BAFFLE - INSTALL

Includes carburetor adjustment
4.805 4067 CKE-
TRI
- I 0.3 - C.
g-0j3-04J
78.23
Subject: California Emission, Carburetion, Application: 1978 California File: POWER PLANT
and Tune-Up Specifications Addition to
- Wagoneer, Cherokee and Truck Fuel and Exhaust Systems
Volume I of the 1978 Jeep Technical Service Models With 360 CID Engine, 2V
Manual Carburetor and Automatic Trans
mission
No. 8-03 December 8, 1977
This bulletin is being issued to add the new emission, Reference to this bulletin should be noted on the
carburetion and tune-up specifications for 1978 appropriate charts in Section IA and lJ in Volume I of
California Wagoneer, Cherokee and Truck models with your 1978 Jeep Technical Service Manual.
360 CID engine, 2V carburetor and automatic
transmission.
Page 1A-2
Emission Components - California
Page 1A-22
Idle Drop - California
I EngIne I Transmission I Emission Package I Idle Drop Rpm I
360 Cal 20
Auto II
I 2V I
Page 1J-51
Tune-Up Specifications - On Vehicle - California

Initial Timing at Curb Idle
Curb Idl, or speed - RPM Total
Lea With Auto in Drive, Dree.
Engine 5tn1,bo, Vacuum Spark
Vacuum Hose Manual In Advance Centrllugs
CID and Transmission Dim,acIed Neutral Model Unit
Number Number at Advance Type
Carbuntlon 2000
Sal
To
II OK
Range
Set
To
OK
Range
RPM
-:
2V
A
BlOC
I 8’
12’ 700
= 3233174 VA-12
2T5
to
37.0
6to
l0.5@
2000
N12Y
0035
OVER

Service Engineering D.portm.nt * 14250 Plymouth Road * Detroit, Michigan 48232
Additional copies c/this bulletin are available through your zone 0/lice.
78-24
Page 1A-23
Model 2100 Carburetor Specifications - California

Initial Automatic
floai I.evsl Fat Idle Choke Cover Fast Idle
Wet Choke Valve Can. Setting Speed
Setting
Float nc Notches Rich Bowl Choke
List Application Level -
choke Vent Bimetal
Number uniseth, ID
Dq Clearance
Set OK Set OK Set OK set OK Set OK
To Range To Range To Rang. To Range To Range
360 0.868 0.113 0.111 1.½ 1500

8RHA2C AutOmatic 0.93 to 0.555 0136 tO 0,126 to 2 to 0.250 YIN. 1600 to 0.120 TFA
California 0.922 0.159 0.14! 2-½ 1700
8-02I-04J
78-25
-- -
VU Jeep
Subject: Oath: December 06,1977
JSP
AddiaA
a S uct
Afrat[etuj
all
ran
y aign
Application: 1978 Cherokee and Truck
File: POWER PLANT Fuel
and Exhaust Systems
This is a Type S Campaign, subject to all campaign

procedures and involving safety-related elements. A copy
of the combined owner notification and correction report
ing card for this campaign is shown in Figure 2.
Another accelerator return spring is being added to all

1978 Jeep Cherokee and Truck models with a 258 CID
engine and 2V carburetor, built between VINs
J8XXXXC000008 and J8XXXXC037866, to assure that
the throttle will close rapidly under the most extreme
operating conditions.
The following part is required.
Spring -Accelerator SF-5358241 4.080

Return
The zone will provide a VIN list and an initial supply of
parts for each dealer with any vehicles involved. How
ever, the campaign procedures apply to all dealers. On all
undelivered, campaign-involved vehicles, the correction
must be made before the vehicle is sold or otherwise put
into service.
Additional parts can be ordered, as needed, on or after

December 21, /977.
PROCEDURE
1 Connect short end of accelerator return spring into
carburetor lever-to-accelerator cable bracket in same hole Fig. 1 Carburetor Return Springs
as existing spring see Figure 1.
2 Connect long end of accelerator return spring into

forward hole of carburetor pull back spring bracket see
Figure I.
3 Check throttle operation.
Fl American Motors Sales CorporatIon

Service Englnaerlng Department e 14250 Plymaith Read s Detrelt, MIchigan 48232
78-26
_______________________________________ __________________ _______________
WARRANTY OPERATION YEAR AND liME

OPERATION DESCRIPTION REPORTING NUMBER MODEL LEVEL
CODE 77 78 79
SPRING, CARBURETOR RETURN-

INSTALL JSPRING CAMPAIGN 4.082 4117 CKE’TRK - 0.1 - G
Applicable Defect
Code: 56-Product Recall
Campaign
CLAIM HAI4DLING
Several vehicles may be listed on a single RFCJRO form, CAU11ON: On multiple-vehicle claims, do not delay any
Reference Warranty Administration Manual, Section 7, claim so that we will receive it beyond the time linus
Product Recall Campaign. outlined in the WAM.
Complete and mail the reporting half of the notification

card Figure 2 for each vehicle as soon as campaign
service is complete.
[ Notice of Product Recall Campaign Involving Your Vehicle

TIM ..el.. S.. I. Is eeed. -b - SSne.s4. .1 - N.MeelTteIS. ..d Met.. V.M.S U.t, An.
anc.epe.*Ms -
dsnnS.4 lb.’ tpfleaetJ.nT..e -
Cb.n.a.,sI.,.d ebb .1.-eylbeS.,.15.. ts.I.n.l nib_ste.
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When your vehicle goes in ror the required attention: Pins, be sure this complete notification card goes with
It bntaae the card I. to be used by the dealer for reporting purposes. In case you do not now own this vehicle.
please send as the "Change of Ownership" infoonation, using side of this card. A. ricaa Mown Corporatia.
Campa.eu Data Reporting Section
National Traffic and Motor Vehicle Safety Act of 1966

Instructions: OWNER Instructions: DEALER
If you do nor now own this car, please just fill p.. below Thps section Ps for the dealer to use when Your car
either a, b o c and MAIL DIRtCTLY TO AMERICAN qoes ‘n tor the reqt,i,fd attention.
MOTORS.
a. Sold or Traded to:________________________ CrVII..

Nfl Phj. P.e,t
Ada,a.
L_LJ I H’
b. presenr owner rains anij aIets not known JSPRING CNIPAIGN 773
0
c. Removed lion service because of collision
damage or otherwise 0 aM. cc Seniesd

YIN fVibes Id.n,.henoe NulebeIl Campip Data Reporting Settles
Fig. 2 Owner Notification and Correction Reporting Card
78-27
Subject: Possible Hesitation or Stumble on Application: 1978 Wagoneer, Cherokee File: POWER PLANT
Initial Acceleration and Truck Models With 360 CID, VS Fuel and Exhaust Systems
Engine and 2V Carburetor Except
California
No. 8O1 November 21,1977
Some owners of 1978 Wagoneer, Cherokee, or Truck another problem such as excessively lean carburetorfuel
models equipped with 360 CID, V-8 engine and 2V mixture, disconnect vacuum line, incorrect ignition
carburetor may complain of hesitation or stumble on timing, or by dirt in the fuel system.
initial acceleration.
Service correction involves installing a delay valve in the

vacuum hose between the EGR valve and the CTO PROCEDURE
switch. The following part will be required:
1 Cut vacuum hose mid-way betweenEGk valve and
O switch.
2 Install delay valve between cut ends of hose.
Valve, Delay 5355276 4.700
NOTE: Delay valve is to be installed with red end of
NOTE: Beforeperforming the procedure outlined in this valve toward CTO switch and blue end toward £GR
bulletin be sure that the condition is not caused by valve.

OPERATION SKILL
79 I.EVEL
VALVE, DELAY - INSTALL 4.700 4273 WAG- - 0.2 - G

CKE
TRK
8-0Io-04J

S.rvlc. Englnnrlng D.partm.nt . 14250 Plymouth Road * Drrolt, Mléhlgan 48232
Additional copies of this bulletin are available through your zono office,
Subject: Improved P rocedures for Clutch Application: 197 7-79 Ci Models File: CHASSIS
-
Group 6.000
No. 9-02 July18, 1979
Improved procedures for replacing the clutch over- NOTE: .4s the spring is pulled forward, it will ride
necessary.
see illustration
wire through grommet hole. Wrap wire around 1 Disconnect clutch pedal push rod at belicrank.
wire- Position second 2 x 4 board against dash
contact any of the brahelines during overcenter 5 Feed 3-foot long double strand of mechanics
spring removal or installation. wire through windshield washer grommet hole.
6 Connect replacement overcenter spring to contact any of the brakelines during overcenter
brake pedal support bracket. spring rerno vat.
in pedal slot. remove clutch pdal from shaft.

Srvla Eaghiaring Dspartmsnt * 14250 Plymouth Rocd * D.trolt, MichIgan 48232
Additional copies of this available through your zone office.
bollo fin are
78-29
BRAKE PEDAL
SUPPORT BRACKET
SNAP RING
9 Install replacement clutch pedal on shaft and NOTE: As the spring is pulled forward, it will ride
11 Connect clutch pedal push rod to beflcrank. 15 Install windshield washer hose grommet
in dash panel.
support bracket. 16 Connect battery negative cable.
spring slides into and seats in pedal slot. necessary.
The Tollowing operations and standard work times will apply:
WARRANTY OPERATION YEAR AND TIME

OPERATION DESCRIPTION SKILL
REPORTING MODEL
NUMBER LEVEL
CODE 77 78 79
PEDAL, CLUTCH-REPLACE 5.135 5006 83-93 . 4 - 4 - 4 G

REPLACE 5.973 5010 83-93 . 3 . 3 - 3 0
9-iOO-OSJ
78-30
Subject: Model T-1SO, 3-Speed Manual Application: 1978 CJ Models Built File: CHASSIS
Transmission With Interflow Lubrication After YIN J8FXXXXO97I93 Clutch Manual
-
System Transmission
* No. 8-03 June 23. I 978
The interfiow lubrication system that is presently used in

the T-l5A, 3-speed manual transmission has now been
incorporated into the T-l50, 3-speed manual
transmission. As a result of the incorporation of the
interflow lubrication system into the Model T-l50
transmission, changes have been made in transmission
component design, lubricant level requirements, and
service parts information. Pertinent information
pertaining to each of these areas is as follows:
TRANSMISSION COMPONENT
DESIGN CHANGES
* Four holes have been added to the rear face of the
transmission case for venting and oil circulation between
the transmission and transfer case Fig. I.
* The transmission to transfer case gasket has been

redesigned as shown Fig. I.
* The transmission adapter plate seal has been

eliminated.
* The rear oil slinger has been relocated to a position in

front of the rear ball bearing Fig. 2.
Fig. 2 Tremac 3-Speed Manual Transmission

Rear Bearing Adapter, Rear Ball
Bearing, and Oil Slinger
LUBRICANT LEVEL REQUIREMENTS
The transmission and transfer case lubricant level
requirements are listed on the following chart.
U.S. Imperial Metric
Capacities Measure Measure Measure
Transmission 3 pints 1.06 Imp. Qts. 1.4 Liters

Fig. I Tremac 3-Speed Manual Housing With Transfer Case 3 pints, 12 oz. 1.24 Imp. Qts. 1.8 Liters
Interfiow Lubrication System
OYER
S.rvlc. Enginoring D.partm.nt * 14250 Plymouth Rood * DVroIt. MichIgan 48232
7Rfll
The oil levels may vary by a pint orso from one unit to the interchangeable with non-interfiow lubrication system
other when checked; however, regardless of overfill transmissions: transmission case, transmission-to-
condition, the oil levels should be corrected to the proper transfer case gasket, oil slinger, and rear bearing adapter.
level. Part numbers for the transmission case, oil slinger, and
rear bearing adapter will be forthcoming from the parts
NOTE: If the transmission isfoundto be underfilled and division as soon as they are available.
the transfer case is correctly filled or underfilled. the
si’stem was not correctly filled at the last servicing or CAUTION: The new transmission-to-transfer case
there is a !eak in the transmission or transfer case. Check gasket 5359022 is available and must be used in all
and correct leaks and correct the oil levels. repairs involving the Model T-l5O. 3-speed manual
transmissions which have the in;erflow lubrication
SERVICE PARTS INFORMATION system.
Transmissions equipped with the interfiow lubrication
system have four parts that are unique and not
8.o62-06J
78-32
P1 Jeep
te: April 11, 1978
Application: 1976, 1977, and
1978 CJ-5, Cl-b, and CJ-7
File: CHASSIS Clutch -
Manual Transmission
This is a Type S Campaign, subject to all campaign TRANSMISSION OIL LEVEL INSPECTION
procedures and involving safety-related elements. PROCEDURE
Copies of the combined owner notification and cor
rection reporting cards for this campaign are shown 1 Obtain a paper cup and remove lip so excess
in Figure 4 and Figure 5. transfer case lubricant can be caught when fill plug
is removed.
1976, 1977, and 1978 CJ-5, CJ-6, and CJ-7 Jeep vehi
cles equipped with a 3-speed transmission may have 2 Remove transfer case fill plug and catch all excess
oil that flows out filler hole see fig. 1. Pour excess
been built with the transmission adapter plate seal
improperly seated. This condition could allow the oil into measuring cup graduated in ounces.
gradual transfer of lubricant from the transmission
to the transfer case. If lubricant transfer takes place
the transmission could eventually become damaged
and inoperative.
Vehicles involved include 1976 Cl models between
VINs J$F93F11000015 and J6F93AH102513, 1977
Cl models between VINs J7F83AA000008 and
J7F93AA128208. and 1978 Cl models between VINs
J8F83AH000071 and J8F93AA064933.
Vehicles built before April, 1977 will require a transfer
case lubricant level inspection. If the inspection in
dicates that four or more ounces of excess lubricant
are present in the transfer case, seal replacement is
required. Proceed to the TRANSMISSION OIL
LEVEL INSPECTION PROCEDURE.
Vehicles built from April 1, 1977 through December FIg. 1 Collecting Excess Lubricant wfth Paper Cup.
16, 1977 require mandatory transmission adapter NOTE: In the event that a graduated cup is not
plate seal and spacer replacement. THESE VEHI available, the inside cavity of Installer Tool J-26852
CLES DO NOT REQUIRE INSPECTION; proceed can be used to measure the lubricant see fig. 2.
to the TRANSMISSION ADAPTER PLATE SEAL
REPLACEMENT PROCEDURE.
Part Dealer
Description Qty. Number Group Net
Seal, Transmission 1 5358980 6.053-2 1.29 ea.
Adapter Plate
Spacer 1 5359069 6.053-20 AS ea.
Gasket, transfer 1 5358840 18.001-3 .21 ea.
case to transmission
The Zone will provide a VIM list and an initial supply
of parts for each dealer with any vehicles involved.
However, the campaign procedures apply to all
dealers. On any undelivered, campaign-involved
vehicle, the correction must be made before the vehi
cle is sold or otherwise put into service.
Additional parts can be ordered, as needed, on or
after May 22, 1978. Fig. 2 Using Tool J-26852 to Measure Lubricant.

SuMs, EngineerIng Department * 14250 Plymouth Road * Detroit, Michigan 45232
78-33
3 If excess lubricant exceeds four ounces, trans 11 Remove bolts attaching transfer case to trans
mission adapter plate seal replacement is necessary. mission and remove transfer case- Remove transfer
Refer to the Tnan’ion Adapter Plate Seal Re case gasket.
placement Procedure in this Diagnosis and Repair NOTE: One transfer case attaching bolt must be
Bulletin. removed from the front end of the case. This bolt is
4 If excess lubricant is less than four ounces, located at the bottom right corner of the transmission.
adapter plate seal is properly positioned. Install fifi 12 Remove transfer case mainshaft gear, washer,
plug. and locknut.
5 Remove transmission fill plug and check lubricant 13 Remove adapter plate seal from rear bearing
level. Correct lubricant level if necessary. adapter.
6 Install transmission fifi plug. 14 If oil slinger is found behind seal, remove it.
7 Apply a daub of white paint above transmission 15 Clean oil from transmission adapter plate and
fill plug to identify campaign completion. rear bearing adapter.
TRANSMISSION ADAPTER PLATE SEAL 16 Inspect transfer case mainshaft gear sealing sur
REPLACEMENT PROCEDURE face for smooth finish to assure seal lip seatin
Replace the gear if the sealing surface is not smoot
1 Remove shift lever knob, trim ring, and boot from
transmission and transfer case shift levers. 17 Inspect inside diameter of rear bearing adapter
for smooth surface to assure proper sealing between
2 Remove floor covering if equipped and remove adapter bore and seal housing. Replace the rear bear
transmission access cover from floorpan. ing adapter if the inside diameter surface is not
3 Place transmission lever in first gear position smooth.
and firmly secure it using rope or equivalent material. 18 Install spacer in place of oil slinger, if originally
NOTE: The shift lever must be secured as described equipped with oil slinger.
to prevent the rear bearing retainer from moving out- NOTE: If the transmission did not originally have an
ward when the transfer case mainshift gear locknut oil slinger, a spacer must not be installed.
is removed, If the rear bearing retainer is allowed
to move outward the internal transmission parts may 19 Coat adapter plate seal lip with gear lubricant.
separate. If the internal parts separate, the thins- 20 Slide seal onto Installer Tool 1-26852.
mission will have to be removed for reassembly.
NOTE: The adapter plate seal is stamped FRONT
4 Raise vehicle. and REAR on the seal housing. When the seal is
NOTE: A visual inspection of the transmission and correctly positioned on the seal installer, the side
transfer case should be made. If oil leakage is evident, marked REAR is against the seal driving surface of
the cause of leakage must be eliminated. the installer. see Fig. 3
5 Drain transfer case and transmission lubricant. NOTE: Seal Installer Tool J.26852 must be used to
install the adapter plate seal to assure proper align
6 Disconnect torque reaction bracket from ment and sealing.
crossmember.
21 Slide transfer case mainshaft gear onto main-
7 Position support stand under clutch housing to shaft. Apply hand pressure against gear and check
support engine and transmission. clearance between forward surface of transfer case
8 Remove rear crossmember. mainshaft gear and rear face of adapter plate seal.
Clearance should be no less than .050" at any point
9 Disconnect front and rear propeller shaft yokes between seal housing and mainshaft gear. If clearance
and mark for assembly reference. is less than .050" use Installer Tool 1-26852 to reseat
10 Disconnect speedometer cable at transfer case. adapter plate seal and repeat clearance check.
FIg. 3 Adapter Plate Seal.
78-34
22 Install transmission mainshaft washer and lock- 29 Remove dowel pins and install remaining trans
nut. Tighten nut to 150 foot pounds torque 205 fer case attaching bolts. Tighten all bolts to 30 foot
newton meters. pounds torque 22 newton meters.
23 Install transmission-to-transfer case gasket on 30 Connect speedometer driven gear to transfer
transmission, case.
24 Shift transfer case to 4L position. 31 Connect front and rear propeller shafts to trans
fer case.
25 Install one 3/8 16 x 4-inch dowel pin on each
-
side of transmission to assist in guiding transfer case 32 Connect torque reaction bracket.
into place during installation. 33 Fill transmission and transfer case with SAE
26 Install and position transfer case on dowel pins. 80W-90 gear lubricant API.G 14. Fill each unit to
bottom of fill plug hole.
27 Rotate transfer case output shaft by turning
yoke until mainshaft gear on transmission engages 34 Apply a daub of yellow paint above transmission
rear output shaft gear in transfer case. Slide transfer fill plug to identify campaign completion.
case forward until case seats against transmission. 35 Lower vehicle and remove rope or equivalent
CAUTION: Be sure the transfer case is flush against material securing shift lever.
the transmission. Severe damage to the transfer case 36 Install transmission plate on floorpan. Install
will result if the attaching bolts are tightened while floor covering, if equipped.
the transfer case is in a bind or is cocked.
37 Install boots, trim rings and shift knobs.
28 Install two transfer case tightening bolts but do
not tighten completely.

OPERATION OPERATION YEAR & TIME SKILL
DESCRIPTION WRC NO. MODEL 78 77 78 LEVEL
TRANLUB CAMPAIGN LUBRICANT
LEVEL-Inspect 6.613 6033 63-84.93 .2 .2 - G
Seal, Adapter Plate-Replace 6.614 A 03-84-93 1.2 1.2 - B
SEAL, ADAPTER PLATE-Replace 6.615 6035 03-84-93 - 1.2 1.2 6
Applicable Defect Code: 56-
CLAIM HANDLING
Several vehicles may be listed on a single warranty Complete and mail the reporting half of of the notifica
claim, reference Warranty Administration Manual, tion card Figs. 4 and 5 for each vehicle as soon as
Section 7, Product Recall Campaigns. The transmis- campaign service is complete.
sion adapter plate seal and oil slinger that is removed
and replaced is a returnable part and must be tagged CAUTION: On multiple-vehicle claims, do not delay
and returned with your regular claim material any claim so that we will receive it beyond the time
shipment. limit outlined in the WAM.
See Reverse Side
78-35
___________________________
_______________________
I s’s ‘I Notice of Product Recall Campaign Involving Your Vehicle

This notice is sent toyots in accordancew ith the requirements of the National Traffic and Motor Vehicle Safety Act.
Jeep Corporation has determined that * detect which relates to motor vehicle safety exists in some 1976, 1977 and 5976
CJ-5. CJ-6 and CJ-7 vehicles equipped wit, threespeed manual transmissions. A condition that allows a gradual dis
placement of lubricant from the transmission to the transler case may exist In some ol the vehicles. Your vehicle.
identified on the revers, side of this card, should be inspected by your Jeep dealer. Any necessary corrections will be
performed by your dealer at no eh.rge to you.
Lubricant in the transmission may he displaced during normal vehicle operation. A 1ow lubricant condition could cause
the tr.nsn,iesion to become damaged or inoperative and could lead to a loss of vehicle control and acr.sh without any
prior warning.
tt year tranamisaion becomes difficult to shut. it may be a warning that the lubricant level is low and should be
checked and refilled, if necessary- However, you may have no prior warning ol lubricant displacement and should avoid
driving at prolonged highway speeds until your vehicle has been inspected and repaired, if necessary, by your dealer.
Your dealer saill have the necessary pans sad will be prepared to make repairs by May 22. t978. The correction usually
requires no more then ninety minutes and in many cases will require less than thirty minutes.
If your dealer should be unable to handle this campaign service promptly after May 22,1978. please contact the local
Zone Office listed in your Owners Manuall or Jeep Corporation. Owner Relations, 14250 Plymouth Road, Detroit.
Michigan 46232 telephone 313.493.2341. It you are unable to obtain this campaign service without charge and within
60 days after your tender of the vehicle to your dealer any time following May 22. 1978. you may contact the Adnsinis’
tenor. National Highway Traffic Safety Administration. Washington. D.C. 20590.
When your vehicle goes in for the required attention: Please be sure this complete notification card goes with it
because the card Is to be used by the dealer for reporting purposes. In case you do nit now own this vehicle please
send us the "Change of Ownership information, using side 2 of this car&

r:i
101
lnstructlo.,t OWNER Instructions: DEALER
It you do not now own this vehicle, please just 1,11 in

Id
1’1 below either a. b. or cI and MAIL DIRECTLY TO
This section is for the dealer to use when your vehicle
goes in for ihe required atTention
I’I AMERICAN MOTORS SALES CORPORATION
Id
là I
C Correction made
a, Sold or Traded to:
Ca
a 0 Correction not required
V Nana :P’ass. Pren
to
I Zone and Dealer Code
Adores.
LI P
C", Stais
b Present owner name and address not known 0

Deal., 5, qnaii,e
c- Removed from service because of collision
damage or otherwise
Campaign Data Aoponing Section

voN :vahcia ioennt,csi,o, Number
Fig.4 Owner Notification and Correction Reporting Card for all 1976 Vehicles and 1971 Vehicles
Built Before April1977.

InstructIonS: OWNER Instructions: DEALER
aV
if you do not now own this vehicle please just fill in
a
a
below either a. b. Or ci and MAIL DIRECTLY TO
This section is for the dealer to use when your vehIcle
goes ‘n for the required attention
AMERICAN MOTORS SALES CDRPORATION
a
a
0 Correction made
ii. a Sold or Traded to
0 Name - Pleas. P1 ni
I
V
to Zone and DealerCode
Address
[I I! I
Cay Si.,.
b Present Owner name and address not known 0

tea’.’ S’qnaiu’e
Removed from service because at collision
damage or otherwise
Se,s,cea
Campaign Data Reporting Secf ion

VTN :ven,cie ioeiu,i,csi,oi’ Nambe,:
FIg. 5 Correction Reporting Card for 1977 and 1978 VehIcles Built from April 1 1977
throu9h December 16, 1977.
78-36
Subject: Manual Transmission Model T-15A ApplIcation: 1973 through 1978 Jeep File: CHASSIS
Shift Confrol Housing Technical Service Technical Service Manuals Clutch Manual
-
Manual Correction Transmission

Group 6.000
No. 8-01 March 6, 1978
This bulletin is being issued to correct an error in the

illustration of the shift control housing used on Model
T-l5A manual transmissions.
The Technical Service Manual, page number, and

illustration Fig. numbers are listed below. Also
included is a corrected illustration.
Technical Illustration INTERLOCK SHIFT

Service Manual !S Fig. Numb& PLUNGER RAIL
1973 6-5 Fig. 22
1974 6-8 Fig. 6-24
‘975 6-8 Fig. 6-24

550060-
1976 6-17 Fig. 6-34 THIRDI FLOGS
1977 6-17 Fig. 6-34
1978 Vol. 2 2B-18 Fig. 2B-35

FORK
8-045-06J

Service Engineering Department * 14250 Plymouth Road e Detroit, Michigan 48232
Additional copies of this bulle fin are available through your zone office.
78-37
Subject: Fluid Overflow From Automatic Application: 1977-79 Jeep Models with File: ‘IIASSIS
Transmission Fill Tube or Vent Tube Caused Automatic Transmission Automatic Trans.
by Overfill or Vent Tube Restriction Group 7.000
No. 9-02 April 30, 1979
On some 1977-79 Jeep models with automatic 3 Check transmission Iluid level as outlined in
transmission, fluid may overflow from the transmission appropriate Jeep i’echnical Service Manual. If fluid level
with owner.
Service correction involves verifying the overflow a If overflow does not occur during road test.
condition, inspecting the vent tube for restrictions, return vehicle to Owner,
checking the fluid level and calibrating the transmission h if overflow does occur during road test,
NOT K: If all UI er/low condition 0eur.c on/i- st-hen
PROCEDURE towün,’ a trailer. :1w road tec, ,riusf be 4’onh/u’wd with i/re
trailer in toIo.
I Inspect transmission fill tube and vent tube for 4 Raise vehicle on hoist. loosen vacuum modulator
evidence of fluid overflow, adapter retainer bolt. Pull modulator outward
a If tubes do not have evidence of overflow, approximately 1/2 to I-inch and drain one pint of fluid
b If tubes exhibit evidence of overflow, proceed modulator attaching bolt alter draining fluid. Lower
to next step- vehicle and road test to verily correction.
2 Check transmission vent tube for restriction by 5 Cheek fluid level again and file new mark on
inserting length of stiff wire into tube, transmission dipstick at adiusted fluid level.
return vehicle to o’wner.

OPERATION SKILL
REPCOORNG NUMRER -7 LEVEL
ovERFLOW. AUTOMATIC TRANSMISSION-

DIA;NOSE AND CORRET 16.022 16205 0.8 0.8 0.8 C
I7.

Service Engineering Deportment e 14250 Plymouth Road e Detroit, Michigan 48232
Additional copies of this bulletin are available through your /one i’ffice
78-38
Subject: Premature Part Throttle Kickdown Application: 1978 Wagoneer and File: CHASSIS
Cherokee Models With V-S Engine and Automatic Transmission
Automatic Transmission
4-
No. 8-91 June 1, 1978
Some 1978 Wagoneer and Cherokee models with V-8 NOTE: & careful not to release 3-2 spring when
engines and automatic transmissions may have a removing retaining pin.
sensitive 3-2 kickdown on light acceleration.
7 Install spacer, new 3-2 spring green, bore plug, and
JM model transmissions built prior to JM32276 can be retaining pin Fig. I.
updated to correct premature kickdown by installing the
new 3-2 valve spring. The following parts are available
and required:
Spring, Control
Valve Assembly
3-2 Valve 8129621 6.660
Green
Gasket, Transmission
Oil Pan 1 8626931 6.507-2
NOTE: When a vehicle with the described condition is

ret urned to the dealer for service, the engine shouldfirst
be checked to assure proper engine operation. On non
Ca4fornia vehicles, the EUR vacuum hose must have a
vacuum delay valve inserted in the hose between the EGR
valve and CTO switch. Reference: Diagnosis and Repair
Bulletin, Power Plant. Fuel and Exhaust System. No. 8-
0!, November 21, 1977. Fig. 1 Control Valve Assembly Spring
PROCEDURE
I Drain transmission. 8 Install valve body and shift detent roller spring.
2 Remove oil pan. 9 Torque all valve body bolts to 10 foot pounds.
3 Remove filter. 10 Install filter and torque retaining bolts to 10 foot

pounds.
4 Remove detent roller and spring.
II Clean transmission oil pan and install new gasket.
NOTE: Do not remove detent solenoid. If detent
solenoid is removed the valve body spacer plate and 12 Install pan and torque bolts to 13 foot pounds.
check balls will separate and foil.
13 Lower vehicle.
5 Remove valve body.
14 Fill transmission with AMC, Dexron, or equivalent
6 Lift gasket slightly for access to 3-2 spring transmission fluid to specified level.
retaining pin. Using needle nose pliers, remove retaining
pin, bore plug, 3-2 spring and spacer Fig. I. 15 Road test vehicle.
OVER

Service Engineering Deportment e 14250 Plymouth Road e Detroit. MIchigan 48232
Additional copies of thés bulletin are available through your zone office.
78-39
WARRANTY
OPERATION YEAR AND TIME SKILL
NUMBER LEVEL
CODE 78
SPRING, 3-2 VALVE - REPLACE... 16.195 6215 WAG- 1.0 G
Includes Road Test CKE
Delay Install
Valve, - 4.700 A .1 G
Except California
846&06J
78-40
Subject: Automatic Transmission Vacuum Application; AU 1974-1978 Jeep File: CHASSIS
Modulator Testing Procedure Models With Automatic Transmission Automatic Transmission
Group 6.000
No.8-03 April 21, 1978
A new procedure has been.developed for bench testing 2 Measure distance of plunger travel with maximum
automatic transmission vacuum modulators. This vacuum applied. Distance from plunger to edge of
information is supplemental to the procedures in Volume cylinder should measure approximately 5/8 inch see
2, page 2C-59 of the 1978 Technical Service Manual, but Fig. 2.
also applies to 1974-1977 vehicles.
NOTE: Maximum applied vacuum should remain
If transmission operating characteristics, pressure tests constant for at least 30 seconds. If modulator will not
or other diagnostic work indicates that a modulator may hold vacuum as required, replace the modulator.
not be operating properly, use the results of the following
tests to determine the condition of the modulator.
PROCEDURE
I Apply vacuum to modulator and observe plunger
travel. Refer to Vacuum Modulator Movement
Specifications Chart for vehicle model year, transmission
model and vacuum readings, for approximate beginning
and ending of modulator plunger travel.
NOTE: The transmission serial number is stamped on a

metal plate attached to the right side of the transmission
case. The serial number must be included in any
comrnunicaf ion involving parts ordering or requestsfor
transmission information.
Fig. 2 Vacuum Modulator
3 Disconnect vacuum source from modulator.
4 Roll lower half of the main housing of modulator on

B - Approximate Vacuum at E - Approximate Vacuum at a flat surface and observe concentricity of plunger
Which Beginning ot Which Ending of cylinder to housing. If plunger cylinder is concentric and
Plunger Movement Plunger Movement plunger is free, modulator is acceptable.
Should Occur Should Occur
All vacuum readings are in inches HG
* Not Applicable
Fig. 1 Vacuum Modulator Movement
Specifications Chart

Service Engineering Deportment e 14250 Plymouth Road e Detroit. Michigan 48232
your zone office.
Additional copies of this bulletin are available througf’
Subject: Gear Shift Knob Replacement Application: 1976-1978 Jeep Models File: CHASSIS
With Automatic Transmission Automatic Transmission
Group 7.000
No. 3-02 March 28.1978
When a shift lever knob is in need of replacement on a PROCEDURE

1976-1978 Jeep model with automatic transmission, it is
no longer necessary to replace the shift lever and knob as 1 Using a punch and hammer, drive out shift lever
an assembly. retaining pin and remove shift lever from steering
column.
NOTE: Replacement shj/i lever knob can also be used on
1973-1975 Jeep Models with automatic transmission. 2 Place shift lever in vice equipped with padded jaws.
3 Using a hammer and chisle, drive off shift lever

knob.
The following part is available and required:
4 Using a plastic mallet, install replacement shift lever
Description Quantity Part No. Group knob.
Knob, Shift Lever I 3216462 7.030 5 Attach shift lever to steering column with retaining
pin.

OPERATION SKILL
CODE
NUMBER 76 I I 78 LEVEL
KNOB, GEAR SHIFT LEVER- REPLACE 7.030 7022 .2 .2 .2 G
8-043-BSA/J

Service Engineering Deportment e 14250 Plymouth Road * Detroit, Michigan 48232
Additional copies at this bUlletin are available through your zone office.
Subject: Transmission Hunting Application: 1978 Wagoneer, File: CHASSIS
Cherokee, and Truck Models With 360 Automatic Transmission
CID, VS and 2V Carburetors Except
California
No. 8-01 February 12,1978
Some owners of 1978 Wagoneer, Cherokee, or Truck NOTE: Beforeperforming the procedure outlined In this
models equipped with 360 CID, VS engine and 2V bulletin be sure that the condition is not caused by
carburetor may complain of the transmission another problem such as excessively lean carburetorfuel
downshifting to second gear at moderate throttle opening mixture, disconnect vacuum line, incorrect Ignition
after the 2-3 shift. Transmission hunting occurs when the timing, or by dirt in the fuel system.
EGR valve opens causing a vacuum drop which
downshifts the transmission from third to second. This PROCEDURE
condition can occur in rapid succession at a constant
throttle on a slight upgrade. I Cut vacuum hose mid-way between EGR valve and
dO switch.
Service correction involves installing a delay valve in the
vacuum hose between the EGR valve and CTO switch. 2 Install delay valve between cut ends of hose.
The following part is required and is presently available:
NOTE: Delay valve is to be installed with red end of
valve toward CTO switch and blue end toward EGR
Description Quantity Part No. Group valve.
Valve, Delay I 5355276 4.700

OPERATION SKILL
CODE
VALVE, DELAY - INSTALL 4.700 4273 WAG- 0.2 C

CKE
TRK
8-034-163
P1 Amedcsi Motors Sales Corporation

Service Engineering Department s 14250 Plymouth Road e Detroit, MIchigan .48232
are available through your zone office.
Additional copies of his bulletin
78-43
Procedure With QLadra-Trac Transfer Case Transfer Case!
Quadra-Trac
No. 9-01 Jan. 12, 1981
This bulletin supercedes Technical Bulletins Number 2, I’ROCEIURE

Series, and Number 13, 7300 Series. Group 18.001, I Inspect vehicle tires. ‘l’ires must all he same size,
dated February 9, 1976. Remove and destroy these type, make, anti tread design. orrect if necessary.
bulletins and replace them with this current bullet iii.
2 Check and ci ,rrect tire inflation pressures if
The Quadra-Trac transfer case in some 1973-79 *Jec-p necessary. All tires must EM inflated to re-c’uI
vehicles may develop a low frequency pulsating grunt me tided press j res arii I ri ,t va rv I v riii ire than 1/2 o
ing, or rasping noise that occurs when nirrieririg at slow I psi 3.45 to f;.895 kl’aj.
speed or when parking the vehicle. This rititse may occur
if the Quadra-Trac differential brake cones tend to stick 3 Raise h it it I an I raise veh ide I II hr ist -

values. This condition is referred to as stick-slip. 4 Theck transfer ease lubricant level. If Level is low,
inspect for leaks and ci ,rrect as necssarv -

lubricant has been developed to correct stick-slip. When 5 Inspect transfer case vent. II’ transfer case is
the new lubricajfl is used, a transfer case remote vent equl pped Wi tli cciii te vent tul it that is ri uteri in to
kit must also be installed. Because water adversely engine compartment, prticeetl to step 8. If
affects performance of the new lubricant, the vent kit. transfer case tItles not have remote vent tube, pro
must be used to prevent water entry and lubricant ceed to steps 1 and 7 fir vent kit installation.
contamination.
6 On CJ models. install remote vent kit as foIlo
sizes, and types, draining and refilling the transfer case a Clean vent area arid remove and discard
b Apply sil curie sealant to threads of replace
NOTE: The new Quo4ra-Trac lubricant is intnufrdfbr ment vent tube fitting and install fitting on
use in vehicles exhibiting stick-slip. For vehicles lion do transfer vase.
not exhibit stick-slip, the current Quadra-7’nw lubricant.
part number 5358652, remains the no’rmai rrplaeemen.t c Cover straight end of vent tube with tape.
lubricant.
The following parts are available and required. above cri,ssmember and to rear of transfer
case. Rotate curved end of tube upward and
Deacription Quantity Part No. Group Remove tape from straight end of tube.
LUBRICANT, Quadra e Cut and connect four-inch length of vent tube

Trac AR 8130444 18 .500 hose to vent tube fitting and vent tube.
STRAP, Tie AR 3223227 3.165 CAUTION: The ho.se must be securely connected to the
KIT, Vent 1 8130445 18. 500 fitting and tube to prevent water from enterinq the
Kit Contents:
Vent Tube Hose 1 step 8.
PU Ameiican Motors Sales Corporation
Service Engineering Department e 14250 Plymouth Road e Detroit, Michigan 48232
Additional copies of this bulletin are available through your zot,e thee
78-44
7 On Cherokee, Wagoner, and Truck models, install unit to drain completely. If transfer case is
original vent tube fitting.
b Apply silicone sealant to threads of replace foot-pounds 27 N-rn torque. If equipped with
ment vent tube fitting arid install fitting on reduction unit, seat unit in transfer case and
transfer case. tighten reduction unit attaching Ixilts. Tighten
3/8-16 bolts 20 foot-pounds 27 N.m torque.
c Lower vehicle. Tighten 5116-18 bolts to 9 foot-pounds 12 Mm
torque.
10 Fill transfer ease and reduction unit, if equipped.
e Insert straight end of vent tube downward with new Quadra-Trat- lubricant. Transfer case
lower straight end of tube to rear of transfer Reduction unit requires title jillil ii ttiiiijiictl.
modulator vacuum tube. NOTE: Shake the Quadra-i’rac juicier; vii ceintainep
igorvniAy beforefilling h’ transfer v’a.s,’. II i.s important
1 Secure upper curved end of vent tube to
that the lubricant be mirerl thor’rwjhly be flirt use.
strap.
II Install and tighten transfer case fill plug to 20 foot-
g Close hood and raise vehicle. pounds 27 N-rn torque.
to vent tube fitting and vent tube.
13 On CJ models, secure upper curved end If vent
CAUTION: The hose must be securely connected to flit tube to vacuum tnt id ulator yam ti iii I iilx u si rig tie
fitting and tube to prevent water frtynt entering the strap and close hood.
transfer case and contaminating the lutrico nt.

I Secure vent tube to transmission filler tube counterclockwise for approxi matelv 15 minutes to
and Quadra-Trac Emergency Drive vacuum circulate lubricant U; ri iughout transfer case.
tube using tie straps and proceed to step 8.
8 Position drain pan under transfer ease, remove CAUTION: Do no! turn I" or hold lit steering wheel af
drain and fill plugs from transfer case and allow the sttq’ poxitwn when drr’inq the "ehu-le in circles.
YEAR AND TIME

COOt NUMBER LVEL
1973-1979
STICK-SLIP, QUADRA-TRAC CORRECT

- 18.670 18395 CIte-Wag 0.6 6
Includes lubricant change and 15 minute Trk-CJ.7
driving time
With reduction unit Add - L2
Vent Kit-Install 18.670 A 0.3 6
9-122-I$J
78-45
____ _____________________

Subject: Quadra-Trac With Reduction Unit - Application: 1977 and 1978 Jeep File; CHASSIS
Disengages From High Range Vehicles With Quadra-Trac and Transfer Case/
Reduction Unit Quadra-Trac
Group 18.000
No. 8-01 May 16,1978
Some 1977 and 1978 Jeep vehicles equipped with PROCEDURE

Quadra-Trac and the optional low range unit may
occasionally disengage from high range. This can be I Remove reduction unit as described in appropriate
caused by improperly shifting the low range unit from Technical Service Manual.
low range to high range or by a worn or otherwise
substandard direct drive sleeve. 2 Remove power takeoff cover.
Service correction involves verifying that the proper 3 Position 11/16 inch, 1/2 inch drive deep well socket
shifting procedure as described in the Owner’s Manual in vise and clamp securely. Allow two inches of socket to
has been used. If the shifting procedures used are correct extend beyond top of vise.
and the Quadra-Trac disengages from high range, inspect
the reduction unit direct drive sleeve. If necessary, replace 4 Mount reduction unit on socket. Be sure socket
the direct drive sleeve, enters bore of sun gear Fig. 2. Reduction unit should be
supported by socket.
NOTE: To insure that a new direct drive sleeve will
improve the condition, compare it with Fig. 1. 5 Move reduction unit control lever rearward to high
range position.
6 Remove snap ring and spacer from mainshalt
Description Quantity Part No. Group Fig. 3.
Sleeve, Direct Drive I 8122689 18.615-17 7 Lift reduction unit housing upward and off gear
train Fig. 4.
Ring, Power Takeoff
Cover to Transfer 8 Slide direct drive sleeve off main shaft.
Case Cover Sealing 1 8122406 18.515-3
NOTE: To insure that the new direct drive sleeve will
Gasket, Reduction improve the condition compare it with Fig. I.
Unit to Power
Takeoff Housing I 8122707 l&610-9 9 Install direct drive sleeve.
WORN. SUBSTANDARD OR TEETH
TEETH WITH A FLAT ON tiii WITHOUT A FLAT ON THE END
END ARE ACCEPTABLE ARE NOT ACCEPTABtE
I I I / I
1
Fig. I Direct Drive Sleeve
OVER

S.rvlc. Enghsnring D.portm.nt * 14250 Plymouth Rood * D.troit, Michigan 48232
office.
Additional copies of this bulletin are available through your zone
78-46
Fig. 3 Main Shaft Snap Ring Removal -
Installation
Fig. 2 Mounting Reduction Unit on Socket
10 Align splines on assembled parts and install

housing. Be sure housing is seated firmly against direct
drive sleeve.
I I Install rear spacer and snap ring. Be sure snap ring is

fully seated in snap ring groove.
NOTE: The snap ring is a select fit component which is

available in seven dWerent sizes and used to maintain
0.004-to 0.009 inch clearance between the spacer and
snap ring. Snap rings can be found in the current Parts
Catalog. Group 18.615-2.
12 Install power takeoff cover and gasket. Tighten

cover attaching bolts to 20 foot-pounds 27 N in torque.
13 Remove assembled unit from support socket.
14 Install reduction unit as described in appropriate

15 Check fluid level of Quadra-Trac and reduction unit

and fill with Jeep Quadra-Trac Lube PN 89972l2.
16 Road test vehicle to insure proper reduction unit Fig. 4 Housing Removal - Installation
operation.

OPERATION SKILL
NUMBER 77 LEVEL
CODE 78
REDUCTION U4IT, GEAR SLEEVE

REPLACE 18.735 18353 0.7 0.7 C
18.1
78-47
Subject: Rear Axle Housing Cover Service Application: 1977-79 CJ Models File: CHASSIS
No. 9-02 May 15. 1979
be aligned prior to installing it.
whether it extends below the bottom edge of the axle cover is rotated, to determine if cover no longer extends
axle housing.
2 Inspect rear axle cover for alignment as follows:
axle housing, realign cover by moving it upward. If bolts to 20 ft. lbs. 27 N.m torque.

OPERATION SKILL
CODE LEVEL
77 78 79
COVER, REAR AXLE - MODIFY 9.007 9051 83-93 0.1 0.1 0.1 C
9-073.09J

ServIce Englnnrlng Department . 14250 Plymouth Road * Detroit, MIchigan 48232
78-48
Subject: Revised Ball Stud Preload Correction Application: All 1978-79 Jeep Models File: CHASSIS
and Front Wheel Shimmy Procedures Axles Propeller Shaft
-
No. 9-01 January 25,1979
Service procedures and related specifications for Front FRONT WHEEL SHIMMY
Wheel Shimmy inspection / correction and front axle Ball Refer to step 7 under Front Wheel Shimmy on page
Stud Preload Correction in the 1978 and 1979 Jeep Tech 2M-5 and change substep b, and substeps g through
nical Service Manuals have been revised. kto read:
These revisions apply to both the 1978 and 1979 Jeep b Loosen lower ball stud jamnut and remove cotter
Technical Service Manuals and are outlined separately pin and slotted nut from upper ball stud.
as follows.
g Install and tighten upper ball stud slotted nut to 10-
20 toot-pounds 13-27 Nem torque to draw lower ball
BALL STUD PRELOAD CORRECTION stud into tapered hole in axle yoke. Do not install upper
ball stud split ring seat at this time.
Refer to Ball Stud Preload Correction on page 2F-5 and
change steps 2, 3, 9, 10, Il, and 12 to read: h Tighten replacement lower ball stud jamnut to 80
foot-pounds 108 Nem torque.
2 Loosen lower ball stud jamnut.
i Remove upper ball stud slotted nut and install
3 Remove cotter pin and slotted nut from upper ball replacement split ring seat using tool J-25 158. Tighten
stud. seat to 50 foot-pounds 68 Nem torque. Install and
tighten upper ball stud slotted nut to 100 foot-pounds
9 Install and tighten upper ball stud slotted nut to 10- 136 Hem torque. Align and install cotter pin without
20 foot-pounds 13-27 N* m torque to draw lower ball loosening slotted nut.
stud into tapered hole in axle yoke. Do not install upper
ball stud split ring seat at this time. j Loosely install axle shafts and steering spindles and
measure turning effort of each steering knuckle. Refer to
10 Tighten replacement lower ball stud jamnut to 80 Ball Stud Preload Measurement in Chapter 2F - Axles,
foot-pounds 108 Nem torque. page 2-F4. If turning effort is less than 10 foot-pounds
14 N.m torque, proceed to next substep. If turning ef
11 Remove upper ball stud slotted nut and install fort is more than 10 foot-pounds l4Nemtorque, replace
replacement split ring seat using tool J-25l58. Tighten upper and lower ball studs and repeat Ball Stud Preload
seat to 50 foot-pounds 68 N*m torque. Correction procedure in Chapter 2F - Axles.
12 Install slotted nut on upper ball stud. Tighten nut to k Install axle shafts and repeat procedure outlined in
100 foot-pounds 136 N.m torque. Align and install step 7.
cotter pin without loosening slotted nut.
1 Install wheels and lower vehicle.
Refer to the Torque Specifications Chart on page 2F-12
in the 1978 manual and on page 2M-6 in the 1979 manual. The current operations and standard work times are not
Change the lower ball stud jamnut set-to torque to 80 affected by this bulletin.
foot-pounds 108 N.m torque. The upper ball stud
retaining nut remains at 100 foot-pounds 136 N.m.
9412-SQl

Service EngIneerIng Department * 14250 Plymouth Road * Detroit, Michigan
48232
Additional copies of this bulletin are available through your zone off/ce.
78-49
Subject: Driveline Noise or Vibration Application: 1978 Jeep CJ Models File: CHASSIS
Equipped With Warn Selective Drive Axles Propeller Shaft
-
Hubs M-245 SE2063019 and M

243 SE2063021
No.8-02 November 17I978
Some 1978 Jeep CJ vehicles equipped with Warn

selective drive front wheel hub models M-243 or M-245 BUILD DATE CODE
may develop a condition which produces noise or slight
vibration after being driven over a bump. This condition
may be caused by rust forming on the internal clutch
assembly due to a slightly oversize sealing surface in the
cap which prevents complete sealing of the selective
control dial 0-ring. The rust that may form on the
internal clutch assembly of the selective drive hub does
not affect the operation of the front axle assembly or
steering. However, the rust may make the selective
control dial hard to turn.
Service correction will involve an inspection and possible

replacement of the drive hubs. Hub Build Date Code Location
Remove the hub covers and check the hub build date
code. The code is stamped on the hub seal recess see
illustration and consists of two letters and a number. Hub Build Date Code Chart
Refer to the Hub Build Date Chart for decoding
procedure. First Letter Second Letter Number
If the hubs were built prior to date code FF8 and hub A through L A through U 0 through 9
internal parts are rusty, replace the hubs as a set. If the represent represent represent
hubs were built on àr after date code FF8 and do not Jan. through Working Day of Year
exhibit signs of rust, reinstallthe hub covers; referto Dec. Month 8 1978
Driveline Vibration, Page 2E-3, Volume 2 of the 1978 F = June F = 6th Working
Jeep Technical Service Manual. Day
NOTE: Do not attempt to clean and lubricate rusty

hubs; replace the hubs as a set only.

RATICN SKILL
NUMBER LEVEL
CODE 77 78
HUB, MANUAL LOCKING - INSPECT .... 35.611 15615 CJ - 0.1 - C
HUB, MANUAL LOCKING - REPLACE .. 35.611 15594 - 0.2 - C
Selective drive
8-102-09J

Service Engineering Department e 14250 Plymouth Road e Detroit, MIchigan 48232
78-50
Subject: Lubrication - Double Cardan Application: All 1976-1978 Models File: CHASSIS
Universal Joint Except CJ Models With Manual Axles Propeller Shafts
-
Transmission Group 9.000
No. 8-01 April 10,1978
This bulletin is being released to emphasize the PROCEDURE

importance of properly lubricating the front propeller
shaft double cardan universal joint. Failure to lubricate I Raise vehicle and support so that front wheels are
this universal joint at the intervals outlined in the free to turn.
Mechanical Maintenance Schedule may result in
accelerated wear. Lubrication of the double cardan 2 Mark propeller shaft yoke and transfer case output
universal joint on Wagoneer, Cherokee, and Truck shaft yoke for assembly alignment reference.
models should occur every 15,000 miles under normal
service and 5,000 mites or 5 months under heavy duty 3 Disconnect front propeller shaft at transfer case.
service. On 0-7 models, lubrication should occur every
5,000 miles under normal service and every 3,000 miles or 4 Push on propeller shaft until slip yoke at axle end of
3 months under heavy duty service. shaft is fully collapsed.
The double cardan universal joint is located at the 5 Rotate propeller shaft and flex universaljoints until
transfer case end of the front propeller shaft. The lubrication fitting for front universal joint spider is
construction which allows the double cardan joint to accessible.
operate smoothly also makes proper lubrication of its
components very important. The lubrication fittings are 6 Lubricate spider until grease just begins to appear
located in the spiders of the universal joints and in the ball around bearing cap seals.
socket yoke see figure I.
7 Repeat steps 5 and 6 for rear universal joint
It will be necessary to obtain an Alemite lubrication spider.
adapter, model number 6783, or equivalent to perform
the following procedure. 8 Rotate propeller shaft and flex universal joints until
lubrication fitting for ball socket is accessible.
9 Lubricate ball socket until grease appears at vent

hole located on rear of ball socket yoke.
10 Position propeller shaft and connect to transfer

case.
11 Remove grease squeezed out of slip yoke vent hole

at axle end of propeller shaft.
12 Lubricate propeller shaft slip yoke until grease

appears at vent hole.
13 Lower vehicle.
The Standard Servicing Operations and work times as

Fig. 1 Double Cardan Universal Joint this bulletin.
8-033-09J

Additional copies 0/this bulletin are available through your zone office.
78-5 1
Subject: Brakedrum and Rotor Repair vs Application: All 1976-79 Jeep Vehicles File: CHASSIS
Group 8.000
It is not necessary to replace drums or rotors if the 8 Install bearings and seal in rotor.
dimensional specifications. Instead of replacement, re 9 Install rotor on steering spindle and check runout
to ensure proper brake operation. correct service pro a Mount dial indicator on support stand or steer
cedures are vcry important. The specifications and pro ing spindle.
of rotor lining contact area and zero indicator.
d Refinish rotor if runout exceeds stated limit.
1 Raise and support front of vehicle Replace rotor if runout is so severe that machining
would cause rotor to fall below minimum replace
cat ions.
3 Remove caliper do not disconncct brakeline. e If runout is within limits, proceed to step 2.
4 Inspect rotor braking surfaces. If surfaces are only

NOTE: Exce.csit’e lateral i-unoul will c-,use rotor
lightly rusted or scored, proceed to step 5- If surfaces wobble resulting in chatter. vibration, and pedal pulsa
are severely scored, cracked, chipped. excessively
tb,?.
5 II rotor surfaces are only lightly scaled, rusted or a Measure variaUon using micrometer or two
Clean rotor huh bearing surfaces and mount rotor in Ib Take readings at four or more equally spaced
tions.
7 Check rotor thickness at center of lining contact dl Refinish rotor if thickness variation exceeds
refinishing if necessary If rotor is within limits, pro below minimum thickness specification -
ness specification or refinishing would leave it below NOTE: Excessive thickness i’ai-ialion will cause pedal
minimum thickness specification, replace rotor. pulsation and vibration when the brakes are applied.
OVER

ServIce EngIneering Department e 14250 Plymouth Rood e Detroit, MIchIgan 48232
Additional copies 0/this bulletin are available through yout zone otlice.
78-52
Rotor RefinishIng 1978 Models

equipment that will machine both of the rotor surfaces Cl 11.7 in. 29.7 cm
duce a tapered rotor. The correct surface finish is 15 Cke, Wag. J-10 Trk 12.0 in. 30.48 cm
to 80 microinches for CJ models; 20 to 60 microinches
for Cherokee, Wagoneer, and Truck models and must J-20 Trk 12.5 in. 31.75 cm
NOTE: i/a rotor is glazed or highly polished, sanding
the rotor may not produce the required rn/or finish. Rotor Lateral Runout All 0.005 in. 0.12 mm
it may be necessary to turn the rotor to meet the
finish requirements. Rotor Minimum Replacement Thickness:
Cl 1.120 in. 28.45 mm
manufacturer’s recommendations for feed and speed Cke. Wag. Trk 1.215 in. 30.86 mm
before machining rotor. Rotor Thickness Variation All. 0.001 in. 0.02 mm
1 Remove rotor from steering spindle. 1977 Models
2 Remove bearings and seal from rotqr and clean Rotor Diameter:
bearing surfaces in rotor hub thoroughly. Cl 13.7 in. 29.7 cm
3 Mount rotor in lathe according to manufacturer’s Cke, Wag, J-lO Trk 12.0 in. 30.48 cm
J-20 Trk 12.5 in. 31.75 cm
Rotor Huh Bore Runout All. .0.010 in. 0.254 mm
manufacturer’s instructions only. Make two cuts if re- Rotor Lateral Runout All 0.003 in. 0.076 mm
CAUTION: Do not attempt to refinish rotor if ma-
chin ing would cause the part to fall below the minimum Rotor Thickness Variation All. 0.0005 in. 0.013 mm
NOTE: if one disc brake assembly requires a new set Rotor Diameter:
of shoes, the shoes on the other assembly must be Cke. Wag. 1-10 Trk 12.0 in. 30.48 cm
rep/aced to ensure even braking.
Rotor Hub Bore Runout All. - .0.010 in. 0.254 cm

All 1.125 in. 28.5 mm
Rotor Diameter:
Ci 11.7 in. 29.7 cm Rotor Thickness Variation All 0.0005 in.O.O13 mm
Cke. Wag. 1-10 Trk 12.0 in. 30.48 cm

BRAKEDRUM SERVICE
J-20 Trk 12.5 in. 31.75 cm
Inspection and Measurement
Rotor Huh to Bore Runout All. 0.010 in. 0.254 mm
lb Raise and support vehicle.
Rotor Lateral Runout All. . . .0.005 in. 0.12 mm
2 Remove wheels.
Cke, Wag, Trk 1.215 in. 30.86 mm 4 Clean drums using soap, and water solution. If
76-53
5 Inspect drums for cracks, severe scoring. distor- BRAKEDRUM SPECIFICATIONS
tiw. or hard spots a series of shiny or dark colored
these conditions. If drums appear in good condition, 1979 Models
proceed to next step.
Maximum Drum Diameter:
6 Refer to Brakedrum Specifications then measure CJ 10.060 in. 25.5 cm
refinishing would not create an oversize condition, pro- Cke. Wag. Trk 11.060 in. 28.09 cm
needs refinishing hut would exceed allowable size limits 1-20 Trk 12.060 in. 30.6 cm
alter machining, replace drum.
Maximum Drum Radial Runout. 0.005 in. 0.12mm
7 Mount drum in lathe according to lathe manu
facturer’s instructions.
1978 Models
Ci 10.060 in. 25.5 cm
Ia Rotate drum 3W degrees and observe readings. Cke. Wag, Trk 11.060 in. 28.09 cm
th Move indicator stylus until readings have been
taken across entire contact surface of drum. 1-20 12.060 in. 30.6cm
Ic Drum runout must not exceed 0.005 inch 0.12
mm total indicator reading at any point. Also note if Maximum Drum Radial Runout. 0.005 in. 0.12 mm
cate tapered or bell-mouthed drum. 1977 Models
10 II drum is within limits and does not need refin- Maximum Drum Diameter:
ishing. install drum. If drum is not within limits or is CJ 10.060 in. 25.5 cm
finishing. Cke. Wag. Trk 31.060 in. 28.09 cm
Brakedrum Refinishing J-20 Trk 12.060 in. 30.6 cm
I Sharpen or replace cutting tool hit if necessary. Maximum Drum Radial Runout. 0.X7 in. 0.18 mm
2 Install anti-chatter hand on drum.

1976 Models
recommendations br feed and speed. Do not remove Maximum Drum Diameter:
more than 0.010 inch 0.25mm of stock during any cut. Ci 10.0W in. 25.5 cm
4 Check drum radial runout again after completing Cke. Wag, Trk I 1.060 in. 28.09 cm
J-20 12.060 in. 30.6cm
NOTE Whet, brake shoes IIe replaced on one Li-heel.
thei’ must also he replaced on the opposite wheel. Maximum Drum Radial Runout. 01K? in. 0.18 mm
78-54
___________________________________________________
WARRANTy YEAR ANO TIME
OPERATION DESCRIPTION REPORTING OPERATION - - - SKILL
CODE NUMBER MODEL 76 77 78 79 LEVEL
SHOESET,FRONTIDISCRRAKE-REpLACE 8.152 8060 0.5 0.5 0.5 0.5 G
Disc Assembly-Clean A 0.1 0.1 0.1 0.1 G
DIsc Assembly-Resurface One 8.163 B 0.5 0.5 0.5 0.5 P
Both 8.163 1.0 1,0 1.0 i.o p

Includes clean, inspect and repack wheel bearings.
NOTE: Refer to the appropriate combinations

listed for operation Brake Shoes. Four Wheels -
BRAKE SHOES, TWO WHEELS IREAR-

REPLACE 8.202 8020 0.8 0.8 1.8 1.8 6
Brake Drum-Reface Both 8.222 A 0.3 0.3 1.3 0.3 p

Rear Axle 9.073 B 0.4 0.4 0.4 0.4 G
Material allowance for hearing lubricant is 50.30.
NOTE: Re/er to the appropriate combinations

listed for Operation Brake Shoes, Four Wheels-
Rep/ace 800018050 as they apply.

WHEELS FRONT-REPLACE 8.102 8110 83-93 0.7 0.7 6
Front Wheel Bearings- Repack 8.909 A 0.4 0,4 G

Remove, wash, inspect. repack. install new seats
and adjust.
Drum-Reface-Both 8.127 B 0.3 0.3 - - P

t036.OIA/J
78-55
Replacement Vehicles Equipped with Power Steering Steering and Suspension
1977 Group 10.000
Revised
No.9-01 January 16, 1979
step D under "1977 Jeep Technical Service Manual" "ASSEMBLY -STEERING GEAR HOUSING
and step E under "1979 Jeep Technical Service COMPONENTS," step 12 should be changed to read:
Manual." Please remove and discard DRB No. 9-01, Install end plug in rack piston. Tighten end plug to 75
November 20. 1978.
The Warranty Administration Manual states that partial "WORMSHAFT BEARING PRELOAD." step 3
or complete overhaul of an assembly shall take
precedence over replacement of that assembly; except should be changed to read: Measure counterclockwise
when the sum total of replacement parts and labor costs one-half inch 13mm from first index mark and remark
at RFC values to repair the assembly would amount to housing. Refer to Figure I below.
80 percent or more of the sum total parts and labor costs
at RFC values to replace the assembly. D. On page 11-58 under the subtitle
‘PITMAN SHAFT OVERCENTER DRAG
The appropriate Jeep Technical Service Manuals state TORQUE," step I should be changed to read: Loosen
that adjustment of the steering gear must be done with the locknut, turn pitman shaft adjuster screw counterclock
wise until fully extended, then turn it back clockwise
gear assembly removed from the vehicle.
one full turn. Step 7 should be changed to read: Tighten
On the other hand, the Standard Servicing Operations
Manual 550 has an operation and time for steering 27 N*m torque after adjusting overcenter drag torque.
the vehicle.

are necessary. Also, note the changes in the Standard

MANUAL
A. On page 11-47 of the SERVICE Fig. 1 Indexing Gear Housing
tONDITION" and after subtitle "POOR RETURN
OF STEERING WHEEL TO CENTER,"add step II. II. 1978 JEEP TECHNICAL SERVICE
MANUAL
PossIble Cause Correction A. On page 2L-8 of the SERVICE
II Kink in Return Hose 11 Replace Return Hose "CONDITION," add step II to subtitle "POOR

S.rvlc. Englnnrlng D.partmmnt * U2$O Plymouth Road * DetroIt, Michigan 48232
78-56
Possible Cause Correction C. On page 2L-32 und&tIié
"STEERING GEAR ASSEMBLY AND
II Kink in Return Hose II Replace Return Hose ADJUSTMENT," step 19 should be changed to
read: Install end plug in rack piston. Tighten end plug
B. On page 2L-12, fig. 2L-7, View A, the to 75 foot-pounds 102 N. m torque.
shown in fig. 2. D. On page 2L-34 under the subtitle "WORM
BEARING PRELOAD," step 3 should be changed to
C. On page 2L-32under subtitle "STEERING read: Measure counterclockwise one-half inch 13mm
GEAR ASSEMBLY AND ADJUSTMENT," step 19 from first index mark and remark housing. Refer to
should be changed to read: Install end plug in rack Figure I.
piston. Tighten end plug to 75 foot-pounds 102 N* m
torque. E. On page 2L-35 under the subtitle
D. On page 2L-34 under the subtitle "WORM
TORQUE," step I should be changed to read: Loosen
BEARING PRELOAD," step 3 should be changed to locknut, turn pitman shaft adjuster screw counterclock
read: Measure counterclockwise one-half inch 13mm wise until fully extended, then turn it back clockwise
from first index mark and remark housing. Refer to
one full turn. Step 7 should be changed to read: Tighten
fig. I. pitman shaft adjusting screw locknut to 20 foot-pounds
SHAFT OVERCENTER DRAG TORQUE," step I
one should be changed to read: Loosen locknut, turn IV. STANDARD SERVICING OPERATIONS
7 should be changed to read: Tighten pitman shaft In the October 9, 1978, printing at the bottom of
adjusting screw locknut to 20 foot-pounds 27 N*m page 2-08-5 is the operation description GEAR, POWER
torque after adjusting overcenter drag torque fig. 2H- STEERING ADJUSTON-VEHICLE with operation
-
115. number I0290. DO NOT USE THIS OPERATION

NUMBER.
III. 1979 JEEP TECHNICAL SERVICE
MANUAL
TION," add step Ii to subtitle "POOR RETURN OF
STEERING WHEEL TO CENTER." Stepl I will read
as follows:
B. On page 2L-12, figure 2L-7, View A, the
shown in fig. 2.
Seat ball in housing with blunt-nosed punch. Spray ball

compressed air. Cover ball with Loctite adhesive 290. Let /
View A
WARRANTY YEA RAND TI ME
OPERATION - SKILL
NUMBER LEVEL
78
CODE
._LL. 79
GEAR ASSEMBLY. POWER STEERING -
R& R 10.500 10310 WAG-CKE-TRK 0.6 0.6 0.6 G

83-93 0.8 0.8 0.8
With snow plow -Add 0.1 0.1 0.1
Gear assembly -Adjust 10.959 A 0.2 0,2 0.2 G
Gear assembly -Replace 10.501 B 0.1 0.1 0.1 G
Gear assembly -Overhaul 10302 C 1.2 1.2 1.2 G
Adjuster Plug -Replace 10.555 D 0.3 0.3 0.3 G
- 10.615 E 0.5 0.5 0.5 C
NOTE: Combinations D and £ include adjust
operation.
9.008-lOA/JC
78-57
Subject: Rivnut Replacement Application: 1977-1978 CJ Models File: CHASSIS
Equipped With Front S tabilizer Bar Steering and Suspension
Group 10.000
No. 8-03 September 6.1978
A procedure has been developed to replace loose or

damaged Rivnuts used on 1977-1978 CJ Models
equipped with a front stabilizer bar.
Service correction involves removing the Rivnut and

installing a 3/8" x 1-I / 2" SAE grade 8 bolt and hardened
nut.
The following parts are available through local jobbers.

The quantities listed are required for each Rivnut
replaced.
3/8"x l-I/2’"
SAE Grade 8
Bolt
3/8"x I’O.D. Fig. 1

flat Washer 2
4 Attach a 3/8" x 1-1/2" SAE grade 8 bolt with a
3/8" Lock 3/8" x I" 0. D. flat washer to wire and pull shank of bolt
Washer I through hole see Fig. 2.
3/8" Hardened NOTE: Leave the wire attached to the bolt shank to help
Nut I pull the bolt through the front stabilizer bar support
bracket during installation.
PROCEDURE BRAKE LINEJ
I Remove front stabilizer bar support bracket bolts
ITOPOF FRAMEI
and pull stabilizer bar and bracket away from frame see
Fig. I. FRONT STABILIZER
BAR SUPPORT BRACKET
2 Using a cold chisel and hammer, remove head of SPACER BOLT HOLE
damaged Rivnut by chiseling horizontally along bottom
of frame rail.
NOTE: When replacing the Rivnut closest to thefront of

the vehicle, partially remove the front stabilizer bar
support bracket spacer by tapping is with apunch toward
the center of she vehicle see Fig. I.
3 Run mechanics wire up through hole where Rivnut

was located and out through elliptical hole located on top
I MECHANICS I
of frame approximately V rearward of Rivnut hole see
Fig. 2.
I WIRE I
* FRONT OF
VEHICLE Fig. 2
Stryic. Enginnrlng D.partm.nt . 14250 Plymouth Rood * D.troIt Michigan 48232
Actd,t,onal copies ot this bulletin are available through your zone
ottice.
7LM
5 Place a 3/ 8 x 1" 0. I. flat washer in spot faced area / 7
of stabilizer bar support bolt hole in bracket and slide
support bracket over exposed threaded area of bolt. Use
wire which was attached to shank of bolt to help pull bolt
through stabilizer support bracket. Install a 3/8" lock
washer and hardened nut see Fig. 3.
6 Tighten nut to 30 ft. / lbs. 41 Newton-meters torque.
NOTE: If the bolt turns during tightening use a 1/2"
crowfoot adapter on the torque wrench and hold the
shank of bolt with a small pair of locking pliers.
Fig. 3
OPERATION DESCRIPTION REPORTING OPERATION - - SKILL
CODE NUMBER MODEL 77 78 LEVEL
RIVNUT,STABILIZERBAR 10.260 10189 83-93 G

One or Two -- Replace 0.5 0.5
Three Add 0.1 0.1
All - Add o.i 0.1
S-103-IOi
78-59
Subject: Sport Steering Wheel Skirt Application: 1977-1978 Jeep Vehicles File: CHASSIS
Replacement Equipped With Sport Steering Wheel Steering, Suspension
No. 8-02 July 10, 1978
A replacement procedure has been developed for the 6 Color coat replacement skirt following procedures
sport steering wheel skirt used on 1977-1978 vehicles outlined in 1978 Jeep Technical Service Manual. Metal
equipped with the sport steering wheel option. Repair and Painting, Page 38-3, Volume 3.
The sport steering wheel skirt is available through the 7 Install new skirt with three retaining screws that
current Parts Catalog under Group No. 10.283-I and can hold center horn button receiver insulator.
be installed as follows:
8 Align steering shaft and steering wheel marks, and
install wheel on shaft.
PROCEDURE
9 Install plate, horn button receiver and bushing with
three screws.
NOTE: The horn button receiver cup has a notch cut in it
2 Remove center horn button by lifting it up and which must be indexed to the 12 o’clock position when
pulling it out. installing.
3 Remove steering wheel nut and washer. 10 Install washer and nut and tighten nut to 25 foot
pounds 34 N/M torque.
NOTE: Check for alignment marks on steering shaft and
steering wheeL Paint alignment marks on shaft and wheel CAUTION: if for any reason a new steering shaft nut
none are present. must be used, inspect and identfi’ the shaft nut thread
trpe before installing the replacement nut. Metric shafts
4 Remove three horn button receiver retaining have an identfving groove in the shaft steering wheel
screws, remove receiver and plate. Use steering wheel splines and Metric nuts are color-coded blue for
puller J-2l232 to remove steering wheel. identification.
CAUTION: Do not hammer on the end of the shaft. II Install center-type horn button by indexing
Hammering could shear or loosen the plastic retainers projection on rubber retaining ring with notch in cup and
which maintain rigidity of the energ p-absorbing feature pushing cup down to engage ring.
of the column.
5 Remove steering wheel skirt by removing three
retaining screws that hold center horn button receiver 13 Reset clock if equipped.
insulator.

OPERATION SKILL
OPERAtION DESCRIPTION REPORTING MODR -
NUMBER LEV[1
CODE 77 78
SKIRT, STEERING WHEEL, SPORT -
REPLACE 10.280 10251 0.3 0.3 M

Service Engineering Department * 14250 Plymouth Rood * Detroit, Michigan 48232
Additional copies of this bulletin are available through your zone ottice.
75%-Rn
VU Jeep
flDate: May 4, 1978
Application: 1978 Cl-S and
CJ.7 Models With Manual
Steering as specified below
File: CHASSIS Steering and
Suspension
This is a Type S Campaign, subject to all campaign small number of vehicles will require parts replace
procedures and involving safety-related elements. A ment. Each vehicle is to be inspected first before
copy of the combined owner notification and correc ordering the campaign parts kit. Under no circum
tion reporting card for this campaign is shown in stances is a replacement kit to be ordered for dealer
Figure & stock!
Some vehicles built between VINs JSXXXXXO3O289 Parts will be available on May 15, 1978.
and J8XXXXXO642O3 may have the steering gear
intermediate shaft coupling machined oversize in the
serration area where it attaches to the steering gear INSPECTION PROCEDURE
cross shaft. This may have prevented the coupling
from properly tightening on the shaft when the 1 Torque intermediate shaft coupling housing clamp
steering gear clamp and bolt were installed. The cou bolt to 55 foot pounds 74 newton meters I see fig
pling may then slip on the steering gear cross shaft ure 1.
when the steering wheel is turned. If coupling slip
page occurs, a raspy noise will be heard in the steering 2 Inspect intermediate shaft coupling by passing a
accompanied by approximately forty degrees of free 3/64" drill approximately .050" diameter wire
play movement in the steering wheel. Should vehicle through entire length of slot see figure 1. If drill or
operation be continued, the steering gear clamping wire will not pass freely through slot, replace inter
bolt may by-pass the notch in the steering gear cross mediate shaft coupling as described below under Re
shaft and result in a loss of steering. placement Procedure.
The steering intermediate shaft coupling on all in 3 If intermediate shaft coupling passes inspection
volved vehicles will be inspected and replaced if apply a daub of white paint on top of steering box,
machined oversize. If replacement is necessary, the in a highly visible area, and return vehicle to owner.
following part will be available and required:
REPLACEMENT PROCEDURE
Part Dealer
Description Qty. Number Group Net 1 Mark position of intermediate shaft to steering
column for assembly reference.
Kit, Coupling 1 8129S11 10.740 S.agea.
2 Remove intermediate shaft to steering column
The Zone will provide a YIN list for each dealer with clamp bolt and nut see Figure 2.
any vehicles involved. However, the campaign proce
dures apply to all dealers. On all undelivered, SI Remove coupling to steering gear clamp bolt and
campaign-involved vehicles, the inspection/correc nut.
tion must be made before the vehicle is sold or other
wise put into Service. 4 Remove intermediate shaft and coupling assembly.
The Zone will not make an initial shipment of parts 5 Wrap intermediate shaft with shop towel and
to dealers for this Product Recall Campaign. Only a place in vise or suitable holding fixture.

Service Engineerinv Department * 14250 PlymouTh Hoed * Detroit, NictOgan 4&232
-‘on,
..,_MUST
THROUGH SLOT WI NTUMeD.ATr SHAFT
COUPUNG HOUSING AFTER THC CLAMPI
NUT HAS UEN TOIQUED TO 33 FT. tB
OR 74 NM
FIgure 1
Figure 2
46 Remove coupling seal retainer ring and pull rubber 11 Install rubber seal and install seal retainer ring.
seal back.
12 Remove intermediate shaft assembly from vise.
7 Remove coupling housing from intermediate shaft.
13 Slide intermediate shaft to steering column re
NOTE: Be careful at this point not to lose the coupling taming clamp over intennediate shaft U-joint clamp
bearings or tension spring when removing coupling ing area.
housing from intermediate shaft.
14 Slide intermediate shaft to steering gear retaining
clamp onto coupling housing.
8 Remove rubber seal.
15 Install intermediate shaft coupling and U-joint
9 Lubricate bearing surfaces of new coupling hous onto mating shafts at steering gear and steering
ing with grease supplied with the parts kit. column with reference marks aligned.
10 Compress coupling bearings against tension 16 Install coupling clamp bolt and nut and torque
springs and slide coupling housing on over bearings. to 55 foot pounds 74 Newton meters.
78-62
______________________
17 Install intermediate shaft to steering column 18 Place a daub of yellow paint on steering box to
clamp bolt and nut and torque to 55 foot pounds 74 indicate campaign compliance and return vehicle to
Newton meters. owner.
WARRANTY
OPERATION REPORTING OPERATION YEAR & TIME SKILL
DESCRIPTION CODE NUMBER MODE 77 78 79 LEVL
COUPLING, INTERMEDIATE SHAFT

FLEXIBLE - Inspect
CJPOT Campaign 10.31 I 10.223 83-93 -a .1 -a C
Coupling-Replace 10.312 A 83-93 - .2 - C
Applicable Detect Code: 56-
CLAIM HANDLING
Several vehicles may be listed on a single warranty Complete and mail the reporting half of the notifica
claim form, Reference Warranty Administration Man- tion card figure 3 for each vehicle as soon as cain
ual, Section 7, Product Recall Campaign. paign service is complete.
The steering shaft coupling that is removed and re- CAUTION: On multiple-vehicle claims, do not delay
placed is a returnable part and must be tagged and any claim so that we will receive it beyond the time
returned with your regular claim material shipment. outlined in the WAM.
8-055-1OJ
National Traffic and Motor Vehicle Safety Act of 1966

Intnictiona: OWNER Iflatnictions: DEALER
If you do not now awn this vehicle, please just fill in This section is for the dealer to use when your
below eIther a, b arc and MAIL DIRECTLY TO vehicle goes in for the required attention.
JEEP CORPORATION.
Correction made
*
SiaanReeMPaist Carrection not required
Add,wa Dear Code
b. Present owner neme end addeesa not known CJPOT CAMPAIGN 782
c, Removed Iron ee,vlce because of colhaori

damage or oth.ew,se 0 biiiVi1l,cte Se-wred
VIM Veeaele ldaesleai.ee Na-teal

hap Corporate,.
Campaign Data Reporting Seetion
‘ Notice of Product Recall Campaign Involving Your Vehicle

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J.a Ceaaai , ss.,j Ibis * g.e.,. shas ,el.Ss I. e.a ..baee ,S..y asae. S a lfl CJ.& a.d CIT ‘aIds., aqSppS eltb
-.aaae aSa-1.
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b-Ia. ,aaaaeb aleba,ead a_she .nag s bata. Tb-a s.ald as_a ISa asae.aae wasp a. ebe as-It. sa. "seat’, aaaa play b-eS. aaaaa
Se .55.a. aaavlaaes w’,paad b5 Inapy I,at Pats_I. bead a awalaps saald .ee Ia - tail - S aa.aal,. -- e btb.aIaat
ass..iae awdtsla-a as e sabkfr anab ,atd paaaa
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.py -a- S ha- - - aai.aua sya.a-. Ia__s apa.asa ya ,tb-’e. a-Ill It bia bat. aapal,aat.
Yea, ‘slid., ida-ems she ...nae Sd l ash. ,ead. abaald ha Iaapaaa..d by a... Isepd.e. It aey, -
saepS.q eelb. ,apS.s at
I*aeaa a. -. Jeep C.apaa.dea ,eea-aaaad. y_ La-a yaay dab-a aaa La, a- a,.Mflaaaae La Inaet yaw Sia- nsa, Tb. Iaaeias
.-.a amaaaa - -e Wa -la-wall aa,awaiae a ,aa, yaar 1a.M. ala aate aba .eplwaa,ne -
taa.tb.ea day dalowyl as. -
s.,e - waia, a. addiIIa.I a_Ia_a issatha
yaw daata. ab.ald S. a..5I, I, basIl. aSia ‘.pws wa’t peaatb SI, ROy SLIme. pIaa.e ‘ .,,iM.h,eI ia-a IJthae ‘talL yaap
&_ii Ma--all a, hap Ca,laeal.ae. Ow. Ralatla.,. lena P&aaeeh III., Oweat, Mb-bias. dalfllSbpba. 117’lflflhII. Ilysa a e.abt
I. abtIa Ib.s’asn.iae aae,I elahial tha,.. - -labIa at day. atIa.yae Iaa at Lb-a.M.a. IayeeaI..ba -y LaIeIIs-elee May 15.1174
ysaln waaas lb. Alt-a-s-a’s., Natjaaaa lab-b’,, Ta.IPI. 5,hts . Wliaetw. o.c sates.
Wbcn your vehicle goes in for the required attention: Picas. be awe this mpIete notification card goeawtth
is beaus. the card is to be ,aed by the dear for reporting pulpo In case you do not now own thia vehicle,
pleas. send us the ‘Change of Ownership" infonnation using side 2 of this d
Map Corporation
Caeapaigm On RepwIinp Sunlit
Fig. 3 Owner NotitlCation and Correction Reporting Card

78-63
Subject: Wagoneer LiSted, Front Fender Applicatlont 1978-7 9 Wagoneer Models File: BODY
WoodgraIn MouldIng RetentIon with Limited Trim Option Body General
No. 9-05 February 2 1979
A procedure has been developed for repairing loose vinyl MOULDING

woodgrain moulding on the front upper corner of the POP RIVET
front fender on Wagoneer Limited models. FENDER -
PLUG
The service correction involves drilling and counter-
boring a hole in the moulding, installing a pop rivet, and
inserting a color-coordinated vinyl plug to fill the re
maining recessa 0.250-INCH DIA.
The following parts are required and will be available

February 2, 1979 Do not order parts before this date
/
0,156-INCH
DEPTH
Description Quantity Part No. Group No
RIVET, Pop 2 4004962 12.078
PLUG, Moulding 2 5750596 12.078
PROCEDURE
1 Measure up from bottom edge of miter joint 1-3/4
inches along center of miter joint and make a mark at
this point see illustration.
2 Push moulding flush against fender and drill 0.125-

inch hole through moulding and lender at mark.
Wagoneer Limited
CAUTION: Care should be taken to prevent the dr//l
chuck from con tatting the moulding when drilling Moulding Retention
through the fender.
5 Apply adhesive to moulding plug, align woodgrain
3 Counterbore a 0a250-inch diameter hole to a depth
of 0.156 inches at original 0.125-inch diameter hole see pattern and install plug in counterbore see illustration.
illustration.
NOTE: Before app/ring adhesive to the plug it mar be
4 Push moulding flush against the fender and install neee.csari’ w trim he plug to fit /7ush with the moulding
pop rivet through lender and moulding. surface.

OPERATION SKILL
CODE
NUMBER 77 78 I LEVEL
MOULDING, WOODGRAIN - REPAIR 26.030 26009 WAG G

Both sides Laaa.a..laLasa.e.Ilsiaae..aa 0-2 01
9-031-RSJ
S.rvlc. Englnnrlng D.portm.nt . 14250 Plymouth Road * D.trolt, Michigan 48232
78-64
Subject: Windshield Cracking During Extreme Application: 1978-79 CJ Models Built File: BODY
Cold Weather Prior to J9XXXXHO35319 Toledo Body General
and J9XXXXH8O4OIS Brampton
No. 9-03 December 8, 1978
Some subject vehicles may exhibit windshield stress PROCEDURE

cracks in extremely cold weather. When this condition
occurs, the crack originates at the bottom of the
windshield at or above the defroster opening. I Using windshield removal and installation
procedures as outlined in appropriate Jeep Technical
Service correction involves replacing the windshield as Service Manual, remove defroster air deflectors.
outlined in the appropriate Jeep Technical Service
Manual and installing new defroster air deflectors. 2 After rearview mirror has been installed on
replacement glass bracket, install new deflectors on
The following parts are available and required: windshield frame:
Description Quantity Part No. Group 3 Complete windshield installation procedure as
DEFLECTOR, Windshield outlined in Technical Service Manual.
Defroster Air, LI-I 1 5750339 25.004
DEFLECTOR, Windshield
Defroster Air, RH I 5750340 25.004

OPERATION DESCRIPTION OPERATION SKILL
REPORTING MODEL
CODE NUMBER LEVEL
77 78 79
GLASS, WINDSHIELD - REPLACE 25.001 25130 83-93 0.8 0.8 G

Includes sealing
Material allowance for sealant is $0.90

Mirror mounting support kit Install
- 25.001 A 0.1 0.1 G
Deflectors, windshield defroster Replace
- 13.115 C 0.1 0.1 G
NOTE: Combination B is not applicable.
8-I IS-BSJ

ServIce EngIneering Deportment * 14250 Plymouth Road * Detroit. Michigan 48232
78-65
Subject: Door Lock and Latch Mechanism Application: All 1978-79 Cherokee, File: BODY
Freeze-Up Wagoneer and Truck Models Body General
No. 9-02 November 10,1978
In an effort to minimize the annual door lock/latch

freeze-up complaints during adverse winter weather, a
service procedure has been developed to help prevent
recurrence.
Service correction involves removing the door trim

panel, blowing any accumulated moisture out of the
affected mechanism, and lubricating the lock or latch
mechanism.
NOTE: If a deicingfluid containing alcohol is used on a LUBRiCATE AT

.‘OINTS INDICATED
lock or latch mechanism, the lock or latch mechanism
muse be lubricated to prevent further freeze-up.
PROCEDURE
I Remove door latch remote control handle and door
window regulator handle.
2 Remove armrest overlay and armrest from door

trim panel.
3 Remove ash receiver screws and ash receiver, if

equipped.
4 Remove lower door trim panel screws and pry door

trim panel nylon spring clips loose with tool J-263 1-01 Door Latch Mechanism
and remove panel. Lubrication Points
5 Cut upper rear portion of water shield dam paper
and fold paper back to gain access to lock and latch 10 Position water shield dam paper and fasten in
mechanisms. place with masking tape. Tape all edges or areas cut or
loosened when removed.
6 Remove moisture from lock assembly by applying
moderate air pressure through face of lock cylinder. 11 Position trim panel on door and install nylon spring
clips in holes of inner door panel.
7 Spray AMC/Jeep Silicone Lubricant 8993542 or
equivalent into keyhole of lock cylinder. 12 Install lower door trim panel screws.
8 Remove moisture from latch mechanism using 13 Install ash receiver and screws, if so equipped.
moderate air pressure to avoid removing lubricant
present on latch mechanism. 14 Install armrest and armrest overlay.
9 Lubricate designated latch areas with AMCJJeep 15 Install door latch remote control handle and door
Lubriplate 8990685 or equivalent see illustration. window regulator handle.
OVER
Service Engineering Deportment e 14250 Plymouth Rood e Detroit. Michlgon 48232
78-66
CODE NUMBER MODEL 77 78 79 LEVEL
LOCK AND LATCH - DOOR - EACH -

LUBRICATE 23185 CKE-WAG-TRK 0.3 0.3 0.3 M
Front 23.050
Rear 23.051
78-6 7
Subject: Wagoneer Limited Trim Package Application: 197$ Wagoneer Models File: BODY
Body General
No. 8-’ May 11, 1978
A new body trim package, the Wagoneer Limited, has 3 To insure proper moulding alignment, stretch a
been introduced on the 1978 Wagoneer models and piece of string at desired level along panel and attach it at
consists of the following items: both ends with tape.
* Bodyside and tailgate woodgrain overlay with new 4 Position moulding on car with backing tape
vinyl surround mouldings attached, and cut to fit.
e "Limited" nameplates 5 Peel backing and press moulding to body of car,

parallel with string.
* New IS" x 7" forged aluminum road wheels
6 Press moulding to body with roller or heavy hand
* HR 78 xl5"Goodyear American Eagle WSW radial pressure.
tires
7 Remove string.
* Bucket seats, center armrest, and door trim panels
upholstered with leather and corduroy fabric. 8 Check moulding alignment and trim moulding with
razor blade, if necessary.
* Deep pile carpeting in both passenger compartment
and cargo area. 9 If moulding comes loose, apply 3M Plastic and
Emblem Adhesive 8061, or equivalent to moulding
* Leather wrapped steering wheel surface and press firmly to body.
* Combination dome and reading lamp Dome/RMding Lamp

* Woodgrain overlay on lower instrument panel
The combination dome/reading lamp replaces the
* Lighted visor/vanity mirror standard dome light. The dome lamp is operated by
either the headlight switch or door switches. Two reading
* Color keyed A/C evaporator housing and duct lamps are built into the housing and illuminate the driver
and passenger seat position. The reading lamps are
A general description and service procedures for new operated individually by a sliding switch located by each
items are as follows: reading lamp.
Body Side and Tailgate Woodgrain Overlay Surround

Mouldings Bulb Replacement
The surround scuff mouldings are made of extruded vinyl

with an adhesive backing. I Squeezedomelamplenstodisengageretainingtabs.
Woodgrain Overlay Surround Moulding Replacement 2 Remove dome lamp lens.
I Use 3M Release Agent 8971 orequivalant to remove 3 To remove bulb pull down and out.
moulding from panel.
4 Insert bulb directly into socket to install.
2 Clean any adhesive residue from surface with a cloth
dampened with 3M General Purpose Adhesive Cleaner 5 Squeeze lens and install in lens opening. Release
8984 or equivalent. lens, be sure retaining tabs are properly engaged.
OVER
Additional copies of this bulletin are available fhrough your zone office.
78.68
Lighted Vanity Mirror 2 Remove lens by pulling down after retaining tabs
have been disengaged.
The color-keyed lighted vanity mirror is attached to the
passenger sun visor. It has two lamp assemblies, one 3 Pull the bulb straight out of socket.
mounted at either end of the vanity mirror. The lamp
switch is located on the right side of the mirror assembly. NOTE: Do not twist the bulb.
Bulb Replacement 4 To install bulb press straight into socket.
I Insert a thin flat tool between lens and housing and 5 Lens is keyed top to bottom. Push lens into proper
pry up. position to install.

OPERATION - SKILL
NUMBER LEVEL
MOULDING WOODGRAIN R & R 26.030 26007 WAG 0.3 G

One 0.2
Each Additional 0.1
Replace one or more 26.030 A
BULB AND/OR LENS, VANITY

MIRROR REPLACE
- 27.091 3474 WAG 0.1 G
BULB, DOME LAMP OR REAR

QUARTER REPLACE
- 3.346 3872 WAG 0.2 C
BULB, READING LAMP - REPLACE 3.346 3352 WAG 0.2 C
LAMP ASSEMBLY, DOME, REAR

QUARTER OR REAR SEAT REPLACE.. - 3.346 3230 WAG 0.2 G
8.061-BSJ
78-69
Subject: Transmission Shift Cover Contacting Application: 1976, 1977, and 1978 File: BODY
Floorpan Cherokee and Truck Models With 4- Body General
Speed Transmission
No. 8-01 December 16,1977
The transmission shift tower may contact the floorpan on 5 Remove a piece of floorpan large enough to provide
the subject vehicles causing a noise similar to gear rattle a one inch I’ clearance between floorpan and tower.
to be transmitted into the passenger compartment. This Cutting operations may be done using an air chisel or by
interference problem will normally occur where the tower drilling a series of closely spaced holes and cutting with a
portion of the shift cover extends through the opening sharp cold chisel Fig. I.
provided in the floorpan for the shift lever.
6 Slide shift lever boot down into position and secure
Service correction involves providing clearance between to floorpan with retainers.
the shift tower and floorpan by removing a piece of the
floorpan at the contact point.
NOTE; Before proceeding with any transmission repairs

involving rattling type noise the vehicles, it is
advised that the vehicle be inspected for the described
interference problem.
PROCEDURE
1 Using large screwdriver, disengage shift lever boot

retainers from floorpan.
2 Slide boot up shift lever.
3 Check tower and floorpan for actual contact or for

signs of contact such as chipped paint or shiny metal.
_.REMOVE MATERIAL AS SHOWN
4 If contact between floorpan and tower is not evident BY SHADED AREA
proceed with diagnostic procedures to isolate cause of
noise. If contact is evident proceed to step 5. Fig. 1

REPORTING OPERATION MODEL SKILL
OPERATION DESCRIPTION NUMBER 76 77 78 LEVEL
COUf
FOUR-SPEED TRANSMISSION TO CKE

FLOORPAN CLEARANCE INSPECT... 20.005 20.125 TRK 0.1 0.1 0.1 C
Cut floorpan to provide clearance.... 20.005 A 0.1 0.1 0.1 C
S-025-BSJ

Service Engineering Department e 14250 Plymouth Road * Detroit, Michigan 48232
Additional copies of this bulletin are available fhrough your zone office.
78-70
Subject: Moisture Entering Parking and Application: 1976-80 CJ Models File: BODY
Body Electrical
No. 80-2 Dec. 7, 1979

Some 1976-80 CM models may have moisture entering MOUNTING
the parking and front directional signal lamp assem


LAMP, Assembly
Parking and Front
HOUSING
BEZEL ASSEMRLY
GASKET, Directional
Lamp Mounting LENS
GASKET
PROCEDURE
a If corrosion is not present, then continue 5 Install assembly with new mounting gasket if
b If corrosion is present, obtain replacement
screws.

CODE NUMBER 76-80 LEVEL

ANDIOR REPOSITION 3.292 3403 CJ 0.1 6
Replace One or both 3.292 A CM 0.1 6
SO-032-BSA

Servic. Engineering Department e 14250 Plymouth Road e Detroit, MichIgan 48232
78-71
Subject: Tailgate Glass Defogger Wire Repair Application: 1977-79 Wagoneer and File: BODY
Cherokee with Tailgate Glass Repair Body Electrical
No.9-01 June 7, 1979

defogger is found to be broken or Chafed adjacent to the

KIT, Rear I 5 Trim insulation from feed or ground wires to

8129876 3.774 expose approximately 1/4 inch of bare wire.
Window
Defogger
wires.
PROCEDURE NOTE: Use 60/40 solder or equivalent such as Eutec Rod
157B for this solder joint.
keeping joint as small as possible. Be sure solderjoint is as
lower channel see fig. I. 8 Slide heat shrinkable tubing over the solderjoints
see fig. 3.
FEED OR
WIRE
WIRE
Fig. 1 Defogger Wire Interference Fig. 3 Tailgate Glass With Defogger Wire In
Position
3 Remove any excess channel sealer that protrudes
from end of channel see fig. 2. 9 Shrink tubing with low heat soldering gun.
OVER
Service Engineering Department e 14250 Plymouth Road e Detroit, MichIgan 48232
Additional copies ot this bulletin are available through your zone otlice.
78-72
10 Secure feed or ground wires with nylon strap to II Install tailgate glass and channel assembly as
inside of square loop located on channel. outlined in appropriate Technical Service Manual.

OPERATION
OPRATION DESCRIPTION REPORTING
NUMBER MODEL - -
L
CODE 77
GLASS, TAILGATE R &R
- 25.127 25150 WAG-CKE 0.4 0.4 0.4 G
Replace 25.127 A 0.1 0.1 0.1 C’.
Wire, flefogger-Repair
Oneside 3.807 K 0.1 0.t 0.1 G
9-G$6-BSJ
7Q-7Q
--. .-
P1J.ep*

Subject: Electric Tailgate Regulator and Application: 1978 Wagoneer and File: BODY
Motor Change Cherokee Models With Electrically Body Electrical
Operated Tailgate Window
No. 8-07 July 28, 1978
There has been a running change in the tailgate window DIAGNOSIS INFORMATION
regulator and motor assemblies on 1978 Wagoneer and
Cherokee models starting with VIN JSXXXXXO88O9O.
The tailgate motor is a two-wire design, using polarity of When diagnosing this system keep in mind the following:
the circuit to change rotation. The motor and drive unit
ase serviced as an assembly. As a result of these changes it NOTE: A wiring schematic of the new electric tailgate
is necessary to update the parts and diagnosis window circuitry is included for use with the following
information, information and procedures.
NEW PARTS I The ignition switch must be in the ON position when

attempting to diagnose electrical problems related to the
instrument panel switch. When checking the tailgate
Quantity Part No. Group switch, turn the tailgate switch with the ignition key to the
Description
UP or DOWN position.
Motor, Tailgate
2 The ground circuit goes to ground through the
Electric Operated
Window Regulator 23.310-I instrument panel control switch.
1 8129549
Regulator, Tailgate 3 The tailgate safety switch must be closed when

attempting to check for current.
Electric Operated
Window Less Spring I 8129550 23.306-I
Diagnosis can be accomplished as follows:
Regulator, Tailgate
Electric Operated Feed Circuit - Instrument Panel Switch
Window With Spring 1 8129551 23.306-1
Harness, Tailgate I Using a 12 volt test lamp ground one end of test
Electric Operated lamp and check for current in red wire running from fuse
Window Regulator 1 5465056 23.320-1 panel to instrument panel tailgate switch.
Switch, Tailgate
2 If no current is present, check circuit breaker and
Electric Operated repair before proceeding.
Window Regulator
On Tailgate 1 5465053 23.330-3 3 With both switches in neutral position, there should
only be current at red wire terminal. If current is
Switch, Tailgate
present at either or both terminals, check for a shorted
Electric Operated
harness or switch,
Window Regulator
On Instrument Panel
W/ Heated Rear Window 1 5465054 23.330-1
3.770 Feed Circuit - Tailgate Switch
Switch, Tailgate
Electric Operated I Check red w/ tr wire for current at tailgate switch. If
Window Regulator no current is found at tailgate switch check for broken or
On Instrument Panel disconnected red w/tr wire.
W/O Heated Rear Window I 5465057 23.330-I2 If tailgate motor is operational from instrument
NOTE: The parts listed above are not interchangeable panel switch and tailgate switch will not work, replace
with the parts used in the earlier design. tailgate switch.
OVER
Service Engineering Deportment . 14250 Plymouth Road * Detroit, MIchigan 48232
WO WA
UP Position 2 With instrument panel or tailgate switch in DOWN
position, test lathp should light, if not replace faulty
I Ground one end of 12 volt test lamp and check for switch.
current in tan wire at tailgate motor.
NOTE: The tailgate safety switch must be in the
2 With instrument panel or tailgate switch in UP CLOSED posilk when checking the DOWN circuit.
position, lamp should light, if not, replace faulty switch.
Motor
NOTE: The tailgate safety switch must be in the
CLOSED position when checking the UP circuit. I Check all circuits as described above.
Down Circuit 2 If all above circuits check good and motor does not
turn, replace motor.
I Ground one end of 12 volt test lamp and check for
current in brown wire at tailgate motor.
The Standard Servicing Operation and work time as published in the current SSO Manual are not affected by this bulletin.
8-082-BSJ
MOrORTG.TI
5!# Fo.tEw,NDOw
-ø
I.______
flows i4J
To.
- -o I TI - I?
Electric Tailgate Window Wiring Schematic

1978 Wagoneer and Cherokee
78-75
Subject: Windshield Wiper Motor Disassembly ApplIcation: 1974,1975,1976,1977, and File: BODY
and Assembly Procedure Supplementary 1978 Jeep Wagoneer, Cherokee, and Body Electrical
Technical Service Manual Information Truck Models Group 3.000
No. 8-06 March 31,1978
This bulletin is being issued to supplement the listed 5 Remove wiper motor-to-dash panel mounting
model-year Technical Service Manual procedures screws and remove motor.
pertaining to windshield wiper motor disassembly and
assembly. The supplementary information includes the 6 Clamp crank arm in vise and loosen crank arm
following: retaining nut, remove nut and arm from motor.
I An additional Troubleshooting in Vehicle diagnosis 7 Remove seal cap, retaining clip, and end plate
procedure for worn-out wiper motor gears. washer.
2 Wiper motor disassembly and assembly which 8 Punch out gear box cover retaining rivets and
includes wiper motor gear replacement. remove cover and gear train.
3 Standard Servicing Operations update. NOTE; Mark ground strap location for reassembly,
9 Repack cover with a waterproof grease, part
DIAGNOSIS PROCEDURE number 8991416 or equivalent.
When the windshield wiper motor gear wear-out is 10 Install gear and pinion over terminal board shaft.
suspected, check under the dash at the motor to insure the
linkage is properly attached. If the linkage is intact, turn II Install gear and shaft in gear train cover.
the ignition to the on position, then turn the wiper motor
12 Install washer and retaining clip.
on and listen for the noise of the motor running. If the
wiper motor runs, but does not move the linkage, gear
13 Install seal cap and crank arm on shaft. Do not
replacement is the recommended repair. If the wiper
secure arm.
motor does not run, refer to the Troubleshooting
Procedures in the appropriate Technical Service Manual. 14 Make sure motor linkage is in Park position. Line
The following parts are listed and available through the crank arm up with the identification marks on cover see
Parts Catalog; however, the current supply of Drive Gear illustration,
Kits is exhausted. Do not order parts until after March
27, 1978.
Description
Drive Gear Kit
Quantity
DISASSEMBLY AND
ASSEMBLY PROCEDURE
Part No.
941916
Group
22.031
a USE THIS SET OF
INDEX M.ARKS TO
LOCATE CRANK ARM
I Disconnect battery ground cable.
2 Manually place the wiper arms in Park position on

windshield.
3 Disconnect wiper drive link from crank under

instrument panel.
4 Disconnect motor wires at motor under hood. OVER CRANK ARM ALIGNMENT

Service Engineering Department e 14250 Plymouth Rood * Detroit, MichIgan 48232
Additional copies 01 this bulletin are available through your zone ott,ce.
78-76
15 Place gear train cover over dowel pins and secure 18 Connect motor wires to motor.
cover. Be sure cover is located properly over locating
dowel pins. 19 Connect wiper drive link to motor crank.
16 Clamp crank arm in vise and secure crank arm nut. 20 Connect battery ground wire.
17 Position motor on dash panel and install mounting

Screws.

JPERATION - SKILL
OPERATION DESCRIPTION REPORTING MODEL - -
NUMBER 74 75 76 77 78 LEVEL
CODE
MOTOR, WINDSHIELD WIPER- R & R 22.027 22010 WAG- .3 .3 .3 .3 .3 C
CKE
TRE
Gear Set - Replace B .3 .3 .3 .3 .3 C
s-035-BSJ
78-77
Subject: CR Radio Antenna and Splitterbox Application; 1978 Wagoneer,Cherokee, File: BODY
Adjustment Procedure and Truck MOdelS With CB Radio Body Electrical
No. 8-05 December 20, 1977
The information contained in this bulletin supersedes all NOTE: Most VSWR meters require the use of a coaxial
previous information published in regards to CB radio jumper cable with two male ends to connect test
antenna and splitterbox adjustment. Please remove and instrument to radio coaxial lead.
discard Diagnosis and Repair Bulletin 8-02, dated
October 13, 1977, File: BODY Body Electrical.
-
3 Turn radio on. Measure VSWR on channels I and
40 using test instrument manufacturer’s instructions.
All 1978 Wagonecr, Cherokee, and Truck Models with a a If VSWR readings for both channels are 3.5 or
CB radio will require an operational inspection prior to less, and are within t .5 of one another, proceed to step
delivery. The inspection involves installing a VSWR 13.
Voltage Standing Wave Ratio meter, such as the b If either VSWR reading is higher than the
Amserv CB Mobile Tester Model AMX 386S, in line specified 3.5 or if the two readings are not within the + .5
between the radio and the splitterbox to measure the spread, the splitterbox must be adjusted. Proceed to step
antenna trim. Adjustment of the splitterbox or antenna 4.
may be necessary depending on the readings of the test
instrument. 4 Adjust the splitterbox see illustration using a 5/64
inch Allen wrench or a 5/64 inch hexagon non-metallic
Most trim adjustments can be made by adjusting the alignment tool available at most radio or television
splitterbox. Thc antenna base is pre-set to a master at the repair outlets.
factory and usually does not require adjustment.
a Insert tool into splitterbox adjusting screw.
The following procedure is to be used for the operational b Turn adjusting screw clockwise or
counterclockwise, until the VSWR readings on both
inspection and adjustment of the splittcrbox/antenna.
channels I and 40 are within + .5 of one another.
NOTE: VS WR checking procedures require transmitter
operation and FCC regulations governing CR radio
operations apply. A copy of these regulations are
available from your district F.C.C. office.
NOTE: For best results when checking VS WR, the car

should be located out-of-doors and at least 3ofeetfrom
other cars, people or buildings. Doors should be closed,
and the antenna mast must be tight on the antenna base.
CAUTION: Before performing the following procedure

be sure that the microphone connector detents are
properly aligned as faulty radio operation could result.
PROCEDURE
I With radio off, disconnect coaxial cable inline

connector located between radio and splitterbox.
NOTE: If adjustment is made usingan Allen wrench, the
2 Connect test instrument to radio and splitterbox wrench must be removed from the splitterbox before
leads. Follow instrument manufacturer’s instructions for checking the VS WI? reading.
connections.
OVER

Service EngineerIng Department e 14250 Plymouth Road e Detroit, Michigan 48232
Additional copies ol this bulletin are available through your zone office.
78-78
5 Observe the VSWR readings on channels I and 40. II Continue to remove antenna and make adjustments
a If readings on both channels are 3.5 or less and in half turn increments until lowest VSWR is attained.
are within .5 of one another, proceed to step 13.
b If either reading is greater than 3.5, an antenna NOTE: Antenna mast must be tight on antenna basefor
base adjustment must be made. Proceed to step 6. meaningful test results.
6 Measure VSWR on channel 20. 12 If necessary, readjust splitterbox so that VSWR

reading on both channels I and 40 are 3.5 or less and with
7 Remove antenna mast from base. ± .5 of one another.
8 Remove mylar tape from top of antenna base. 13 Turn radio off. Disconnect and remove test
instrument.
9 Insert a 5/64 inch Allen wrench at least 3-1/2" long
into antenna base adjusting screw. 14 Connect inline connector between radio and
splitterbox, be sure connection is tight.
10 Turn antenna adjusting screw clockwise or counter
clockwise 1/2 turn. Securely install antenna mast; and
measure VSWR on channel 20.

OPERATION SKILL
NUMBER 77 78 79 LEVtL
CODE
RADIO, CB - INSPECT 3011 WAG - 0.1 G

AM CR 15.326 CXE
AM/FM CR 15.328 TRK
Splitterbox Adjust
- 15.032 A 0.1 C
Antenna - Adjust 15.032 B - 0.1 - C
Subject: flectrie Taligate WMdow Regulator ApplicatMa: 1974, 1975, 1976, 1977 HI.: BODY
Pbdou Gear Shaft Loose and 1978 Wagoneer and Chatokee Bet ElectrIcal 1977 and
Modib With Electric Tailgate WIndow Prior Group 3.000
No. 8 .04 October 13, 1977
If the electrically operated tailgate window, on one of the WARNING: Regulatorapring tension MUST be retained
above vehicles, is inoperative and the problem is caused as before removing motor and drive unit from regulator.
a result of a loose pinion gear shaft on the window
regulator, it is no longer necessary to replace the window 7 Install a 1/4 inch by 1 inch screw, with flat washer,
regulator. between the sector gear teeth Fig. 1.
Effective repairs can be made, providingthe gear teeth are 8 Remove motor attaching screws and slide motor
not damaged, by restaking and welding the pinion gear from under regulator.
shaft in accordance with the following procedure.
9 Remove regulator attaching screw and regulator. If
attaching screws are not accessible, proceed as follows:
PROCEDU RE
a Graspregulatorarm asfaroutboard as possible.
b Push downward on arm until sector gear holes
1 Lower tailgate window. align with attaching screw.
c Hold regulator arm down and insert screw
2 Open tailgate. between sector gear teeth.
d Remove regulator attaching screws and
3 Remove tailgate carpet and access cover. regulator.
4 Remove retainers attaching regulator arms to 10 Clean regulator in solvent and dry with compressed
channel. air.
5 Disengage regulator ann pins from channel. 11 Wire brush area around pinion gear shaft.
6 Support window glass in raised position. 12 Stake pinion gear shaft in position.
SECTOR GEAR 13 Tack weld pinion gear shaft in three places Fig. 2.
WELD
3 PLACES
Fig. 1 Locking Electric Operated Window Fig. 2 PinIon G.ar Shaft Weidment
Regulator Gears OVER
Service EngIneering Department e 14250 Plymouth Road e Detroit, Michigan 48232
Additional copies ot this bulletin ate available through your zone ottice.
14 Clean welded area using a wire brush. 20 Engage regulator arm pins to channel.
15 Paint welded area using black AMC/leep spray 21 install retainers attaching regulator arm to channel.
paint, part number 8990636, or equivalent.
22 Install tailgate window.
16 Lubricate regulator pinion gears and sector gears
with Lubriplate Multi-Purpose grease, or equivalent. 23 Install tailgate access cover and carpet.
17 Install regulator in tailgate. 24 Close tailgate.
18 Install regulator motor. 25 Raise tailgate window and check for proper
operation.
19 Remove screw from between sector gear teeth.

PERATION SKILL
R!PORTING MDDEI
CODE
NUMBER 74 I 75 76 77
-
78 LEVEL
REGULATOR. ELECTRICAL TAILGATE

WINDOW - REPAIR 23.306 233fl WAG. 0.8
II 0.8 0.8 0.8 0.8 G
CKE
8-006-BSJ
Subject: Broken Electrical Connector- Application: 1974, 1975, 1976, 1977, FIlet BODY
Tailgate Window Motor and 1978 Wagonee and Cherokee Body ElectrIcal 1977 and
Models With Electrically Operated Prior Group 3.000
Tailgate Window
No. 8-03 October 13, 1977
lithe electrically operated tailgate window, on one of the

above vehicles, is inoperative and the problem is caused as
a result of a broken electrical connector on the motor, it is
no longer necessary to replace the motor.
Effective repairs can be made by cutting the frmale

connector from the wires, installing two quick connect
terminalsand tilling the connector cavity on the motor
with a sealer. The following parts will be required.
Description Quantity Part No. Grow

Sealer
Gasket.in-a-Tube AR 8993317 15.260
Terminal 1/4 Inch

Quick Connect 2
FILL CAVITY
PROCEDURE WITH SEALB
TAN WIRE
1 Lower tailgate window.
2 Open tailgate.
BROWN WIRE
3 Remove tailgate carpet and access cover.
4 Raise tailgate window, using safety switch. Electric Tailgate Window Motor
5 Loosen window regulator screw.
6 Remove motor from window regulator.
13 Fill motor connector cavity with Gasket-in-a-Tube
7 Disconnect female connector from motor. Sealer, part number 8993317, or equivalent see
illustration.
8 Cut off wires at female connector,
14 Install motor on window regulator.
9 StrIp ends of both wires.
15 TIghten window regulator screw.
10 Attach 1/4 inch quick connect female terminal to
each wire. 16 Install tailgate access cover and carpet.
11 Connect tan wire to upper motor terminal see 17 Lower tailgate window, using safety switch.
illustration.
18 Close tailgate.
12 Connect brown wire to lower motor terminal see
Illustration. 19 Check tailgate window for proper operation.
OVER
Service EngIneering Department e 14250 Plymouth Rood e DetroIt. MichIgan 48232
SefAi#annI rnniae a? 1MM hpIiictin am awailahia th,n,,nh unur 7nnn nftirn
OPERATION SKILL
CODE
NUMBER 74 75 I 76 77 I 78 LEVEL
MOTOR.
- REPAIR
TAILGATE WINDOW
23.310 2331 WAG- 0.6 0.6
i
I 0.6 0.6
II 0.6 G
CKE .-
I I .
7-ooa-ssJ
78-83
Subject: CB Radio Antenna And Splitterbos ApplIcation; 1978 Wagoneer,Cheinkee, FIle: BODY
Adjustment Procedure and Truck Modek WIth CB RadIo Body Electrical
N.. 8-02 October 13, 1977
This bullet Is being reissued to change the warranty 6 Turn transmitter channel selector to channel 20.
reporting aides. Please roniove and discard DRB No.
8.01, CB Radio Antenna and Splitteibox Adjistinent 7 Disconnect antenna mast from base, and remove
Procedures, dated September 8, 1977, Ella: BODY -
mylar tape from antenna base.
Body Electrical and Insert this new bullet.
All 1978 Wagoneer. Cherokee and Truck Models 8 Adjust antenna base adjusting screw slug using a
equipped with a CB radio will require an operational 5/64 inch Allen wrench at least 3% inches long. Insert
Allen wrench into antenna base and turn adjusting screw
inspection prior to delivery. Some radios may also require
slug clockwise or counterclockwise, one quarter turn at a
an adjustment of the antenna and splitterbox.
time, until lowest possible reading on SWR test
instrument is atlained.
The following procedure is to be used for the operational
inspection and adjustment of the antenna and splitterbox.
A test instrument, such as a VSWR Voltage Standing NOTE: Antenna mast must be installed securely to
obtain an accurate SWR reading.
Wave Ratio meter or a CR Mobile Tester Amserv Model
AMX 386S must be used for inspection or adjustment. 9 Measure SWR on channels I and 40.
a IISWR on channels I and 40 is 3.5 or less radio is
PROCEDURE within specifiéations and no further adjustment is
required. Proceed to step Il.
NOTE: For best results when checking S WR. the vehicle b If SWR on channels land 40 is greater than 3.5,
should be located out-of-doors and at least 1N feet front the splitterbox must be adjusted. Proceed to step 10.
other vehicles, people. or buildings. Doors on vehic!e
should be closed.
1 Disconnect coaxial cable between transmitter and 10 Adjust splinerbox using a 5/64 inch hexagon
splitterbox at inline connection near splitterbox. non-metallic alignment tool available at most radio or
television repair outlets.
2 Connect transmitter end of coaxial cable to a jumper
wire. Jum per wire should not be more than 18 inches long. NOTE: If adjustment is made using an Allen wrench, the
wrench must be rein ovedfrom splitterbox before checking
3 Connect jumper wire to transmitter terminal of test S WR reading.
instrument.
a Insert alignment tool into adjusting screw hole on
4 Connect splitterbox end of coaxial cable to antenna side of splitterbox.
terminal of test instrument. b Turn adjusting screw clockwise or counterclock
wise, in one quarter turn increments, until a reading of 35
Turn radio on. measure SWR on Channel I and 40. or less is attained on channels I and 40.
5
a IfSWR readingon channels I and 40 is 3.5 or less ii Disconnect splitterbox end of coaxial cable from
radio is within specification and no further adjustment is antenna terminal of test instrument.
required. Proceed to step 11.
12 Disconnect jumper wire from transmitter end of
b If SWR reading of 3.5 or less cannot be attained coaxial cable.
on channels I and 40 antenna must be adjusted. Proceed
to step 6. 13 Connect coaxial cable between transmitter and
splitterbox at inline connection near splitterbox.
OVER
Service EngineerIng Department e 14250 Plymouth Road e Detroit. Michigan 232
78-84
The following standard operations and work times will apply.
COOL NUMBER 76 77 18 LEVEL
RADIO, cl-INSPECT 3011 WAG- - 0.1 G

AM Cl 15.326 CKE
AM/EM CS 15.321 IRK
Antenna and Splitter Box-Adjust .. 15.032 A - - 0.2 G
78-85
Subject: Cracked Headlamp Bulb Application: 1977 and 1978 Cl-S and File: BODY
CJ7 Models Built Between VINs Body Electrical
J7XXXXX1OS71SandJSXXXXXO13U6S 1977 Group Body Section
No. 8-01 September27, 1977
If a sealed beam headlamp unit is reported to be cracked 8 Aim headlamps.

on aU-S or 0-7, built between the above VINs check to
be sure that the lamp was positioned in the shell properly. 9 Install headlamp door.
When replacing the unit, make sure that the shell lances
align properly with the bosses on the lamp. If an
Interference between one ofthe shell lances and the lamp
bosses is encountered, correct the condition as outlined in
the following procedure.
PROCEDURE
1 Remove headlamp door.
2 Remove headlamp retaining ring.
3 Remove and discard cracked bulb.
4 Position replacement bulb in shell and check for

proper alignment.
LANCED AREA 3
5 File lanced area of shell that interferes with bosses of REWORK AS NECESSARY
bulb see illustration.
6 Install headlamp bulb.
7 Install headlamp retaining ring.

OPERATION SKILL
NUMBER LEVEL
CODE 77 78 79
SHELL, HEADlAMP - REWORK 3.245 3373 8343 0.2 0.2 - M
Both Headlamps - Add 0.1 0.1
Includes_aiming_heodlamps
B’002*BSJ

Additional copies of this bulletin ore available through your zone office.
78-86
_________

Subject: Air Control Cable Operation Application: 1978.81 CJ-5 and CJ-7 File: BODY
Models Heater - Air
Conditioning
No. 81-1 April 13, 1981
In November, 1980, a new cowl fresh air intake duct 10 Tilt heater housing back, pull housing rearward,
assembly was phased into production of 1981 CJ models. and lower housing.
The new duct assembly provides improved air control
cable and intake duet vent operation and can also be 11 Disconnect heater contro] cables.
used on all 1978-81 CJ-5 and CJ-7 models.
12 Remove defroster duct and tube assembly.
If service diagnosis indicates that a bind in the fresh air
intake duct linkage caused the air control cable to bind 13 Remove fresh air intake panel from cowl.
or break due to excessive cable operating effort, the new
fresh air duct assembly should be installed along with a 14 Remove fresh air intake duct assembly from cowl.
replacement air control cable if necessary.
Installation
The following part is available and may be required:
1 Install defroster duct and tube assembly.
Description Quantity Part No. Group 2 Raise and secure windshield.
DUCT ASSEMBLY, 3 Install replacement fresh air intake duct assembly.
Fresh Air Intake 1 5758809 22.020
4 Install fresh air intake panel on cowl.
PROCEDURE
5 Connect heater control cables.
Removal
6 Position heater housing assembly on dash panel.
1 Disconnect battery negative cable.
7 Install nuts attaching heater housing to dash panel.
2 Drain two quarts of coolant from radiator into
clean container. 8 Install glove box.
8 Disconnect heater hoses at heater housing. 9 Connect speedometer cable.
4 Remove heater housing drain hose. 10 Install screw attaching heater housing to bracket.
5 On models with air conditioning, remove screws 11 On models with air conditioning, connect v "s to
attaching evaporator housing to instrument air conditioning control switches and install
panel. Move housing away from panel and dis evaporator housing on instrument panel.
connect wires at air conditioning control
switches. 12 Connect drain tube to heater housing.
6 Remove screw attaching heater motor housing to 13 Connect heater hoses.
bracket.
14 Refill radiator.
7 Remove nuts that attach heater housing to engine
compartment side of dash panel -
Disconnect speedometer cable. The standard servicing operations and work times
published in the appropriate SSO manual are not
Remove glove box. affected by this bulletin.
Si-060-13J

Service EngIneerIng Deportment e 14250 Plymouth Road . Detroit, Michigan 48232
Additional cop,es ol This bulletin are available through you’ zone office
78-87
Subject: Heater Diagnosis and Repair Application: All 1978-79 Jeep Vehicles File: BODY
Heater-Air Conditioning
No. 9-01 April 6, 1979
For all heater repairs, the logical and proper procedure is 4 Check engine coolant temperature. If coolant does
diagnosis before disassembly. Never assume any not achieve proper operating temperature 189°F;
component to be the cause of a problem without 87° C after engine warm-up, thermostat may be staying
verification. A systematic diagnosis procedure is open or radiator cap may be leaking or developing
extremely important in avoiding time consuming and insufficient pressure.
costly repair delays caused by incorrect or unnecessary
repairs. The most effective approach to any heater NOTE: Insufficient radiator cap pressure can increase
malfunction involves four basic procedures which are: engine warm-up time.
problem definition and initial inspection, coolant flow
checks, vacuum system checks, and a check of all heater 5 If problem was revealed during initial inspection,
system mechanical components. The four procedures repair as necessary and return car to owner. But, if initial
should be performed in the sequence outlined and as inspection did not reveal problem, refer to next
described in the following paragraphs. procedure in diagnosis sequence Coolant Flow Checks.
-
PROBLEM DEFINITION AND COOLANT FLOW CHECKS

INITIAL INSPECTION
Problem definition is the first and most important step in I Check thermostat operation. Perform this check
resolving any heater malfunction. Have the owner only when coolant is well below operating temperature of
describe and, if possible, demonstrate the problem 189°F 87°C. Remove radiator cap and start engine.
condition before proceeding any further. Increase engine speed momentarily and observe coolant
motion in radiator top tank. There should be no
I Have owner describe and demonstrate problem. appreciable flow through tank. If pronounced flow
Problem may simply be misundertanding how heater occurs, thermostat is inoperative and should be replaced.
If flow was negligible, proceed to next step.
controls work. If owner knows how to operate controls,
proceed to next step. If owner does not know how
controls operate, demonstrate proper use and return car 2 Place heater controls in MAX heat position and
operate engine until it reaches operating temperature. If
to owner.
engine coolant reaches proper operating temperature but
heat output is still insufficient, proceed to next step. If
2 Raise hood and inspect heater system underhood heat output is sufficient, return car to owner.
components. Look for: loose or missing hose clamps,
collapsed hoses, loose or missing radiator cap,
insufficient coolant in radiator, damaged or loose fan WARNING: The engine coo/ant is hot and under
belt, disconnected vacuum hoses, and visually observable pressure. Wear safety goggles, cover the radiator cap with
coolant leaks. On CJ Models, check for evidence of a shop towel and remove the cap slowly to prevent
coolant in the heater housing drain tube. coolant surge out of the radiator.
3 Inspect interior components and controls. Be sure 3 Remove radiator cap slowly and note coolant
heater controls operate correctly and do not bind. Also level.
be sure control cables and vacuum lines are securely If coolant level is OK, install cap and proceed to next
attached and are not kinked. On Cherokee, Wagoneer
step. If coolant level is low, add coolant as necessary and
and Truck models, signs of coolant on the passenger side check heater output again. If output is now OK, return
floormat or carpeting may indicate problem with heater
car to owner. If output is still insufficient, proceed to next
core or related components. Refer to Mechanical
step.
Component Checks, step 6.
OVER

Service EngineerIng Department e 14250 Plymouth Rood * DetroIt, MIchigan 48232
Additional comes of this bulletin are available through your zone office.
78-88
4 Bleed air from system. Loosen clamp attaching3/4- MECHANICAL COMPONENT CHECKS
inch ID. return hose to heater core and allow air that
may be trapped in cooling system to bleed off. Check
heater output again. If OK, return car to owner. If not A malfunction of the cable operated heater doors can
OK, proceed to next step. also restrict or completely block heater air flow. In
addition. misadjusted door cables or a cracked or
5 Stop engine and remove radiator cap. Test cap for damaged heater housing can restrict or diffuse air flow.
leakage and capacity using cooling system pressure
tester. If cap is OK, proceed to next step. If cap is faulty, I Check cable operation. Cables must be securely
replace cap and check heater output again. If output is connected and not binding. Adjust cables if necessary.
now OK return car to owner. If not OK, proceed to next
step. 2 Check heater air intake for foreign material. On
Jeep vehicles, the intake is located on cowl between hood
WARNING: Coolant is hot and under pressure. Wear and windshield.
safety goggles and be sure the hose end is directed into the
bucket or drain pan. 3 Check air flow from outlet ducts. Be sure that
carpeting is not blocking ducts.
6 Check for system restrictions. Remove heater return
hose from heater core outlet Attach length of heater hose 4 Check heater housing for cracks. Operate fan at
to outlet and secure end of hose in bucket or drain pan. intermediate speed and listen br escaping air. Wet
Have helper stan and operate engine while you observe fingers and probe around housing to further detect any
flow from hose into container. possible cracks or voids.
7 If coolant flow is restricted, check flow out of water NOTE: Small cracks or voids in the heater housing can
pump, inlet hose, and through water valve using a length be repaired using 3-M Strip Caulk 8578 or equivalent.
of heater hose and a container as described in step 6.
5 If above components are OK. verify system
NOTE: & sure to inspect the heater core inlet and outlet operation and check for internal obstructions in heatei
tubes and the water pump and thermostat housing inlet housing by comparing performance with known good
and outlet necks for casting flash which can also restrict car. If air flow is not comparable to known good car,
flow. check and repair heater housing as necessary.
6 If coolant was observed on passenger side carpeting

8 If flow is restricted at any point, repair or replace on Cherokee. Wagoneer. Truck models or in heater
components as necessary. If cooLant flow was OK at all housing drain tube on CJ models, remove heater core and
points, proceed to next procedure in diagnosis check for leaks. Cap one outlet tube in core, apply IS psi
sequence- Vacuum Checks. air pressure to core, and immerse it completely in
container filled with water. Bubbles at any point on the
VACUUM CHECKS core indicate leak. Replace or repair core as necessary if
leak is evident.
Improper vacuum assisted heater door operation or
coordination can restrict or completely block heater air NOTE: Cheek Cherokee. Wagoneer and Truck model
flow. The vacuum motors, hoses, and reservoir can be heater core end caps /br proper positioning see
checked using Vacuum Tester J-23738 or applying illustration.
vacuum by connecting a hose to an intake manifold TOP
fitting and operating the engine. Refer to Chapter 3D -
Heater in the appropriate Jeep Technical Service Manual IN

for system operation and component location.
I Check operation of each vacuum motor using

Tester J-23738 or by apply engine vacuum.
OUT
2 If tester indicates a motor or hose will not maintain
steady vacuum, replace as necessary and check operation
of replacement component.
3 11 vacuum motors and hoses test OK, check vacuum

reservoir if equipped. If reservoir will not hold vacuum,
replace it. If reservoir is OK. proceed to next step. HEATER CORE TUBE LOCATION
4 Check vacuum assisted heater door operation. If
doors are binding or stuck, repair as necessary and check The Standard Servicing Operations and work times as
operation again. If doors operate correctly, proceed to published in the current SSO Manual are not affected by
next sequence in diagnosis procedure - Mechanical this bulletin.
Component Checks. 9-041-13A/J
78-89
Subject: Heater Core Repair Application: 1978 Wagoneer, Cherokee, File: BODY
and Truck Models Heater -
Air Conditioning
No. 8-02 April 27, 1978
The Service Diagnosis, Page 3D-7 of the 1978 Technical b If leakage continues after tightening hose
Service Manual, Volume 3 is applicable when diagnosing clamps, proceed to Heater Core Leak Repair.
heater related problems; however, due to a design change
at the beginning of the current model year the following 3 If coolant is found at bottom edge of housing,
additional information is of importance. proceed to Heater Core Leak Repair.
The heater core has tubes running through the core area HEATER CORE
connected on one end with end caps see illustration. If LEAK REPAIR
the end caps leak, the following could result:
I Remove heater core as described on page 3D-8,
S Coolant may be found dripping from the bottom of Volume 3 of the 1978 Jeep Technical Manual.
the heater core housing.
2 Inspect heater core for leaks, if heater core is
* Coolant may be found around the heater core inlet repairable, have a competent repairman make necessary
and outlet. repairs.
Service correction for heater core leaks involves NOTE: It is suggested that the heater core end caps be
inspection and repair as directed in HEATER CORE checked for proper positioning at this time see Fig. 1.
LEAK INSPECTION.
3 Pressure test heater core for leaks prior to installing
It is also possible to mislocate the heater core end caps in vehicle.
when installing them. If the heater core end caps are
positioned differently than shown in the illustration, the 4 Install heater core as described on page 3D-8,
following could occur Volume 3 of the 1978 Jeep Technical Service Manual.
* Coolant flow may be blocked, resulting in no heat. HEATER END CAP

REMOVAL AND INSTALLATION
* Coolant may not flow through the complete heater
core circuit, resulting in partial heater output. 1 Remove heater core as described on page 3D-S.
Volume 3 of the 1978 Jeep Technical Service Manual.
Service correction for mislocated end caps involves
removing the heater core and having a competent 2 Compare heater core end cap positions with Fig. 1,
repairman remove and correctly install end caps that are
incorrectly positioned. The recommended repair TOP
procedure can be found under HEATER CORE END
CAP REMOVAL AND INSTALLATION. IN
HEATER CORE
LEAK INSPECTION
I Pressure test cooling system and inspect heater hose l2
connection at heater core and check bottom edge of OUT
heater housing for coolant.
2 If leakage is evident at heater core connections,

tighten hose clamps and recheck for Leakage.
a If leakage stops after tightening hose clamps,

return vehicle to owner. Fig. 1 Heater Core End Caps
PU Ameilcan Motors Sales Corporation

S.rvlc* Englnnrlng Deportment * 14250 Plymouth Rood * Detroit. Mlchlgon 43232
78-90
3 If end caps are incorrectly positioned on heater core, 5 Install heater core as described on page 3D-S.
have competent repairman remove and correctly install Volume 3 of the 1978 Jeep Technical Service Manual.
end caps.
4 Pressure test heater core prior to installing in

vehicle.
OPERATION DESCRIPTION OPERATION MODEL SKILL
REPORTING -
NUMBER LEVEL
CODE 78
HEATER LEAK INSPECT- 13.028 13067 WAG.CKE4RI 0.2 C

Includes pressure test system and cap, tighten
loose bolts, nuts, and add coolant if required
Leak, Heater core - Repair 13.028 A 0.7 C

With air conditioning Add- 0.1
End cap, heater core R&R

- 13.028 B 0.6 6
With air conditioning Add- 0.2
Note: Combinations A and B cannot be used

together
END CAP, HEATER CORE R&R - 13.028 13069 WAG-CKE-TRK 0.7 6
With air conditioning Add - 0.1
8-041 - I 3J
78-91
Subject: Heater Noise Moan Application: 1978 CJ-5 and CJ-7 File: BODY
Models With V-8 Engine Heater-Air Conditioning
No. 8.01 November 21,1977
A loud noise moan may be emitted from the heater on NOTE: Arrow on valve must be toward heater core.
some 1978 CJ-5 or CJ-7 models with V-8 engine. The
noise is most noticeable at wide open throttle and at 5 Slide hose clamps over ends of valve and tighten.
engine speeds above 2500 RPM.
6 Fill radiator to proper level.
This condition can be corrected by installing a flow
control valve in the heater inlet hose approximately 4 7 Check for coolant leaks and verify that noise has
inches from the connection in the intake manifold. The been eliminated.
following parts will be required.
Valve, Flow I 5455957 11035

Control
Clamp, Hose 2 G443632 13.086

HOSE
PROCEDURE
1 Drain approximately 2 quarts of coolant from

radiator.
/
2 Cut heater inlet hose approximately 4 inches from
connection on intake manifold.
3 Position hose clamps over cut ends of hose.

TO
4 Install flow control valve between cut ends of hose HEATER CORE
see illustration.
Flow Control Valve Installation

REPORTING OPERATION MODEL SKILL
NUMBER 77 LEVEL
CODE 78 79
VALVE, FLOW CONTROL-

INSTALL 13.034 13031 83-93 - 0.3 - C
8-018-I 3J

Service EngIneering Deportment * 14250 Plymouth Road * Detroit, Michigan 48232
are available through your zone ottice,
Additional copies ot this bulletin
78-92
Subject: Seat Cover Button Replacement Application: 1977 and 1978 Jeep File BODY
Models With Seat Cover Buttons Instrument Panels -
Seat Assemblies
No. 8-01 April 25, 197$
In the event that a seat button has been pulled from a seat Wagoneer Cherokee Rear Seat Back
-
cover, it is not necessary to replace the seat cover when

only a seat button and retainer are required. The seat I Fold rear seat back down.
buttons can be found in Group 29.367-I and the retainers
in Group 29.367-2 of the current Parts Catalog. The 2 Remove necessary hog rings from bottom edge of
procedures for replacing seat cover buttons are as seat cover to allow positioning of seat button retainer.
follows:
3 Slide seat button retainer Into position and insert
SEAT BUTTON
REPLACEMENT PROCEDURES 4 Pull seat cover back to installed position and install
hog rings.
CJ-5 and CJ-7 Individual Seat Back and
Wagoneer Seat Back-Bench Seat 5 Return seat back to upright position.
I Remove front seat per appropriate Technical Truck Seat Back - Bench Seat
Service Manual.
I Remove seat back.
2 Remove hog rings from bottom of trim to loosen
seat cover. 2 Remove necessary hog rings from bottom edge of
seat cover to allow positioning of seat button retainer.
3 Pull loose cover forward.
4 Starting at bottom edge of seat cover, slide seat seat button stem through seat cover and retainer.
button retainer up into position between cover and seat.
Push button stem through seat cover hole and seat button 4 Pull seat cover back to installed position and install
retainer, hog rings.
5 Pull loose cover back to installed position and 5 Install seat back.
install hog rings.
Truck Seat Cushion - Bench Seat
6 Install front seat per appropriate Technical Service
Manual. I Remove seat per appropriate Technical Service
Manual.
Cherokee Truck Individual Front Seat Back
-
2 Remove necessary hog rings from rear edge of seat

1 Unzip front seat back zipper to loosen cover, cover to allow positioning of seat cover and retainer.
2 Pull loose cover forward. 3 Slide seat button retainer into position and insert
3 Starting at bottom edge of seat cover, slide seat
button retainer up Into position between seat cover and 4 Pull seat cover back to installed position and install
seat. Push button stem through seat cover and seat hog rings.
button retainer.
5 Install seat per appropriate Technical Service
4 Pull seat cover back to installed position and close Manual.
zipper.
OVER

Service Engineering Deportment e 14250 Plymouth Road e Detroit, MIchigan 48232
78-93
OPERATION SKII.L
NUMBER 78 LEVEL
CODE 77
BUTTON, SEAT TRIM INSTALL

- 29.367 29837 CJ-15 .3 .3 G
Each Back Panel Front
- 16-17 .2 .2
25-45-46 .3 .3
Each Back Panel - Rear 15-16-
17-IS .3 .3
25-45-46 .4 .4
Each Seat Cushion 25-45-46 .3 .3
8.059-BSA/J
78-94
Subject: Paint InIormation-7800 Phase- Application: 7800 Jeep Vehicles File: BODY
Out/7900 Phase-In Program-Supplement Metal Repair-
Painting-Water
Leaks/Wind Noise
No. 8-02 August 23. 197$
On July 28, 1978 DRB 8-01, File: BODY, Metal Repair- formulas that were marked N/A have become available.
Painting-Water Leaks/ Wind Noise was issued to provide and are listed below. Any formulas that have not been
available paint infonnation pertaining to the 7800 Phase- published will be available through local paint jobbers
Out! 7900 Phase-In Program. Since that time some of the within the next few weeks.
ALPACA BROWN RUSSET METALLIC SABLE BROWN

ENAMEL ENAMEL METALLIC ENAMEL
DITZLER DITZLER DITZLER

P/N DAR3IO6 P/N DAR3JOS P/N DAR3I12
Mixing I Quart Mixing I Quart Mixing I Quart
Code Setting Code Setting Code Setting
DMR453 20 DMR477 16 DMR44O 2
DMR49O 60 DMR433 32 DMR433 12
DMR43S 130 DMR435 112 DMR43S 32
DMR433 190 DMR452 282 DMR453 76
DMR47Ô 580 DMR460 772 DMR49O 174
DXR495 600 DXR495 792 DMR4S2 314
DMR482 1040 DMR499 1022 DXR495 334
DMR476 1034
8-107-BSA/J

Service Engineering Department e 14250 Plymouth Road e Detroit. MIchigan 48232
Additional copies of this bUlletin are available through your zone office.
78-95
Subject: Paint Information 7800 Phase- Application: 7800 Jeep Vehicles File: BODY
Out/ 7900 Phase-In Program Metal Repair - Pabting -
Water Leaks/Wind Noise
No. 8-01 July 28, 1978
As part of the 7800 Phase-outf 7900 Phase-in program 9K Sable Brown Metallic
twelve new exterior 1979 colors are being used on 1978
model vehicles as follows: 9L Saxon Yellow
9A Alpaca Brown 9N Morocco Buff
9B Olympic White 9P Bordeaux Metallic
9C Russet Metallic 9T Ensign Blue
9E Wedgwood Blue 9W Mandarin Orange
9H Cumberland Green Metallic NOTE: Some intermix formulas are marked N/A
because they were not available at time ofpublication.
9J Arrowhead Silver Metallic Contact your local paint jobber for information no:
contained herein.
ALPACA BROWN ALPACA BROWN ALPACA BROWN ALPACA BROWN
ENAMEL ENAMEL LACQUER LACQUER
DITZLER SHERWIN-WILLIAMS DITZLER SHERWIN-WILLIAMS

35-30169 P/N 34-30169
Mixing I Quart Mixing I Quart Mixing I Quart Mixing I Quart

Code Setting Code Setting Code Setting Code Setting
FSW8O 5.9 L4W3OI 4.7
F5M78 35.2 L4B320 28.5
F5BSI 88.0 L4M338 56.9
N/A F5N76 182.0 N/A L4S345 104.3
F5N85 334.0 L45343 284.0
V6V175 379.0 L4N3 14 882.0
F5SIOI 907.0
OLYMPIC WHITE OLYMPIC WHITE OLYMPIC WHITE OLYMPIC WHITE


P/N DARMO7 P/N 35-30146 P/N D0L3107 P/N 34-30146
DMR486 2 F5Y89 2.9 DMA3I3 I L4Y310 i.9
DMR4S7 34 FSBSI 5.7 DMA382 6 L4B320 3.8
DMR49I 6t F5Y72 18.2 DMA329 14 L4Y340 15.2
DMR400 1116 V6V175 63.0 DMA346 25 L4W3OI 952.0
DXR495 1136 F5W80 I.006.0 DMA3II 1,120
DMR499 1376

Service EngineerIng Department e 14250 Plymouth Road e DetroIt. MIchigan 48232
78-96
RUSSET METALLIC RUSSET METALLIC RUSSET METALLIC RUSSET METALLIC

P/N 35-30174 P/N D0L3108 P/N 34-30174
F5S69 58.0 DMA36O 20 L4Y333 33.8
F5M71 131.0 DMA3I2 70 L4S335 146.0
kTI A F5S74 204.0 DMA3O7 230 L4E306 484.0
"
F5RIOO 306.0 DMA356 990 L4M338 878.0
F5N76 454.0
V6Vl75 499.0
F5E84 906.0
WEDGW000 BLUE WEDGWOOD BLUE WEDG WOOD BLUE WEDGWOOD BLUE


P/N DAR3IO9 P/N 35-30147 P/N DDL3109 P/N 34-30147

DMR4IO 10 F5P92 10.5 0MA342 6 L4M3I8 4.7

DMR49I 205 FIBS! 31.5 DMA346 60 L4B320 18.0
DMR4I4 420 FSL6S 62.! DMA32I 104 L4L305 40.7
DXR49S 440 V6VI7S 107.0 DMA3II 704 L4W301 948.0
DMR400 1,275 FSW8O 1,000.0 DMA3IO 1,084
CUMBERLAND GREEN CUMBERLAND GREEN CUMBERLAND GREEN CUMBERLAND GREEN

METALLIC METALLIC METALLIC METALLIC

P/N DAR3IIO P/N 35-30093 P/N 00L3110 P/N 34-30093
DMR435 36 FSG9O 191.0 DMA3O7 10 L463!! 242.0

DMR4S2 92 F5B8I 385.0 DMA3O4 120 L4B320 484.0
DMR433 156 V6V175 430.0 DMA358 260 L4S345 886.0
DMR49O 304 F5SIOI 902.0 DMA3!2 430
DMR44I 584 DMA3O9 600
DXR495 604 0MA384 990
DMR499 1.014
ARROWHEAD SILVER ARROWHEAD SILVER ARROWHEAD SILVER ARROWHEAD SILVER


P/N DAR3IIS P/N 35-30176 P/N DDL3IIS P/N 34-30176
Mixing I Quart Mixing I Quart Mixing I Quart Mixini I Quart

DMR45O IS F5W80 7.2 DMA3!1 2 L4M321 18.5

DMR435 45 F5P92 21.5 DMA357 12 L4L305 53.0
DMR4I4 93 F5L68 38.7 DMA375 24 L4B320 212.0
DMR490 153 FSB8! 139.0 DMA32O 134 L4S345 482.0
DMR433 228 V6V 175 184.0 DMA312 294 L4S343 884.0
DXR495 248 F5S 101 901.0 DMA3IO 994
DMR499 1,023
78-97
SABLE BROWN SABLE BROWN SABLE BROWN SABLE BROWN

P/N 35-30148 P/N DDLSII2 P/N 34-30148

F5M78 63.0 DMA3O9 4 L4S343 37,5

F5S69 169.0 DMA3I2 32 L4S335 97.6
Kit
"/n A F5881 338.0 DMA384 72 L4M338 187.7
V6V!75 383.0 DMA3S8 166 L4B320 352.0
F5N85 912.0 DMA3O7 876 L4N314 878.0
DMA3IO 986
SAXON YELLOW SAXON YELLOW SAXON YELLOW SAXON YELLOW


P/N DAR3II3 P/N DDL3II3 P/N 34-30092

DMR49I 14 DMA346 10 L4B320 1.0
DMR4S! 54 DMA322 50 L4Y333 72.6
DMR400 394 N/A DMA328 340 L4Y303 190.0
DMR4R7 898 DMA3II 1,040 L4W301 946.0
DXR495 918
DMR499 1.208
MOROCCO BUFF MOROCCO BUFF MOROCCO BUFF MOROCCO BUFF


P/N DAR3II5 P/N 35-30149 P/N DDL3II5 P/N 34-31149

DMR47S IS FSRIOO 6.7 DMA3I3 6 L4R304 9.4
DMR49O 40 FSB8I 26.7 DMA392 IS L4B320 20.7
DMR486 410 F5Y93 153.0 DMA358 30 L4Y303 178.0
DMR400 1,140 V6V175 198.0 DMA329 210 L4W301 942,0
DXR495 1,160 FSW8O 999.0 DMA3II 890
DMR499 1.250 DMA3IO 1,090
BORDEAUX METALLIC BORDEAUX METALLIC BORDEAUX METALLIC BORDEAUX METALLIC


P/N DAR3III P/N 35-30150 P/N DDL3III P/N 34-30150
DMR435 4 F5P92 38.4 DMA3 12 22 L4B320 24.0
DMR49O 16 F588 I 86.3 DMA32O 72 L4M32! 72.1
0MR433 36 F5E84 150.0 DMA3!5 452 L4E306 162.1
DMR452 254 F5S 101 258.0 DMA363 892 L4S345 274.0
DXR495 274 V6V 175 303.0 DMA3IO 992 L4M338 874.0
DMR476 1.032 F5M78 902.0
78-98
ENSIGN BLUE ENSIGN BLUE ENSIGN BLUE ENSIGN BLUE

P/N DAR3II7 P/N 35-30*70 P/N DDL3II7 P/N 34-30170
DMR4E6 16 F5P92 41.4 DMA329 4 L4M321 42.8
DMR400 56 FSW8O 120.0 DMA357 48 L40320 41.7
DMR490 126 FSB8I 210.0 DMA3II 188 L4W30 I 276.0
DMR450 236 V6V175 255.0 DMA3S8 338 L4L336 872.0
DXR495 256 F5L70 912.0 DMA342 1,018
DMR4IO 1,026
MANDARIN ORANGE MANDARIN ORANGE MANDARIN ORANGE MANDARIN ORANGE


P/N DAR3II6 P/N 35-30171 P/N DDL3II6 P/N 34-30171
Code Setting Code Setting Code .Selting Code Setting
DMR4OI 50 F5881 19.0 DMA358 8 L4B320 11.5

DMR4S4 320 F5Y87 147.0 DMA3II IS L4Y333 106.2
DMR49I 430 V6V175 192.0 DMA36O 32 L4E317 956.0
0MR476 770 F5E86 993.0 DMA3O7 86
DXR495 790 DMA336 1,080
DMR464 1,360
8-106-nSA/i
78-99
Service Technical Letter IFiIe:$orvicoGoneral
I No.9.10 I
July 24, 1979$
Subject Information
1977-79 Cherokee-Wagoneer-Truck panel and watershield paper, the paper becomes
Models damaged and must be replaced,..to prevent water
leaks.

p.rition Qty. Part No. Group

Rear Door, Left

Rear Door, Right

Front Door,Left

Front Door, Right

Sufficient for
One Door

as published in the current SSO Manual are not
affected by this bulletin.

78-100
D Dealer Principal Service Writer
X Service Manager Mechanic No. 9-06 March30. 1979
Subject Information

liberal amount of wD-4O penetrating lubricant, or
drying, repeat the above procedure using ArC/Jeep
Golden Eagle window defogger is installed on a bronze tone
Out Spare Tire Carrier 1976-79
- mounted on the swing-out spare tire carriers. The
CJ-5 and Ui-i Models carrier may be damaged if larger than specified

Service Engineering Dept. * 14250 Plymouth Rd. * Detroit. MIch. 48232
Additional copies 0/this letter are available through your zone of/ice.
78-in I
Li Dealer Principal Service Writer
Service Manager Mechanic Ne. 9-05 March 3, 197$
Subject Information
Compress i cii Pressure Spec if icat ion Tin compression pressure speci fications for
Update - 1977-79 Six- md Fight- 1Q77-79 six- and eight-cylinder engines have been
Cylinder Engines updated. pressure specifications
flit’ for both
six- and right--cylinder engines are now 120 to
j50 psi with a maximum allowable pressure

ig77-7 Jeep Technical Service Manuals.
Roof Rack Moan - 1979 Jagonit’r and A roof rack nean nay be produced by the front end
Cherokee Mriln mi I of tin’ roof rack. The moaning noise can be
eliminated liv positioning the front end rail over
the center stafichion with the large diameter of
lie end ra i I toward the front of the vehicle.
N0TE TIe reef rack moan is very similar to an

axle noise. Re sure not to misdiagnose the noise.

Additional copies a/this letter are available through your zone office.
70 Ifl
fljeep,

OF INTEREST TO: File: ServIce General
0 Dealer Principal Service Writer
X ServIce Manager X Mechanic Ne. 9-02 October 2, 1978
Subject Information
Service Technical Letter Number The subject Service Technical Letter was
8-07, dated September 28, 1978 inadvertently numbered 8-07. The correct number
should be 9-01. Please make the necessary
correction and file this Service Technical Letter
in the Service General of your 1979 Diagnosis and
Repair Bulletin binder.
All 1979 Jeep Models Equipped With All Jeep Models equipped with QuadrrTrac built
Quadra-Trac-Transnission to after August 4, 1978 and VIM J9A15NN009209 have
Quadra-Trac 0-Ring Seal an 0-ring seal between the automatic transmission
and Quadra-Trac mating surface.
The Quadra-Trac housing has been machined to

accept the 0-ring seal that replaces the gasket
previously used.
Part numbers for the 0-rtng seal and Quadra-Trac

assembly wIO-ring seal are as follows:
0-ring, Transfer 1 5359090 18.500

Case to Transmission
Transfer Case 1 8128994 18.500

Assembly WQT
NOTE: If the front half of Quadra-Trac housing

needs replacing, you must order the old style
housing group 18.510-2, PN 8122386 and a
gasket group 18.500-3, PN 998315. The front
half of the Quadra-Trac housing that is machined
to accept the 0-ring seal is not available as
a replacement part at this time.
over
P’I American Motors Sales Corporation

Service Technical Letter Icont’dI
Subject Information
All 1979 Jeep Models -Starter The starter solenoid on the subject vehicles has
Solenoid With Blade Terminals blade type terminals attached to the S and I stud
terminals. The addition of the blade terminals
allows either an early or late style harness to
be connected to the solenoid.
CAUTION: Do not remove the blade type terminals

on service applications that require the study
type push-on terminals. Loosening the stud
retaining nut may cause a loss of the internal
connection and render the solenoid inoperatiVe.
1978 Jeep Owner’s Manual Supplement Under separate cover, we have sent to all dealers
several copies of a supplement to the Owner’s
Manual for 1978 Cherokees equipped with the Brush
Guard accessory. In the event that you need
additional copies, contact your local Zone Office.
1979 Jeep Technical Service Manual On pages 2E-6 and 2E-8 of the 1979 Jeep Technical
Correction Service Manual, tool number 3-28488 appears twice
on DARS Chart step 7 and step 12. This tool
number should be 3-24649. Please make the neces
sary correction.
fl Dealer Principal X Service Writer
X Service Manager X Mechanic No. 8-06 August 18, 178
Subject Information
Power Steering Gear Diagnosis In some instances, power steering gear assemblies
have been replaced even though an in-dealership
repair was all that was necessary. Complete
diagnosis and repair procedures are described
in the appropriate Technical Service Manual.
Be sure to follow these procedures.
1978 Model BBD-2V Carburetor - Carburetors built after date code K7l8 suffix A
Accelerator Pump Change stamped on the metal identification tag have a
new design accelerator pump which has no check
ball or drilled passage in the bottom of the
pump well.
1979 CJ-7 Models Equipped With The soft top used on 1979 CJ-7 Models has longer
Soft Top sides at the rear quarter panel area to allow the
snaps to be installed on the vertical section of
the quarter panel rattier than on the upper flange
as was the case in 1978 see 1979 CJ-7 Model
installation instruction sheets for detailed
installation procedures.

ServiceTechnical Letter
D Dealer Principal Service Writer
Service Manager Mechanic No. 8-05 June 23, 1978
Subject Information
Canvas Top Installation CJ-7
- Prior to installing a canvas top on a CJ-7 model
Models Which Previously Had a that has had a factory installed hardtop and a
Factory Installed Hardtop and Roll* rollbar, check the hole in the top-center of the
bar rolibar for burrs. This hole is drilled in the
rollbar for use in attaching the rubber bumper
used on CJ-7 models that have the hardtop option.
Remove the burrs as necessary to eliminate the
possibility of contact with the canvas top
material.
Brake Master Cylinder Push Rod Master cylinder push rod retainers are available
Retainer - 1977-1978 CJ Models as an individual part part number 8129287,
With Manual Disc Brakes group 8.054. It is not necessary to order a
master cylinder push rod to obtain a push rod
retainer.
Batteries in CJ Models Built CJ models built after May 16, 1978 have a nylon
After May 16, 1978 strap around the battery and battery tray. This
strap is installed for transportation tie-down
only. It may be left on or removed, but is not a
necessary part after the vehicle has reached its
original destination.
Valve Train Noise - V-S Engines On some V-S engines, the valve rocker arm may
contact the spring retainer if the keepers sink toc
far into the retainer. To validate this condition
remove the retainer and inspect the bottom surface
for flaring. However; the presence of tooling
marks on the retainer surface will not affect the
operation or the durability of the retainer.

El Dealer Principal X Service Writer
X Service Manager X Mechanic No. 8-03 March 28, 1978
Subject Information
Spark Plug Fuel Fouling at Low Reports of wet-fuel-fouling of spark plugs on

Mileage - New Vehicles dealer inventory vehicles have been received.
This is the result of numerous start/stop engine
operations during transportation or dealership
maneuvering of inventory vehicles. This condition
predominately occurs during colder temperatures
in the winter months. This problem can be
prevented by occasionally bringing the engine to
operating temperature during the start/stop
maneuvering. It can be corrected, if it occurs,
by simply air drying or cleaning the effected
spark plugs.
1978 Jeep Technical Service Manual The torque specification for the front and rear
Revision Transfer Case
- output shaft yoke on page 20-11 of the 1978 Jeep
Technical Service Manual, Volume 2 should read as
follows:
Service Service
Set-To In-Use
Torque Recheck
120 Foot Pounds Torque
90-150 Foot Pounds
Quadra-Trac Use When Plowing Snow It is recommended that the Quadra-Trac emergency
drive be engaged when plowing snow on slippery
surfaces. This means that the Quadra-Trac
emergency drive light would be on and the control
in the glove box would be set in the red area.
This will prevent excessive exercising of the
limited slip clutches and prevent their damage.
However, it is imperative that the control in the

glove box be repositioned to the normal green
position immediately upon completion of snow
plowing.

7A-10Q
Service Technical Letter cont’dI
Subject Information
$adra-Trac - Front Output Shaft There has been a running change on the front out
Spline Change put shaft and yoke assembly splines. The earlier
splines had ten teeth, the later have twenty-
six teeth. If a Quadra-Thac assembly is to be
replaced, check the number of teeth on the front
output shaft; if necessary, order a new front yoke
with a twenty-six tooth spline. The new yoke
assembly part number is 8129363.
7QA Ifl
fl Dealer Principal LXJ Service Writer
LXI Service Manager Mechanic No. 8-02 November 18. 1977
Subject Information
T’pographical Error 1977

- The dimensional thickness of the direct clutch
Technical Service Manual, page flat steel plates, referenced in the note
7-50 and 1978 Technical Service immediately following step 9 should be changed
Manual, page 2C-53 from 0.0195 to 0.0915.
Battery Post Contamination The battery posts on some low mileage vehicles
All Models or service batteries may develop a condition,
referred to as "black post". If a no-start
condition is encountered, or when a new
battery is put into service, clean the battery
posts with a cylindrical wire brush and apply
a thin coat of grease.
Correction of Rear Wheel Cylinder The rear wheel cylinder dimension for CJ
Diameter - 1976 Technical models listed in the "Brake Size and Application
Service Manual, page 9-41 and Chart" is incorrect. Please change this
1977 Technical Service Manual, dimension from 15/16 inch to 7/8 inch.
page 9-47.
Fl Ameñcan Motors Sales Corporation

78.111
Q Dealer Principal Service Writer
fl Service Manager Mechanic tic. 8-01 September 15,1977
Subject Information
Rocker Arm Pivot Hole Off Some V-S engines with build date codes
Center -1978 Models With between 107N, P, ZZ0 and 107N, P, z16
V-8 Engines may experience a rough idle or a miss on
one or more cylinders. This condition
may be caused by the valve not seating
properly as a result of the rocker arm
pivot hole being slightly off center. If
this condition is encountered, replace the
rocker arms on any dead cylinders. Also
replace bridge pivots, if scored. A com
pression test should be performed to
isolate the dead cylinders.
NOTE Before replacing rocker arms

or bridge pivots, check ignition initial
timing and carburetion to be sure they
are set to specifications.

78-112
Subject: Six-Cylinder Camshaft Application: 1977-80 Jeep Vehicles Filet POWER PLANT
No. 80-3 Feb. 4, 1980
if incorrect valve timing is indicated after checking CAUTION: Do not loosen or disconnect
ing bolts and move condenser up and out
Service correction mvolves replacing a broken of way


ment.
1 Disconnect battery negative cable, by inserting G448423 screw into pin and
NOTE: Do not waste usable coolant, Collect drained located when center punching the pin.
2. Drill through pin center using 5/32.inch
3 Remove fan and shroud. 3 Insert G448423 screw into drilled pin
and carefully pull pin from camshaft.
radiator, prevent metal chips from entering the pan.

5 if equipped with air conditioning:

S.rvic. Enghieerlng Deportment . 14250 Plymouth Road * Detroit, Michigan 48232
79-1
CAUTION: If the camshaft moves rearward, repo light film of AMC Perfect Sal. or equivalent, on out
the camshaft cannot moist If the camshaft moves
result, Use vibration damper bolt to pull seal into front
14 Install camshaft gear and timing chain. Tighten cover. Turn bolt until tool bottoms against cover,
camshaft gear bolt to 50 foot-pounds 68 N’m
torque. Check valve timing as outlined in 1980 23 Remove tool arid install vibration damper on
108 N.m torque.
pounds 22 N’m torque and connect fuel lines. bolt torque value is reached, the damper can be held
from turning by placing two 5/16 X 1.1/2-inch bolts
sides of timing case cover gasket with sealer. Apply 24 If equipped with air conditioning:
1/8-inch 3 mm bead of sealer to joint formed at
pulley.
19 Position timing case cover on engine. Place 26 Install radiator, Connect radiator hoses, trans
screws.
pounds 9 N’m torque and 5/16-18 oil pan screws
to 11 foot-pounds 15 N’m torque.
24 N’m torque.
ment oil seal on tool with 11p facing outward. Apply 30 Connect battery negative cable.
YEAR AND TIME

CODE NUMBER LEVEL
77 75 79
PIN, SPRING CAMSHAFT GEAR

DRIVE- REPLACE 1.040 1163 6-CyL 1.7 1.7 1.7 1.7 G
With Air Conditioning- Add 0.3 0.3 0.3 0.3
sO-044.O1AIJ
79-2
Subject: New Timing Chain Assembly and Application: 1979 Jeep Vehicles with File: POWER PLANT
Deflection Inspection Procedure Eight-Cylind er Engines Engines
No.9-01 June 20.1979
A new timing chain, camshaft sprocket, and crankshaft RIGHT SIDE /
sprocket have been phased into production for eight- OF ENGINE

cylinder engines.
The new parts can be installed in previous year 304, 360,
and 40! CID engines as a set only, These parts can not be
used as replacements for the heavy-duty timing chain and
sprockets.
ROOT OF
CAUTION: The new chain and sprockets are not CAM SPROCKET -
interchangeable on a one for one basis with the previous Q TOOTH PUSH CHAIN
design components. If one component of the new design
is used, the other two components must he of the new
0 ,.-
OUTWARD
SCRISt ON
PUSH CHAIN
design. o INWARD SCRIBE
ON BLOCK
BLOCK
The new timing chain has different deflection

characteristics than does the previous design chain. The
following chain deflection inspection measurement
procedure is required to determine the necessity for
replacement.
The following pans are available and may be required: TOTAL
DEFLECTION
Description 7/8 INCH MAX.

Quantity Pad No. Group No. 22 MM
CHAIN, Timing I 3234433 1.130 Camshaft And Crankshaft Sprockets And

Timing Chain As Viewed From
SPROCKET, Front Of Engine
Camshaft I 3234234 1.134
SPROCKET,
Crankshaft I 3234235 1.132 4 Push chain in toward centerline of engine and mark
block at point of maximum inward chain deflection.
PROCEDURE
5 Pull chain outward from centerline of engine and
I Remove timing case cover. Refer to appropriate mark block at point of maximum outward chain
Technical Service Manual for procedure. deflection.
2 Rotate camshaft or crankshaft sprocket until all 6 Measure between the two marks to determine total
slack is removed from right side of chain. deflection.
3 Determine reference point on timing chain for 7 Replace chain assembly if deflection wear exceeds
deflection measurement as follows: 7/8 inch 22 mm.
a Measure up from dowel on left side of engine
3/4 inch 19 mm see illustration. 8 Install timing case cover following procedure in
b lay straightedge across timing chain from appropriate Technical Service Manual.
point at root of camshaft sprocket tooth to point 3/4 inch
19 mm above dowel The Standard Servicing Operation and work times as
c Grasp chain at point where straightedge published in the current 550 Manual are not affected by
dissects chain. Use this point for reference spot. this bulletin.
9-077-OIAIJ
‘I American Motors Sales Corporation
S.rvlc. Englnnring D.p.rtm.nt * 14250 Plymouth Road * D.troit, Michigan 48232
Additional copies of this bulletin are ava,lable ttwough your zone office.
79-3
Subject: New Voltage Regulator Tester Application: 1975-81 Jeep Vehicles File: POWER PLANT -
Engine Electrical
No. 81-1 June 11, 1981
A new voltage tester that will verify the condition of condition of a replacement regulator before installation.
voltage regulators used with 10-SI series Delco, Ki Also, when using the tester to diagnose a suspected
series Bosch, Motorcrait, and 8-AL series Motorola voltage regulator malfunction, be sure to follow the test
alternators is now available through the amserv pro- procedures outlined in the instruction manual supplied
grain under code number OT 60884. Because the new with each tester.
tester is capable of simulating the field, stator, battery,
ground, and indicator light circuits, the tester is able to The standard servicing operations and work times as
perform a complete check on all of the regulator published in the current SSO manual ae not affected by
operating modes. this bulletin.
The new tester should be used to verify voltage
regulator condition before replacement or to verify the
81-095-03413

S.rvlcs Engln.srlng Dpartm.nt * 14250 Plymouth Road * D&roit. Michigan 48232
Additional copies of this bulletin are available thmugfi your zone office.
79.4
__IL_icc

Subject: Tachometer RPM Drop Application: 1979 CJ Models File: POWER PLANT
When Operating Cigar Lighter or Equipped with Tachometer Engine Electrical
Backup Lamps
, No.9-04 Dec.7, 1979
The tachometer in some 1979 CJ-5 and CJ.7 models Ii I.

RED WITh
may indicate a false RPM drop when the cigar lighter RED
or backup lights are activated.
Service correction involves modifying the tachometer
wiring.
L_..J L il L-_J L_.J
PROCEDURE C rtnLp U PEP$4F

1 Open hood.
[uhUnUoLn’Th
3 Disconnect outer bulkhead connector inside

[ {0ED[DL1H1W1D
EJEJL__ICE- cJ
engine compartment from dash panel connector.
4 Reaching under instrument panel, remove screws C 1BIBDU__UUDOn
that hold fuse block to dash panel. Rotate fuse block irriri i
from hole in dash panel and separate fuse block from
dash panel connector. Rotate rear of fuse block so
-
that wires face out see illustration. C

5 Locate red wire and cut wire approximately
1-1/2 inches from fuse block see illustration. Tachometer Wiring Modification
Tape exposed end of wire to harness to ensure that
wire cannot contact any body components. 10 Connect fuse block and dash panel connector.
Position fuse block into dash panel and tighten retain
6 Strip approximately 1/2 inch of insulation ing screws.
from 1-1/2-inch long red wire attached to fuse block.
11 Connect outer bulkhead connector
7 Strip approximately 1/2 inch of insulation engine compartment.
from red with tracer wire about 1-1/2 inches from
fuse block see ifiustration. 12 Connect battery negative cable.
8 Join two stripped wires and solder joint with 13 Close hood.
rosin core solder or equivalent.
14 Reset clock and check operation of tacho
9 Wrap joint with electrical tape. meter.

YEAR AND TIME
LEVEL
CODE NUMBER 80 81
79
HARNESS, IN&FRUMENT PANEL- MODIFY 3.165 3347 83-93 0.3 0
9.118.oaJ
S.rvla Enginaring D.partna.nt * 14250 Plymouth Road * D.troit, Michigan 48232
Additional copies of this bolletin are available through your zone office.
79-5
Subject: Oil Pressure Gauges and Sending Application; All 1979 Ci Models File: POWER PLANT
Units Enginc Electrical
No. 9-03 February 21, 1979
Either a Stewart-Warner or Faria oil pressure gauge is If it becomes necessary to replace a gauge and sending
used in 1979 CJ Models. The Stewart-Warner gauge has unit, be sure they are replaced as a matched set only. Part
four terminals and requires a Stewart-Warner sending numbers for the gauges and sending units are as follows:
unit fig. 1. The Faria gauge has three terminals and
requires an Introl sending unit fig. 2. Description Quantity Part No. Group No.
NOTE: The gauges and sending units must be used as GAUGE,

matched sets only. They have djfferent resistance values Stewart-Warner
and cannot be interchanged. Oil Pressure 5460640 3.605
The same diagnosis and test procedures are used for both SENDING UNIT,
sets. When checking gauge operation, refer to the Stewart-Warner 5460643 3.605
following charts for correct resistance values.
GAUGE. Faria
STEWART-WARNER RESISTANCE Oil Pressure 1 5750279 3.605
VALUES OHMS SENDING UNIT,
40 60 80 Introl I 3212004 3.605
PSi 0 20
OHMS 234-246 149-157 101-106 65-69 33-35
FARIA RESISTANCE
VALUES OHMS
ftsi Oj 40 80
[OHMS 73 20 10
REAR ViEW - GAUGE SIDE VIEW - SENDING UNIT
Fig. 1 Stewart-Warner Oil Pressure Gauge and Sending Unit
OVER

Srvic. Enylnarlng D.partm.nt * 14250 Plymouth Road * Detroit, MIchigan 48232
Additional copies of this bulletin are available through your zone
ott/ce.
79-6
REAR VIEW - GAUGE SIDE VIEW - SENDING UNIT
Fig. 2 Faria Oil Pressure Gauge and Introl Sending Unit
The Standard Servicing Operations and work times as published in the current SSO manual are not affected by this bulletin.
9-057.035
79-7
Subject:AmmeterCircuitandWiringfliagram ApplIcation: 1978-79 Cherokee, File: POWER PLANT
Revisions Wagoneer, and Truck Models Engine Electrical
No. 9-02 February 13, 1979
This bulletin is being issued to revise the ammeter circuit

illustration for Cherokee, Wagoneer, and Truck models
on page IL-43, Volume I of the 1978 Technical Service
Manual and on page IL-45 of the 1979 Technical Service
Manual. The revised circuit illustration is shown in figure
1. In addition, the wiring diagram for Cherokee,
Wagoneer, and Truck models on page W-5 in the 1979
Technical Service Manual has also been revised to
identify splice "B" as shown in figure 2.
AMMETER
YELLOW
DASH
CONNECTOR
80293
Fig. 1 Ammeter Circuit - Cherokee -
Wagoneer Truck Models

-
Fig. 2 Wiring Diagram W-5 Cherokee - -
Wagoner Truck -
9-056-SGJ

ServIce Englnnrlng D.partm.nt * 14250 Plymouth Road * DetroIt, MIchigan 48232
79-8
Subject: Choke Jumper Harness Application: 1979 Wagoneer, Cherokee File: POWER PLANT
and Truck Models Equipped with a V-S Engine Electrical
Engine and Electric Choke
No.9-01 December8, 1978
Some 1979 Wagoneer, Cherokee and Truck models may 5 Install air cleaner if no corrections are necessary. If
have a choke jumper harness routed too close to the choke jumper harness needs routing corrected, refer to
choke heat tube or exhaust manifold. A new choke choke harness routing procedure. If choke jumper
harness routing procedure and replacement choke harness or engine harness needs replacing refer to harness
harness have been developed for extreme cases having replacement procedure.
choke harness heat damage.
Service correction involves routing the choke jumper CHOKE JUMPER HARNESS
harness away from the choke heat tube and / or exhaust ROUTING PROCEDURE
manifold. Replacement of the choke jumperharness, oil
pressure sending unit, and engine harness may be 1 Route choke jumper away from exhaust manifold
necessary if found to be damaged. and choke tube see illustration.
The following parts are available and may be required: 2 Install nylon tie strap around engine harness and
jumper harness loom approximately 1 inch from end of
Description Quantity Part No. Group loom see illustration.
HARNESS, Electric
Choke 1 5750277 3.169
SENDING UNIT,
Oil Pressure 1 3231347 3.605
HARNESS, Engine 1 5750029 3.165
STRAP,
Nylon Tie 1 3223227 3.165
INSPECTION PROCEDURE
1 Remove ai cleaner.
2 Inspect choke jumpeT harness for proper routing

and/or heat damage from choke heat tube or exhaust
manifold see illustration.
3 11 choke jumper harness has heat damage, inspect

engine harness for possible related damage.
4 Inspect oil pressure sending unit as described in

Chapter IL of 1979 Jeep Technical Service Manual.
TO OIL
NOTE: A defective oil pressure sending unit can cause SENDING UNIT
damage to the choke jumper harness.
Manual Transmission Vehicles
OVER

S.rvI Englnnrlng Dpartmnt * 14250 Plymouth Road * Detroit. MIchigan 48232
79.9
HARNESS REPLACEMENT 2 Replace engine harness if heat damaged by
PROCEDURE excessive heat.
3 Replace oil pressure sending unit if found to be

I If choke jumper harness has heat damage replace
harness and route as described in choke jumper harness defective during inspection.
routing procedure.
TO CARSURETOR
SOLENOID
BATTERY
FEED
TOOIL
[ING Urj
Automatic Transmission Vehicles

OPERATION SKILL
NUMBER LEVEL
CODE 77 7K 79
HARNESS, ENGINE CHOKE JUMPER AND
OIL PRESSURE SENDING UNIT -
INSPECT 3.165 3339 WAG-CKE.TRK 0.2 G

Harness, choke jumper - Reroute 3.165 A 0.1
Harness, choke jumper - Replace 3.165 B 0.1
NOTE: Combinations A and B cannot be used
together.
9-022-03.J
79-10
Altitude Performance
Subject: Application 1968-80 Jeep File: POWER PLANT -
No. $0.7 Nov. ID, 19S1
fonnance adjustments for 1968-80 Jeep vehicles re control label, part number EF 8130457, to the engine
adjustments are intended to improve driveability perfor component that an be readily removed from the
certified.
These unique labels are available in a kit, part number engine compartment to identify these vehicles.
Distribution Services On 1968-8OJeep vehicles originally sold foroperation at
The adjustment procedures and unique labels must he ment or specified in the apropriate Jeep Thchnical Ser
and the general public. A notification is also privicled in speed should be reset according to the procedures and
81-114-04A/J

Srvlc. Enginaring D.partm.nt * 14250 Plymouth Road * Detroit, Michigan 48232
Additional copies of this bulletin are available through your zone otf,ce
79-11
Subject: Engine Performance Application: 1979 Jeep Six- File: POWER PLANT
Diagnosis and Eight-Cy under Engines Fuel And Exhaust
. Systems
No. 9-07 Jan. 16, 1981
Procedures for diagnosing an engine rough idle or cold EGR Valve Opening Test
engine stalling at idle speed condition on 1979 Jeep six-
and eight-cylinder engines are outlined in Chapter 1A of NOTE: The engine must be at normal operating
the 1979 Jeep Technical Service Manual. Included temperature for this test.
among the possible causes for these conditions is faulty
EGR valve operation. To avoid an incorrect diagnosis of 1 Operate engine at hot curb idle.
these conditions, it is necessary to check EGR valve
operation to make sure that it is operating properly and 2 Open and close throttle rapidly and check for
that it does not stick open. Should an EGR valve stick movement of EGR valve diaphragm. Be sure
open, a greater than normal amount of exhaust gas throttle is opened enough to allow engine speed to
would be recirculated and ëould result in an engine reach 1500 rpm.
rough idle condition.
a If valve diaphragm moves, proceed to EGR
Valve Closing Test.
Service diagnosis involves checking the EGR system for
vacuum leaks, disconnected hoses, correct hose routing, b If valve diaphragm does not move, proceed to
and testing EGR valve operation as outlined in this next step.
bulletin and in Chapter 1A of the 1979 Jeep Technical
Service Manual. The EGE valve is an exhaust emission 3 Check vacuum hoses again, repair as necessary,
control system component and is warranted under the and repeat step 2.
5-year/50,000 mile emission warranty.
a If valve diaphragm moves, proceed to EGR
Valve Closing Test.
PROCEDURE
b If valve diaphragm does not move and
1 Check for leaking or disconnected vacuum hoses. vacuum hoses and connections are in good
condition, .proceed to EGE Valve Replace
a Repair or replace any leaking or disconnected ment.
hoses, verify service correction and return
automobile to owner. EGR Valve Closing Test
b If condition is not corrected, proceed to next NOTE: The engine must be at normal operating
step. temperature for this test.
2 Verify correct vacuum hose routing. Refer to 1 Operate engine at hot curb idle,
vacuum diagrams in Chapter 1J in 1979 Jeep
Technical Service Manual. 2 Press EGR valve diaphragm inward. Engine speed
should decrease immediately if valve is operating
a Correct hose routing if necessary, verify properly.
service correction and return vehicle to
owner. a If engine speed does not change and engine
idles properly, check for restricted passage
b If hose routing is correct and condition is stifi between valve and intake manifold, or for
evident, proceed to EGR Valve Opening Test. seized valve.

Srvlc. Englnnring Dpartm.nt * 14250 Plymouth Road * D.trolt, Michigan 48232
Additional copIes ol this bulletin are available thrnugh your zone office.
79-12
b If engine does not idle properly and speed is the EGR aystent The sensor must be removed, cleaned,
not affected greatly, check vacuum hoses and and installed when replacing the EGE valve.
connections again and check for seized value.
4 Clean mating surfaces of valve, manifold, and
3 If EGR valve diaphragm will not move when press- restrictor plate.
ed, valve is seized in open position. Proceed to
EGR Valve Replacement. 5 Assemble EGR valve, gaskets, and restrictor
plate.
EGR Valve Rplacement
6 Install EGE valve assembly and valve attaching
1 On eight-cylinder engines, remove air cleaner, bolts, Tighten bolts to 14 foot-pounds 19 N-rn
torque.
2 Disconnect vacuum hose at EGR valve.
7 Connect vacuum hose to EGR valve.
3 Remove EGR valve attaching bolts and remove
valve, gaskets, and restrictor plate. Discard 8 On eight-cylinder engine, install air cleaner.
gaskets.
The standard servicing operations and work times as
NOTE: On 304 GD eight-cylinder Jeep engines with published in the 1979 Jeep SSO Manual are not affected
California certification, a back-pressure sensor is part of by this bulletin.
9-123O1A/J
79.13
P1 Jeep
Diagnosis and Repair Bulletin No. Below
SIàJSCE Dale:
BACSENS CAMPAIGN 1rpe E Product Recall December 19, 1979 Revised
Campaign: Exhaust Gas Recirculating EGR Back-
Pressure Sensor Replacement and Adjustment of Idle Applicalion: 1974-1979 Jeep Vehicles
Mixture Setting Lean Idle Diop Specification Change See Application Chart Below
to 50 RPM for all Six-Cylinder Engines File: See Chart Below
JEEP APPLICATION CHART
1974 1975 1976 1976 1977 1978 1979

California California 49-State California California California California
360 CID 258 CID 232 CID 258 CID 258 OlD 304 ClD 304 CID
304 CID 258 CID 304 OlD 304 CID
306 OlD 304 CID 360 CID
401 CID 401 CID
FILING INSTRUCTIONS
Model TB/DRB
Year Group No. No.
1974-1975 4.000 TB-S
1976 4.000 TB-4
1977 4.000 TB-02
This is a ‘1pe E Campaign, subject to campaign proce Idle Drop Emissions Control Information Label. This
dures and involving emission-related elements which service is to be performed on all vehicles, regardless of
may result in non-compliance with Federal or State mileage returning for the recall repair.
emissions requirements. The combined owner notifica
tion and correction reporting card for this campaign is NOTE: THE LEAN DROP SPECIFICATION DIF
shown in Figure 1. FERS FROM THE SPECiFICATION IN THE SERV
ICE MANUAL AND ON THE EMiSSIONS LABEL
The zone will provide a yIN list for each dealer with any 6-CYLINDER ONLY. A LEAN IDLE DROP OF 50
vehicles involved. However, the campaign procedures RPM IS TO BE USED.
apply to all dealers. BACSENS Campaign Kits will be NOTE: If any portion of the EGR system has been
at the Zone PDC’s the week of October 22, 1979. altered or made inoperative, the vehicle is still eligible for
a free replacement bach-pressure sensor and 6-cylinder
Parts can be ordered, as needed, on or after October 24, vehicles are also eligible for an idle mixture adjustment.
1979. Additional parts andior labor required to make an al
tered system operational will be on a customer-pay basis
Some 1974-1979 Jeep vehicles have defective exhaust only. Ifyou encounter this situation, make sure customer
gas recirculation EGR back-pressure sensor valves. consent is obtained before proceeding with repairs.
Refer to Jeep Application Chart for model year and
engine displacement. Service correction involves re The 6-cylinder kit contains a new EGR back-pressure
placing the EGR back-pressure sensor with a newly sensor, gaskets and a combined Campaign and Lean Idle
designed sensor regardless of sensor’s present condi Drop Emissions Control Information Label and blue
tion, performing an idle mixture adjustment on all idle screw mixture limiter caps. The 8-cylinder kit,
6-cylinder engines, and affixing a Campaign Label 8- contains a new EGR back-pressure sensor, gaskets and a
cylinder or a combined Campaign and 6-cylinder Lean Campaign Label.
TI Am.rlcan Motors Sai*s Corporation
Service Engineerina D.partmenl * 14250 Plymouth Road * Detroit, MichIgan 48232
79-14
The following kits will be required: The BACSENS parts kits contain all necessary parts required to service a
vehicle involved in this campaign. THE SENSOR IS NOT TO BE ORDERED SEPARATELY AS IT IS A PART
OF THE BACSENS PARTS KIT.
Kit Sensor Year Engine Carb. Model 1I’ansnilssion

8130500 8129586 1975 Cal. 258, IV Cd M
1976 Cal. 258, IV Cd M,A
1977 Cal. 258, IV Cd M
8130502 8129588 1976 N/Wide 258, All Cd A,M

N/Wide 232, IV Cd M
8130505 8130392 1975 Cal. 360, 4V d-Series A

1976 N/Wide 304, 2V Cd M

Cal. 360, 4V d-Series M4,A
8130506 8130393 1976 N/Wide 304, 2V Cd A
8130508 8130395 1976 Cal. 304, 2V Cd M3
1977 Cal. 304, 2V Cd M3
1978 Cal. 304, 2V Cd M3
1979 Cal. 304, 2V Cd M3
8130507 8130396 1974 Cal. 360, 2V J-Series A

1976 Cal. 304, 2V Cd A
BACSEN’S REPAIR PROCEDURE
1 Remove air cleaner. 9 Install air cleaner

2 Remove vacuum lines from exhaust back-pressure 10 Start engine and verify EGR valve operation Refer
sensor and EGR valve. to appropriate Thchnical Service Manual for EGR check
3 Remove EUR valve, back-pressure sensor, restrictor ing procedure.
plate if applicable, and gaskets. 11 On 8-cylinder vehicles, affix campaign label beside
4 Manually pull EGR valve pintle off seat to ensure present underhood maintenance label See Figure 2-b.
freedom of movement. If EGR valve pintle moves freely,
proceed to step 5. NOTE: 13’pe campaign number 795 and dealer code
If EGR valve pintle does not move freely, clean pintle number on campaign label before affixing to vehicle.
area. If pintle does not move freely after cleaning, Apply clear film overlay to label.
replace EGR valve and proceed to step 6. 12 On 6-cylinder vehicles:
5 Clean EGR valve mounting surface. a Readjust idle mixture setting by idle drop
6 Clean manifold, restrictor plate if applicable, and method new specification is 50 RPM on all
all mating surfaces. 6-cylinder engines. Refer to appropriate Thchnical
7 Using new gaskets, install restrictor plate if appli Service Manual for idle drop procedure.
cable, new back-pressure sensor, and EGR valve. b Install blue limiter caps after 6-cylinder idle
Tighten attaching nuts to 13 foot-pounds 17 N.m tor mixture adjustment.
que. c Affix combined Campaign Label and 6-Cylinder
8 Connect vacuum lines to back-pressure and EGR Lean Idle Drop Emissions Control Information
valve See Figure 2-A & 2-b. If vacuum lines show signs Label beside present underhood maintenance label
of deterioration replace them. See Figure 2-a.
NOTE: Vacuum line from CTO switch must be NOTE: 23’pe campaign number 795 and dealer code
connected to back-pressure sensor nipple that has number on campaign label before affixing to vehicle.
030-inch restrktor Apply clear film overlay to label.
70.1 c
_________________
_____________
CARBURETOR
EGR PORT
EGR VALVE EXHAUST BACK

PRESSURE SENSOR
INNER
FRONT SPORT
0
Vacuum Hose Routing for 6-Cylinder non Vacuum I-lose RoutIng for 8-Cylinder AJ41263
TYPE RECALL CAMPAIGN NO. 795

HERE BEFORE AFFIXING LABEL
1 American Motors Corporation American Motors Corporation

RECALL CAMPAIGN CAMPAIGN
4 4
U NUMBER C0
D
2
2
BACK-PRESSURE TRANSDUCER BACK-PRESSURE TRANSDUCER
C
0
‘U TO THE EGR VALVE Ui TO THE EGH VALVE
I
2 2
cca. UNIT REPLACED BY DEALER 8 0. UNIT REPLACED BY DEALER
CODE NUMBERj I CODE NUMBER
ATTENTION
ALL 6 CYL. ENGINES
ADJUST TO 50RPM TYPE DEALER CODE HERE
BEFORE AFFIXING LABEL
LEAN IDLE DROP
I L
Campaign Label for 6-Cylinder Campaign Label for 8-Cylinder
Including Lean Idle Drop
Emissions Control Information
Fig. 2-a Fig. 2-b

CODE NUMBER MODEL 74 75 76 77 78 79 LEVEL
SENSOR EGA BACK-PRESSURE 4.890 4.295 6-cyl -4 -4 .4
Replace BACSENS Campaign 8-cyl -3 -3 -3 -3 -3 -3
Includes idle mixture adjustment

on 6-cylinder and replace EGR
valve and vacuum lines It required.
Condition Code Defect Code: 56
7tlA
__________________
CLAIM HANDLING
Several vehicles may be listed on a single warranty CAUTION: On multiple vehicle claims, do not delay
claim, reference Warranty Administration Manual, any claim so that CCL will receive it beyond the time
Section 7, Product Recall Campaigns. outlined in the Warranty Administration Manual.
The EGR Back-Pressure Sensors and the EGR’s that are

removed and replaced are returnable parts and must be
tagged and returned with your regular claim mateñal NOTE: All 1977 and prior model Jeep vehicle warranty
shipment. claims are eligible fora2S% parts mark-up. All 1978 and
subsequent Jeep vehicle warranty claims are eligible for
Complete and mail the reporting halfof the notification a 30% parts mark-up. See Warranty Bulletin 79-08 A/J
card Figure 1 for each vehicle as soon as campaign dated 9/1/79 for details.
flnp utlq.flqp ,IlOa*a

P50W qmcw Mfl I Notice of Ptothjct Recall Campaign Involving Youf VeiicI.
10W0dS USC u6,Sduno
ijoti,.i
‘tttSlOdloO nits liQict. OS,4Swv
yIN IV.rt. Idt,,tItc.t Ott Sttttr
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fl’ISSOS ON
111111 L J C,,saiy. . N..twis ise....
NotIce of Product R.caM CampSg. InvoMg You VeNd. Produot Recall c.m..Egn RtooflMg Card
OStCS IMe heLls
* I
IIydotW..M.rI.yt.ttI ø.....,CIItt
c*Io_ !flI* a I ItI.td MAIL RICTLY1O
AMcAN MOTO3 SttLESCORPORATIO..
.-----.---.-
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-----I--
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Fig. 1 - Owner Notification and Correction Reporting Card
79-17
Subject: Servicing Fuel Tank and Vapor Application: 1979 Jeep Wagoneers and File: POWER PLANT
Control System Expansion of P road ures in
- Cherokees Fuel and Exhaust Systems
1979 Technical Service Manual
No.9-OS Junelb,l979
The purposes of this bulletin are to clarify and expand Basic Procedure
upon the procedures that already appear in the 1979 Jeep
Technical Service Manual and to serve as a guide forany The basic service procedure includes:
in-the-dealership training. Its basic goal is to help you
assure careful, thorough and precise work whenever I Repair or replacement of damaged parts.
servicing the subject fuel tank and vent systems, whether
after an accident orfor other reasons. 2 Verification of the condition of all parts and
connections.
Background
3 Final testing of the serviced system.
In the interest of the quality of ambient air, it is important
to contain gasoline vapors as the fuel tank is filled and Repair or Replacement of Damaged Parts
during vehicle use. The fuel tank and vapor control
system of these vehicles is designed and built to permit In cases where collision damage has occurred, be sure
filling at normal pump rates and to contain fuel vapors that any needed repairs to the rear quarter panel, rear
during vehicle operation. The perspective illustration floorpan extension and rear wheelhouse panel have been
below shows the basic systems for 1979 models. Any completed. Then inspect the fuel tank and vapor control
servicing of a 1979 vehicle, using the procedures in this system components that attach to those pieces.
bulletin, must be done with care and thoroughness to
assure proper performance of the systems. Repair of the metal components in these systems is not
recommended. Straightening or rewelding metal tubes
Direct aid, including at-the-dealership instruction if that may have been bent significantly or gouged could
needed, is available from your Zone Service Department result in fatigue cracks and leakage. Whenever any metal
in order to help you get the best possible servicing results. part in these systems is damaged, it should be replaced
rather than repaired.
CANISTER-TO-VENT HOSE
LINE
TO FUEL !ILTER
R H CANISTER 8-CYL
I H CANISTER 6-CYL
1979 Wagoneer and Cherokee Fuel

Tank and Vapor Control System
OVER
S.rvlc. Engln..ring D.portm.nt * 14250 Plymouth Road * Detroit, Michigon 48232
79-18
Rubber hoses can be trimmed at the ends to assure a tight a If air does not flow from the canister-to-vent
seal only if there is enough hose stock remaining to hose or appears to be restricted, disconnect canister hose
prevent the hose from being stretched during use. Hose from the rollover vent tube assembly. Blow air through
damage at any other location would indicate the need for the upper small steel line as described previously. Air
replacement. should flow freely from the steel line where the canister
hose was disconnected.
Verification of Parts and Connections
If not, replace the rollover vent tube assembly, part
number 5358695. If so. locate blockage in canister line.
The most desirable verification process is the direct test Repair or replace as necessary.
method. This procedure describes that method.
NOTE: During this test, air should not escape through
I Visually inspect all components for external
any of the other outlets of the rollover tent tube
damage and for correct assembly Refer to the assemh/i’. If it does, replace the rollover tent tube
illustration for specific components and routing. assem h/i.
CAUTION: Before proceeding, he sure tank is no more
than 3/4 full. b If air does flow freely from canister-to-vent
hose, continue with step 6.
2 Disconnect filler neck hose, filler air vent hose, 6 Blow low pressure compressed air through the lower
tank-to-metal vent tube hose and rollover vent hose from small steel line of the rollover vent tube assembly. Air
the tank. Discard the old clamps removed from the filler should flow freely from the tank-to-metal vent tube hose
neck hose and filler air vent hose. and from rollover vent hose. Repair or replace as
3 Remove the rollover check valve from the rollover necessary.
vent tube assembly. Discard the rollover check valve. a If air does not flow from either hose, replace
the rollover vent tube assembly.
4 Disconnect the canister-to-vent hose from the b If air flows freely from one hose but not the
"tank" fitting on the charcoal canister. other, locate the blockage in the nonflowing hose or the
rollover vent tube assembly. Repair or replace as
5 Blow low pressure compressed air 2-3 psi through necessary.
the upper small steel line of the rollover vent tube c If air flows freely from both hoses, continue
assembly inside the quarter panel. Air should flow freely with step 7.
from the canister-to-vent hose.
ROlLOVER ROLLOVER VENT

CHECK VALVE TUBE ASSEMBLY
FILLER
FILLER
AIR
NECK
METAL VENT VENT ROLLOvER
AND TUBE HOSE
TUBE VENT
ASSEMBLY
HOSE
FILLER
NECK
HOSE
TANK-TO-
METAL VENT
TUBE HOSE
GROMMET
EXTENSION
VENT TUBE
FUEL TANK EXTENSION
Fuel Tank and Vapor Control

System Components
2
79-19
7 Insert and securely position a new Fuel tank filler 3 Use a bicycle tire pump suggested maximum size -
tube extension, part number 5359816. into tank filler IS inches long x I inch diameter to pressurize the system
tube. Reconnect the filler neck hose to the tank. Use new to 1.10 inches of mercury or until the column of water is
hose clamp, part number 3203077. IS inches higher than the zero pressure condition usually
about 30 strokes on the pump. Ifsystem pressurization is
not indicated by the manometer, check the systcm for
8 Insert and securely position a new fuel tank vent kinked, blocked, or disconnected hoses,
tube extension, part number 5359815. into tank vent
tube. Reconnect the filler air vent hose to the tank. Use NOTE: Do not pressuri:e the flu’1 system to niorc titan 3
new clamp, part number 3203077. inches of mercury 41.5 inches of’ Lt’ater. 1.5 psi.
9 Reconnect the tank-to-metal vent tube hose and 4 Apply a soapy water solution to every tube and hose
rollover vent hose to the tank. connection in the system. ‘heck each joint for air leaks
bubbles. Repair as necessary.
10 Check the routing of the filler neck, filler air vent,
rollover vent and tank-to-metal vent tube hoses. Be sure 5 Disconnect the tank-to-metal vent tube hose from
that no sags are present that could act as a reservoir for the metal vent tube. Plug the hose and tube with rubber
liquid fuel. Reroute and trim hoses if necessary. If the plugs, cork or similar item. Again, pressurize the system
filler neck hose or filler air Vent hose require trimming, as described in step 3. If system pressurization is not
use new clamps, part number 3203077. indicated by the manometer, recheck the system for
kinked or disconnected hoses. If the system does
II Install rollover check valve. As a matter of service pressurize, continue with step 6.
prudence, use a new valve, part number 5358297. Be sure
the valve is positioned vertically and that the fittings are 6 Remove the plugs from the tank-to-metal vent tube
tightened securely. hose and the metal vent tube. Reconnect the hose to the
12 Confirm integrity of complete system as described tube.
in final testing.
7 Pinch the rollover vent hose about one inch away
ATTENTION PARTS DEPARTMENT: For your from the rollover vent tube assembly. Pressurize the
convenience in parts ordering and stocking, a Venting system as described in step 3. If system pressurization is
Service Kit, part number 8/30408, group 4.141. which not indicated by the manometer, the rubber hoses are
contains 1-53598 15. 1-5359816, 1-5358297 and 4- assembled incorrectly or the metal vent tube is plugged.
3203077, is available. Repair or replace as necessary.
Final Testing of Serviced System 8 Disconnect the manometer. Reconnect the vent-to-
canister hose to the "tank" fitting of the canister.
This procedure requires the use of a manometer such as
Tool J-7090-0I which is available through Kent-Moore 9 Disconnect the tire pump from the fuel return line.
Tool Company. In the event that you do not already have Unplug the filter fitting and reconnect the return line to
a manometer, an illustration of how to fabricate one is the filter.
included with this bulletin.
Availability of Aid From Zone Service Department
I Disconnect the vent-to-canister hose from the
"tank" fitting of the canister if connected. Connect the As usual, if it appears that additional clarification or
hose to the manometer input. direct, in-the-dealership aid would enhance your own
efforts, contact your District Service Manager who will
2 Disconnect the fuel return line from the fuel filter in answer questions or schedule any needed training.
the engine compartment. Plug the filter fitting to prevent
fuel flow from the filter, connect air pump to fuel return
line.

OPERATION SKILL
NUMBER LEVEL
CODE 77 78 79
FUEL TANK/VENT SYSTEM - VERIFY
PARTS, AND CONNECTIONS 4.155 4017 WAG-CKE 1.0’ P
Includes Final Testing
Tube assembly, rollover vent - Replace 4.143 A 0.2
‘Includes 3 minutes helper time.

9-Ill 7-04.!
3
79-20
NYtON
TIE
STRAP
CLEAR
PlASTIC
HOSE
WOOD
BOARD
Manometer Construction
I Drill holes for hose attachment as shown in the

illustration.
2 Attach 6-foot length of clear plastic hose to board

using nylon tie straps, part number 3223227, inserted
through holes see illustration.
3 Fill hose with water to a point 15 inches from

bottom of ioop in hose see illustration.
79-21
Subject; Left Rear Quarter Panel Rattle ApplicatIon: 1978-79 Wagoneer and File: POWER PLANT
Cherokee Models Fuel & Exhaust Systems
No. 9-04 May 19, 1979
Some 1978-79 Wagoneer orCherokee models may havea 3 Remove inside rear quarter panel trim.
rattle in the left rear quarter panel area.
4 Cut insulation into strips approximately 2 inches x
This may be caused by movement of internal check ball 9% inches save any remaining for repair on another
and ramp inside the rollover check valve. vehicle.
Service correction involves wrapping the exterior of the 5 Completely wrap rollover valve with two insulation
rollover check valve with vinyl insulation, strips.
The following part is available and required: NOTE: Upon completion ofshe wrapping operation, be
sure the rollover valve female fitting is perpendicular to
Description Quantity Part No. Group No. the ficorpan of the vehicle.
INSULATION I 3693126 13.440 6 Install quarter panel trim.
7 Install spare tire carrier and tire if equipped.

PROCEDURE
8 Close tailgate.
1 Open tailgate.
2 If equipped with inside-mounted spare, remove

spare from carrier and remove carrier,

WARRANTY YEAR AND TIME -
-
OPERATION DEScRIPTION REPORTiNG MODEL - sJt
LEVL
CODE 77 78 79
VALVE, ROLLOVER - INSULATE 4.165 4201 CKE-WAG 0.2 0.2 6
lnsldemountedsparetlre-R&R 4.165 A 0.2 0.2 C
9-079’-BSJ

Srvla Englnndng Dsportmutt . 14250 Plymouth Rood * D.tvolt, MIchIgan 48232
Additionat copies of this bulletin are available through your zone office.
79-22
Subject: Inaccurate Fuel Gauge Reading at Application: 1979 Cherokee and File: POWER PI.ANT
Empty Caused by Incorrect Gas Tank Sending Wagoncer Models Fuel and Exhaust System
Unit Calibration
No. 9-03 April 30,1979
The fuel gauge in some 1979 Cherokee and Wagoneer REPAIR PROCEDURE
models may indicate empty when the tank still contains
between four and five gallons of fuel. This condition may I Remove fuel tank as described in 1979 Technical
be the result of an inaccurate fuel tank sending unit. Service manual.
the vehicle, removing the sending unit from the fuel tank - -
and reshaping the sending unit lever arm to correspond 3 Check sending unIt with an ohmmeter for
with the attached template. Any sending unit found with continuity through resistor for normal resistance change
previous rework should be discarded and replaced. as lever is moved through its full arc of travel.
a If sending unit is electrically faulty, replace it.
Before proceeding to the repair procedure, verily the b If sending unit is electrically accurate, proceed
accuracy of the fuel gauge by using the DARS charts on to step 4.
page of 1979 Technical Service If tests
indicate inaccuracy in the sending unit, proceed to the 4 Reshape sending unit lever to correspond with
repair procedure. If tests indicate inaccuracy in the fuel attached template.
gauge, refer to page IL-5 of the 1979 Technical Service
Manual for fuel gauge replacement procedure. 5 Install sending unit in tank.
6 Install fuel tank as described in 1979 Technical

Service Manual.

Op - SKILL
NUMBER LEVEL
CODE 77
SENDINGUNIT,FUELTANK-DIAGNOSIS.. 3.614 4197 KE-WAG 0.2 C

Sending unit - Remove, Adjust, and Install .... 3.614 A CKE-WAG 0.9 C
With skid plate Add 0.3
Sendingunit-Replace 3.614 B CKE-WAG 9.9 C
With skid plate Add - 0.3 C
NOTE: Combination A and B cannot he used
together. Both include drain, R & Rand re/ill
fuel tank as required.

Service Engineering Dportm.nt * 14250 Plymouth Rood * Detroit, Michigan 48232
Additional copies of this bulletin are available through your zone oflite.
79-23
1979 Cherokee and Wagoneer Model Fuel Tank Sender Template
79-24
Subject Warm Engine Operation - Application: Some 1979 Jeep Models FiIt POWER PLANT
Supplement to Diagnosis an d Repair Bulletin Built Before J9X15XX047200 and Fuel and Exhaust Systems
No. 9-01, Dated November 10, 1978 J9X25XX042459 Equipped with 360-
2V Engine and Automatic Transmission
Except Model 46 Trucks J-20
No. 9-02 January 25, 1979
Some 1979 Jeep vehicles with a 360-2V engine and auto- If visual inspection indicates that the vehicle is built
matic transmission were built with an optional component as described above, perform the DRB/1.sheet procedure
location of the EGR CTO and spark CTO switches. These except as follows:
components and their locations were referred to in the
subject bulletin and parts kit instruction sheet, 1-1446. * The EGR Cr0 switch that you should "lay aside
for later installation" in step 6 is the two-port switch.
On vehicles with the optional component location, the EGR
Cr0 switch a two-port switch is on the intake manifold * In step 8, the spark CFO switch is a three-port
and the spark CFO switch is on the thermostat housing. Cr0 switch and must be discarded. The new spark Cr0
switch provided in the kit must be used.
9-025-O4Jc

-Tn
Subject: Warm Engine Driveability Application: All 1979 Jeep Vehicles File: POWER PLANT
Equipped with 360-2V Engines and Fuel and Exhaust Systems
Automatic Transmissions Except
Model 46 TruckJ-20
No.9-01 November 10, 1978
Some of the subject vehicles may have any of several PROCEDURE

engine-related driveability conditions reported after the
initial engine warm-up. These conditions may have many
descriptions all relating to less than smooth, acceptable I Open EG R and Spark Control Kit and remove 63-
operation. inch length of hose. Cut hose into following lengths:
Engine-related driveability conditions may be corrected Hose Length Quantity

by adjusting ignition timing and carburetor settings to
the specifications listed in the 1979 Jeep Technical
Service ManuaL 2" ± 1/8" 3
If this does not fully remedy the reported condition, install 2!" ± I / w’
the following kit which will be available on November20, 24" ± I / 8"
1978. Do not order parts before this date.
Description Quantity Part No. Group CAUTION: Do not substitute hose lengths, hose size
0.157-inch 1. D. or hose routing when performing this
Kit, EGR and 1 8130406 4.700 procedure. Correct automatic’ transmission shift
Spark Control operation is dependent on proper vacuum signals at the
vacuum modulator. All emission and spark control
This kit consists of the following parts:
devices must he as specified and operational. Incorrect
Description Quantity Part No. vacuum hose lengths, hose routings or non-operational
emission related devices will cause a change in the
required vacuum signal at the automat ic transmission
E.G.R. Valve I 3233596 modulator and cause damage to the transmission.
Orifice Plate 3234775
2 Drain coolant from radiator.
Switch, CTO I 3229450 or 3216448
3 Remove air cleaner.
Valve. Vacuum Delay
Brown and White I 3235939 4 Remove original EGR valve and orifice plate.
Valve, Vacuum Delay 5 Install new FOR valve and orifice plate with new
Purple and Black I 3236284 gaskets fig. I.
Tee, Heater Nipple & 6 Remove EUR CTO switch from thermostat housing
EGR CTO I U 444150 and lay aside for later installation.
Gaskets 2 3221283 7 Install 3/8-inch pipe plug in thermostat housing in

place of original EGR CTO switch fig. I.
Pipe Plug G 444660
8 Remove original spark control CTO switch from
Label, Emission Control intake manifold and discard.
Maintenance. California 5359782
NOTE: For wrench and CTO switch turning clearance, it
Hose, 0.157 ID x 63.0" Long 8130407 may be necessary to disconnect the fuel line from the
carburetor and loosen the upper air conditioning
Instruction Sheet 1-1446 compressor bracket.
fl American Motors Sales Corporation

Service EngineerIng Department * Lt250 Plymouth Road * DetroIt, MIchIgan 48232
Acfciitionat copies at this bolIetin are available through your zone office.
9 Install new spark control CTO switch in right front 19 Remove original vacuum check valve and hoses
corner of intake manifold fig. I. between spark CTO switch and vacuum tee fitting.
NOTE: Connectfuel line to carburetor [disconnected in 20 Install vacuum delay valve brown and white in
step 8 and tighten upper air conditioning compressor vacuum circuit between spark CTO port I and vacuum
bracket 1 equipped. source. Use 2-inch and 10-inch lengths of vacuum hose
fig. I.
10 Disconnect heater hose from heater hose nipple
located on right rear of intake manifold. NOTE: The vacuum delay valve must be installed with
the white side installed toward the vacuum source.
II Remove vacuum fittings at right rear of intake
manifold to provide turning clearance for heater hose 21 Connect 21-inch long vacuutn hose to spark CTO
nipple. center port 0 and distributor vacuum advance fig. I.
12 Remove transmission filler tube to engine bolt and 22 Connect existing hose from carburetor spark port to
move filler tube to provide turning clearance for heater spark CTO switch number 2 port fig. I.
hose nipple.
23 Install delay valve purple and black in EUR CTO
13 Remove heater hose nipple from right rear corner of vacuum circuit between CTO switch port F and existing
intake manifold. vacuum tee at EGR valve. Use two. 2-inch lengths of
vacuum hose fig. I.
14 Install heater nipple and EGR CTO switch tee
fitting in right rear corner of intake manifold fig. I. NOTE: Install vacuum delay valve with black side
toward the EGR CTO switch.
IS Install heater hose nipple in tee fitting.
24 Connect port 5 on EGR CTO switch to FOR port
16 Install EGR CTO switch in tee fitting fig. I. on carburetor. Use 24-inch length of vacuum hose fig. I.
Connect heater hose to nipple.
25 Move accelerator pump rod to number 4 hole in
17 Install vacuum fittings in right rear corner of intake overtravel lever fig. 2.
manifold.
26 Carefully scribe letter on carburetor
IS Return transmission filler tube to original position identification tag located on left front corner of
and install retaining bolt. carburetor to identify pump rod modification.
HOSE
VACUUM
DELAY VALVE
BRO.l/WHITE
SWITCH
Fig. I Hose Routing
-2-
79-27
27 Install air cleaner.
2 Fill radiator with coolant.
29 Check operation of engine and check for coolant

leaks.
30 Install new emission control label on California PUMP

vehicles only. LEVER
Fig. 2 Accelerator Pump Stroke Adjustment
WARRANTY YEAR AND liME

OPERATION DESCRIPTION REPORTING OPERATION - SKILL
CODE NUMBER MODEL 77 78 79 LEVEL
KIT, EGR AND SPARK CONTROL -
INSTALL 4.701 4291 15,16,17,18,25,45 - - 1.0 C
9-025-04J
-3-
79-26
Subject: Improved Procedurea for Clutch Application: 1977-79 CJ Models File: CHASSIS
-
Group 6.000
No. 9-02 July18, 1979
Improved procedures for replacing the clutch over- NOTE: As the spring is pulled forward, it will ride
necessary.
see illustration.
wire through grommet hole. Wrap wire around 1 Disconnect clutch pedal push rod at bellcrank.
contact any of the brahelines during overcenter 5 Feed 3.foot long double strand of mechanics
spring removal or installation, wire through windshield washer grommet hole.
6 Connect replacement overcenter spring to contact any of the brahelines during overcenter
brake pedal support bracket. spring removal.
in pedal slot. remove clutch p da1 from shaft.

S.rvlcs Englnnrlng D.povtmnt . 14250 Plymouth Rood * D.trolt, MichIgan 48232
79.29
9 Install replacement clutch pedal on shaft and NOTE: As the spring is pulled forward, it will ride
11 Connect clutch pedal push rod to belicrank. 15 Install windshield washer hose grommet
in dash panel.
support bracket. 16 Connect battery negative cable.
spring slides into and seats in pedal slot, necessary.
WARRANTY OPERATION YEAR AND TIME

SKILL
NUMBER LEVEL
CODE 78 19
PEDAL, CLUTCH-REPLACE 5.135 5006 83-93 . 4 .4 .4 G

REPLACE 5.973 5010 83-93 . 3 . 3 . 3 G
9-100-05J
7930
VU Jeep
Application: 1979 Cl-S and CJ-7 Models

Equipped with Manual Transmission
as Specified Below
CHASSIS, Clutch-Manual
File: Transmission
This is a Type "5" Product Recall Campaign subject Part Dealer

to all campaign procedures and involving safety- Description Qty. Number Group Net
related elements. A copy of the combined owner notifi
cation and correction reporting card for this campaign Gasket, transfer 1 5359022 18.001 .35
is shown in Figure 2. case to trans
mission with
3-speed
Some 1979 Jeep CJ-5 and CJ-7 model vehicles equipped transmission
with 3-speed or 4-speed manual transmissions built
between VIN’s J9F93EC067887 and J9F83AC098774 Gasket, transfer 1 936615 6.053 .35
may have an incorrect transmission-to-transfer case case to trans
gasket. mission with
4-speed
transmission
On three-speed transmissions the incorrect gasket
will prevent lubricant interflow between the trans INSPECTION PROCEDURE
mission and transfer case. This condition can result
in the gradual transfer of transmission lubricant into 1 Look inside vehicle to determine whether vehicle is
the transfer case. On four-speed transmissions the in equipped with 3-speed or 4-speed manual transmission.
correct gasket will allow lubricant to leak directly out
of the transmission. If lubricant transfer or leakage 2 Raise vehicle.
occurs, the transmission will eventually become
damaged and inoperative. 3 Inspect transmission-to-transfer case gasket. In
spection area is junction of forward face of transfer
case and side of transmission 3-speed or transmission
Service correction involves inspecting the adapter 4-speed, on passenger side of vehicle. Use
transmission-to-transfer case gasket on all vehicles work light or flashlight to view inspection area clearly.
involved and replacing it with the following correct This inspection area is shaded in Figure 1.
part if necessary. Refer to the Gasket Inspection
Procedure. a With 3-speed transmission, the entire shaded
area in illustration should be covered by transfer
case-to-transmission gasket material. If the in
Under separate cover, the Zone should have already spection area is completely covered by gasket
provided a VIN list to each dealer with vehicles in material, the correct gasket is in place and no
volved. However, the campaign procedures apply to further work is necessary. If gasket material is
all dealers. On each undelivered campaign involved not visible in the inspection area, the incorrect
vehicle, theinspection/correction must be made before gasket may have been installed, and the transfer
the vehicle is sold or otherwise put in service. case-to-transmission gasket must be replaced
with the correct gasket, part number 5359022.
The following parts may be required and are available b With 4-speed transmissions, transfer case-to-
from your local PDC. transmission adapter gasket material should

Service EngIneerIng Department * 14250 Plymouth Road * Detrell, MichIgan 48232
79-31
not be visible in the inspection area. If gasket 48 Remove rear crossmember.
material is not visible, the correct gasket is in
place and no further work is necessary. If the 9 Disconnect front and rear propeller shafts at trans
entire inspection area is completely covered fer case. Mark position of shaft yokes for assembly
by gasket material, the transfer case-to- reference.
transmission adapter gasket must be replaced -
Use gasket part number 936615. 10 Disconnect speedometer cable at transfer case.
Ic If correct gasket is in place, lower vehicle and 11 Remove bolts attaching transfer case to trans
return to owner. If incorrect gasket was in mission and remove transfer case.
stalled. replace gasket. Refer to gasket replace
ment procedure. 12 Remove and discard transfer case-to-transmission
gasket.
INSTALLATION
1 Clean gasket surfaces of transmission and transfer
case thoroughly.
2 Position correct replacement transfer case-to-

transmission gasket on transmission.
3 Install transfer case on transmission and install

transfer case attaching bolts. Tighten bolts to 30 foot-
pounds 41 N.m torque.
4 Connect front and rear propeller shafts to transfer

case. Be sure to align shafts and yokes using refer
ence marks made during removal. Tighten shaft-to-
yoke clamp strap nuts to 15 foot-pounds 20 N.m
torque.
INspEcTION AREA 90298 5 Connect speedometer cable.
FIg. 1 Inspection Area 6 Position rear crossmember on frame rails and

loosely install two crossmember bolts to hold cross-
member in place.
GASKET REPLACEMENT PROCEDURE
7 Align rear support cushion studs in rear cross-
REMOVAL member and install stud nuts and washers-
1 Remove transfer case shift knob, trim ring, and 8 Connect torque reaction bracket to rear cross-
boot. member and install remaining crossmember attaching
bolts.
2 Remove front floor carpeting.
9 Remove engine support stand.
3 Remove transmission access cover plate from
floorpan. 10 Fill transmission and transfer case to level of fill
holes with SOW-90 or SAE 90 gear lubricant.
4 Raise vehicle.
11 Lower vehicle.
5 Drain lubricant from transfer case. Install drain
plug when case is emptied of lubricant. 12 Install transmission access cover plate on
floorpan.
6 Disconnect torque reaction bracket from rear
crossmember 13 Install carpeting on front floor.
7 Position support stand under clutch housing to 14 Install transfer case shift lever boot, trim ring,
support engine and transmission. and knob.
79-32
Warranty Year and Time

Operation Description Reponing Operation Model - - - Skill
Code Number 77 78 79 tent
Gasket, Transfer Casa-to-Transinissinn/Adapte,
- Inspect 18.003 18003 83-93 - 0.1 6
Gasket, Transfer Case-to-Transmission/Adapter
- Replace 1t004 A 3-Spd 11
- - C
4-Spit - - L3 C
Applicable Defect Code: 56
CLAIM HANDLING tion card Fig. 2 for each vehicle as soon as campaign
Several vehicles may be listed on a single warranty
claim, reference Warranty Administration Manual, CAUTION: On multiple-vehicle claims, do not delay
Section 7, Product Recall Campaigns. any claim so that CCI will receive it beyond the time
limit outlined in the Warranty Administration
Complete and mail the reporting half of the notifica- ManuaL
-
- flp ut&qalfl -1101100
E peo InnowAld o*i
UDUOS 6U!pOde S400 usledweo
Notice of Product ReCaP CampaIgn InvoMmg Your Ve4ilcIe
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EEI Notice of Product Recall Campaign Involving Your Product R.call CanpaIgn R.poqtlng Card
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Fig. 2 Owner Notification and Correction Reporting Card
79-33
Subject: New Automatic Transmission Application: 1979 Jeep Models with File: CHASSIS
Forward C lutch, Direct Clutc h and Oil Pump Automatic Transmission Automatic Transmission
Assemblies
No. 9-03 May 10, 1979
The forward clutch, direct clutch and oil pump When servicing the forward or direct clutch, discard the
assemblies used in 1979 Jeep automatic transmissions original waved steel plate and assemble the clutch using
have been changed. The new components were phased the exact number of steel and composition plates
into production beginning with the transmission serial specified in the Clutch Plate Application Chart. In
numbers listed in theTransmission Identification Chart. addition, when servicing the forward clutch, discard the
original clutch piston and replace it with the new part
The forward and direct clutch changes include a new listed below.
forward clutch piston and an increase in the number of When servicing the oil pump, discard the original oil
steel and composition plates used in both clutches. In pump pressure regulator booster valve, valve bushing
addition, a new thicker 0.0915 inch 2.33 mm flat steel and pressure regulator spring and replace them with the
plate is used for both clutch applications. To new parts listed below.
accommodate the increased clutch plate usage, the waved
steel plate was deleted from both clutch assemblies. Refer The following parts are available and required:
to the Clutch PlateApplication Chart for clutch plate usage.
The oil pump assembly has a new pressure regulator
booster ‘valve, valve bushing and spring. These new PISTON, Forward
components provide an increase in transmission Clutch I 8130416 6.595-3
operating pressure of approximately 10 psi 69 kPa. The
pressure increase is required for effective operation of the BUSHING and Valve,
new higher capacity clutch assemblies. Transmission Pressure
Regulator Booster I 8131698 6.512-1
Although the new components can be used in 1979
transmissions built prior to the listed serial numbers, the SPRING, Transmission
following precautions must be observed. Pressure Regulator I 8131699 6.512-3
TRANSMISSION IDENTIFICATION CHART
Model Application Serial Number
400 JC Six-Cylinder i-5 and 7 3177
400 is Eight-Cylinder ‘i-S and 7 4217
400 i M Chcrokee-Wagonecr 22388
400 JK Six-Cylinder J-lO Truck 2078
48 iR Eight-Cylinder .t-l0.,l-20 Truck 5056
CLUTCH PLATE APPLICATION CHART

Forward Clutch Direct Clutch
Flat Steel Composition Flat Steel Composition
Plates Driven Males Drive Plates Driven Plates Drive
400iC 5 5 4 4
400JS 5 5 4 4
400iM 5 5 5 5
400JK 5 5 4 4
400JR 5 5 5 5
Flat Steel Plates are all .0915-inch 2.33 mm thick.

9-072-OSJ
Service Engineering Department * 14250 Plymouth Road * Detroit, Michigon 48232

Additional copies of th,s bulletin are available through your zone of/ice.
79.34
Subject: Fluid Overflow From Automatic Application: 1977-79 Jeep Models with File: CHASSIS
Transmission Fill Tube or Vent Tube Caused Automatic Transmission Automatic Trans.
by Overfill or Vent Tube Restriction Group 7.000
No. 9-02 April 30, 1979
On some 1977-79 Jeep models with automatic 3 Check transmission fluid level as outlined in
transmission, fluid may overflow from the transmission appropriate Jeep Technical Service Manual. If fluid level
with owner.
Service correction involves verifying the overflow a If overflow does not occur during road test,
condition, inspecting the vent tube for restrictions, return vehicle to owner.
checking the fluid level and calibrating the transmission b If overflow does occur during road test,
NOTE: If an overflow condition occurs onlt when

PROCEDURE towing a trailer, the road test must he conducted with the
trailer in tow.
I Inspect transmission fill tube and vent tube for 4 Raise vehicle on hoist, Loosen vacuum modulator
evidence of fluid overflow. adapter retainer bolt. Pull modulator outward
a If tubes do not have evidence of overflow, approximately 1/2 to I-inch and drain one pint of fluid
b If tubes exhibit evidence of overflow, proceed modulator attaching bolt after draining fluid. Iower
to next step. vehicle and road test to verify correction.
2 Check transmission vent tube for restriction by 5 Check fluid level again and file new mark on
inserting length of stiff wire into tube. transmission dipstick at adjusted fluid level.

OPERATION SKILL
OPERATION DESCRIPTION REPORTING MODEt -
NUMBER LEVEL
CODE 77 78 79
OVERFLOW, AUTOMATIC TRANSMISSION-

DIAGNOSE AND ‘ORRET 16.022 16205 0.8 0.8 0.8 C
9.063-I7J

Add,t,onat copies of this bulletin are available through your zone otl,ce.
79-35
Subject: 1979 Jeep Technical Service Manual Application: All 1979 Jeep Modelswith File: CHASSIS -
Correction Automatic Transmission DARS

- Automatic Transmission Automatic
Chart Transmission
No.±!-01 October 27, 1918
The DARS Chart on page 2C-l5 of the 1979 Jeep Technical Service Manual needs to have the instructions and illustrations
revised as follows:
9-019- 16J

79-36
_________
A

Procedure With Quadra-Trac Transfer Case Transfer Case/
Quadra-Trac
No. 9-01 Jan. 12, 1981
This bulletin supercedes Technical Bulletins Number 2, PROCEDURE

Series, and Number 13, 7300 Series, Group 18.000, 1 Inspect vehicle tires. Tires must all be same size,
dated February 9, 1976. Remove and destroy these type, make, and tread design. Correct if necessary.
bulletins and replace them with this current bulletin.
2 Check and correct tire inflation pressures if
The Quadra-Trac transfer case in some 1973-79 Jeep necessary. All tires must be inflated to recom
vehicles may develop a low frequency pulsating grunt mended pressures and not vary by more than 1/2 to
ing, or rasping noise that occurs when cornering at slow 1 psi 3.45 to 6.895 kPa.
speed or when parking the vehicle. This noise may occur
if the Quadra-Trac differential brake cones tend to stick 3 Raise hood and raise vehicle on hoist.
values. This condition is referred to as stick-slip. 4 Check transfer case lubricant level. If level is low,
inspect for leaks and correct as necessary.
lubricant has been developed to correct stick-slip. When 5 Inspect transfer case vent. If transfer case is
the new lubricant is used, a transfer case remote vent equipped with remote vent tube that is routed into
kit must also be installed. Because water adversely engine compartment, proceed to step 8. If
affects performance of the new lubricant, the vent kit transfer case does not have remote vent tube, pro
must be used to prevent water entry and lubricant ceed to steps 6 and 7 for vent kit installation.
contamination.
6 On CJ models, install remote vent kit as follows:
sizes, and types, draining and refilling the transfer case a Clean vent area and remove and discard
b Apply silicone sealant to threads of replace
NOTE: Th new Quadra-Trac lubricant is intendedfor ment vent tube fitting and install fitting on
use in vehicles exhibiting stick-slip. For vehicles that do transfer case.
not exhibit stick-slip, the current Quadra-Trw, lubricant,
part number 5358652, remains the normal replacement c Cover straight end of vent tube with tape.
lubricant.
The following parts are available and required. above crossmember and to rear of transfer
case. Rotate. curved end of tube upward and
Description Quantity Part No. Group Remove tape from straight end of tube.
LUBRICANT, Quadra e Cut and connect four-inch length of vent tube

Trac AR 8130444 18.500 hose to vent tube fitting and vent tube.
STRAP, Tie AR 3223227 3.165 CAUTION: The hose must be securely connected to the
KIT, Vent 1 8130445 18.500 fitting and tube to prevent water front entering the
Kit Contents:
Vent Tube Hose I step 8.
Service Engineering Deportment * 14250 Plymouth Road e Detroit, Michigan 48232
79-37
7 On Cherokee, Wagoneer, and Truck models, install unit to drain completely. If transfer case is
onginal vent tube fitting.
b Apply silicone sealant to threads of replace foot-pounth 27 N-rn torque. If equipped with
ment vent tube fitting and install fitting on reduction unit, seat unit in transfer case and
transfer case. tighten reduction unit attaching bolts. Tighten
3/8-16 bolts 20 foot-pounds 27 N-m torque.
c Lower vehicle. Tighten 5/16-18 bolts to 9 foot-pounds 12 N-rn
torque.
10 Fill transfer case and reduction unit, if equipped,
e Insert straight end of vent tube downward with new Quadra-Trac lubricant. Transfer case
lower straight end of tube to rear of transfer Reduction unit requires one pint, if equipped.
modulator vacuum tube. NOTE; Shake the Quadra-Trac lubricant container
vigorously beforefilling the transfer case. It is important
f Secure upper curved end of vent tube to that the lubricant be mixed thoroughly before use.
strap.
11 Install and tighten transfer case fill plug to 20 foot-
g Close hood and raise vehicle. pounds 27 N.m torque.
to vent tube fitting and vent tube.
13 On CJ models, secure upper curved end of vent
CAUTION: The hose must be securely connected to the tube to vacuum modulator vacuum tube using tie
fitting and tube to prevent water front entering the strap and close hood.
I Secure vent tube to transmission filler tube counterclockwise for approximately 15 minutes to
and Quadra-Trac Emergency Drive vacuum circulate lubricant throughout transfer case.
tube using tie straps and proceed to step 8.
8 Position drain pan under transfer case, remove CAUTION: Do not turn to or hold the steering wheel at
drain and fill plugs from transfer case and allow the stop position when driving the vehicle in circles.
YEAR AND TIME

QPERATION OESCRIPTION MODEL
CODE NUMBER LEVEL
1973-1919
STICK-SLIP, QUADRA-TRAC CORRECT - 18.670 18395 Cke-Wag 0.6 6

Includes lubricant change and 15 minute Trk-CJ-7
driving time
With reduction unit - Add 0.2
Vent Kit Install
- 18.670 A 0.3 6
9-122-181
79-38
Fl Jeep
Date: June 19, 1980
Subjec Application: 1979-80 Jeep
paign
Cherokee, Wagoneer and J-10
May
‘Thucks
File: CHASSIS-Prop.
Shaft-Axles
This is a b’pe ‘tS" Product Recall Campaign subject to all limited, replacement rear wheel bearing kits are not to
campaign procedures and involving safety-related be ordered for dealer stock!
elements.
Some 1979 and 1980 Jeep Cherokee, Wagoneer and J-10
1uck models equipped with the AMC/Jeep rear axle 1 Raise and support vehicle.
built between 1979 VIN numbers J9A18NN069283
and J9F45NC154704 and 1980 VIN numbers 2 Inspect rear axle housing cover to determine what
JOE1SNN000048 and J0D45NN024993 may have rear type of axle is in vehicle.
wheel bearing retainers and seals on some of the subject
models which may have been assembled improperly a If axle has round, dome shaped cover Fig. 1,
during production. This condition could result in wheel vehicle has AMC/Jeep axle and will require repair if
bearing damage and possible disengagement of the campaign identification mark is not present. Place
wheel and axle shaft from the axle while the vehicle is in campaign-inspection identification paint mark on
motion. cover Fig. 1 and proceed to repair procedure.
Service correction involves an inspection to determine b If axle has oval, irregular shaped cover Fig. 1,
what type of axle Dana or AMC/Jeep is in the vehicle vehicle has Dana axle and does not require any
and replacement of BOTH right and left rear wheel repairs.
bearings, seals, retainer rings, and retainer plates on
AMC/Jeep axles. 3 Lower vehicle.
The following parts kit is required:
NOTE: Each vehicle will require TWO kits.
Part
Description Qt No, Group Price
KIT, Rear Wheel
Bearing 2 8130510 8.300 $13.40
KIT Contents: inner oil seal, retaining ring,

wheel bearing, outer seal, retainer plate AMC/JEEP AXLE DANA AXLE
HOUSING HOUSING
COVER COVER
The Zone will provide a YIN list and an initial supply of
parts equal to 40% of the vehicles on your VIN list for FIg. 1 Axle Housing Cover Identification
each dealer with any vehicles involved. However, the
campaign procedures apply to all dealers. On all JEEPAXLE REPAIR PROCEDURE
undelivered, campaign-involved vehicles, the
correction must be made before the vehicle is sold or Axle Shaft and Bearing Removal
otherwise put in service.
1 Raise and support vehicle and remove rear wheels.
July 7, 1980. Because campaign parts supplies are 2 Remove rear brake drums.
Service Engineering Department * 14250 Plymouth Road * Detroit, MichIgan 48232
79-3 9
NOTE: Make sure that the brake linings are kept free of
grease and oil.
3 Remove nuts attaching brake support plates and

retainers to axle tube flanges. Nuts are accessible
through holes in axle shaft flanges.
4 Remove axle shafts using Adapter Ibol J-21579 and

Slide Hammer J-2619-O1 See Fig. 2.
TOOL TOOL
J-21579 J-2619O1
/
Sc,
Fig. 3 Notching Bearing Retaining Ring -
Cherokee-Wagoneer-J-1O Truck Axle

70543
8 Pack wheel bearing lubricant in cavity of
Fig. 2 Axle Shaft Removal -
replacement oil seal and between seal lips and install
Cherokee-Wagoneer-J-1 0 Duck seal on axle shaft seat. Outer face of seal must face axle
shaft flange.
5 If cup portion of wheel bearing assembly remains in
the axle housing after the axle shafts are removed, NOTE: In order to prevent damaging the seal, it is
remove the bearing cups using tools J-2619-01 and important that the seal lips be lubricated before
J-26941. installation and that the seal lips contact the machined
portion of the shaft only.
6 Remove axle shaft inner oil seals from axle housing
tubes. 9 Pack replacement wheel bearing with wheel bearing
lubricant. Force lubricant through cup rib ring end
Axle Shaft Bearing Replacement until it comes out at other end, around bearing.
CAUTION: Under no circumstance should the axle 10 Install wheel bearing on axle shaft. Be sure cup rib
shaft retaining ring or bearing be removed using a ring is facing axle shaft flange.
torch. Heat will transfer into the axle shaft bearing
journal and weaken it. 11 Install bearing retainer ring on axle shaft.
1 Mount axle shaft in vise. Use protectivejaws on vise 12 Press bearing and retainer ring on axle shaft
to avoid scratching or damaging shaft. simultaneously using tool J-22192-01 or .J-23674 and
2 Drill ¼-in. 6mm diameter hole in retaining ring.
Hole depth should be approximately three-fourths of
ring thickness.
CAUTION: Do not allow drill to contact the axle shaft.
3 Position a chisel over the drilled hole in the

retaining ring and cut a deep groove in the retaining
ring with the chisel. This will enlarge or split the ring
allowing the ring to be removed from the axle shaft See
Fig. 3.
4 Slide retaining plate and oil seal toward axle shaft

flange to provide room for bearing removal tool between
seal and bearing.
5 Remove axle shaft bearing using arbor press-and tool

J-22912-01 or J-23674 See Fig. 4.
6 Inspect axle shaft bearing and seal surfaces for

scratches. Remove scratches using crocus cloth.
Fig. 4 Axle Shaft Bearing Removal -
7 Install retainer plate on axle shaft. Cherokee-Wagoneer-J-10 ‘Duck Axle
79-40
arbor press. Be sure bearing and retainer ring are CAUTON: This procedure is necessary to ensure that
properly seated squarely against axle shaft shoulder. the seal and bearing cup rib ring are seated squarely in
the axle tube. The seal can be damaged if this procedure
NOTE: When the seal and bearing seat against each is not followed.
other; some lubricant should be forced out of the other
side of the bearing.
Axle Shaft and Bearing Installation
1 Clean inner oil seal and bearing bores in axle

housing tube and install replacement inner seal using
tool J-25135-01, then apply wheel bearing lubricant to
seal and to bottom one-third of cavity between §eal and
bearing bore shoulder.
2 Apply thin coating of wheel bearing lubricant to

outside diameter of wheel bearing cup and outer oil seal.
CAUTION: lhke care to avoid damaging the oil seal

when installing the shaft.
3 Insert splined end of shaft into differential side gears

and start cup rib rings and seals into axle tube.
FIg. 5 Axle tUbe Flange Bolt and Nut
4 Align retainer plate and bolts and push axle shaft Tightening Sequence
into housing as far as possible. Install nuts on bolts
finger tight only. 6 Tighten nuts to final torque of 50 foot-pounds 68
N.m torque in a cross pattern Fig. 5.
NOTE: The outer oil seal must be squarely seated
against the bearing. 7 Install rear brake drum, locknuts and wheels.
Tighten rear wheel nuts to 72 foot.pounds 98 N.m.
5 ‘lIghten all nuts alternately and evenly in a cross torque.
pattern Fig. 5 to approximately 15 foot-pounds 20
N.m. torque to seal and cup rib ringevenly in axle tube. 8 Remove supports and lower vehicle.
ALPHA
SERVICE CODE YEAR & TIME SKILL
OPERATION DESCRIPTION FOR CLAIM MODEL -79- -80- LEVEL
REAR AXLE - inspect & Identify

Includes Drive-in/Drive out A Wag-Che Truck 0.1 0.1 0
BEARINGS, REAR AXLE SHAFT Replace both sides
-
includes inspection and Drive-in/Drive-out B 1.4 1.4 6
CLAIM HANDLING & CAMPAIGN REPORTING Cover Sheet: contains instructions for the owner and
shows the dealer where to imprint his dealer plate.
Owners of record will be mailed the AMC and Jeep CCD Copy: to be submitted to CCD for campaign
combined Product Recall Campaign Notice and Claim reporting and crediting.
Form Fig. 6. This form is to be used in place of a
warranty claim and a campaign reporting card.
Factory Copy: to be used as a packing copy for
returnable parts when required.
This Product Recall Campaign Notice and Claim Form
is a six-page form that is pre-printed with the Dealer Accounting/Dealer Service/Owner File
customer’s name and address and the campaign name Copy: this copy is for the dealer file.
and number. The entire form will be mailed to the owner
of record along with a cover letter outlining the defect Customer Copy: to be given to the customer as a record
and instructions to present the complete form to the of the campaign service performed.
dealer at the time the vehicle is serviced.
Reply Card: to be used by the owner if ownership or
The six copies are: address has changed.
79-41
-- __
Upon presentation of this form by an owner, the dealer total campaign VIN range contained in the Campaign
should: DRB to ensure the vehicle is eligible to receive
* Imprint the combined notice and claim form in the campaign services.
upper right hand corner with his dealer plate and
remove the cover sheet. When using a blank form, be sure to enter the owner’s
* Complete the header information boxes. name and address, yIN, Zone PDC and Dealer Code,
* Have the owner sign the form on the owner signature campaign name or number, date of compliance and
line dealer’s signature in the areas provided and X the
* Perform the required campaign service as outlined in appropriate service box as outlined in the Diagnosis and
the DEB. Repair Bulletin.
* Complete the form by entering the ItO. date, mileage
and placing an X in the appropriate alpha code box Based on the alpha box checked, the dealer will
indicating the campaign service which was automatically be credited on the mid or end-of-month
performed. The alpha code, which takes the place of memorandum of warranty transactions code 40
the cost code and operation number, can be found on referencing the claim number on the form. The single
page 3 of this DRE. credit shown will include brive-infDrive-out,
* Sign the form in the area provided and mail the CCD corresponding labor, parts cost and applicable parts
copy to CCD in Milwaukee. mark-up.
NOTE; Do not make out a separate warranty claim. Although it will no longer be necessary for the dealer to
The new form is the warranty claim. enter the parts and labor costs for processing of the
recall claim, the dealer may wish to complete the
In the event the owner misplaces or neglects to bring in internal records box in the lower left hand corner of the
the campaign notice and claim form, the dealer should claim. The figure shown in this box should be entered on
use a blank Campaign Notice and Claim Form. A small the dealer’s claim register along with the claim number.
supply is included with this DRE. Should you need more
forms, they are available from your Zone Service Starting with this JEEPAXLE Campaign, it will no
Department. longer be necessary to complete a warranty claim form
and a campaign reporting card after servicing an AMC
Before providing campaign services for a vehicle where or Jeep vehicle involved in a product recall campaign.
the owner fails to present the campaign notice and claim
form, the dealer must check the Vehicle Identification PLEASE NOTE: All prior campaign claims will
Number yIN against his Campaign VIN List or the continue to be handled as in the past.
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FIg. 6 Sample Completed Combined Product Recall Campaign Notice and Claim Form
NOTE: This sample claim represents inspection and replacement of the rear axle shaft bearings. An inspection
only would be alpha code A.
79-42
P1 Jeep
I Diagnosis and Repair Bulletin No. 802
Date: May 27, 1980
Application: 1979 and 1980
Jeep CJs
File: CHASSIS - Axle and
Prop Shaft
This is a TS’pe ‘S" campaign subject to all campaign INSPECTION PROCEDURE

procedures and involving safety-related elements.
1 Place transmission gear selector in neutral and raise
Some 1979 Jeep CJ models built between VIN vehicle.
J9M83AC849545 and J9M83AC851591 and 1980 Jeep
CJ models built between VIN J0M93AH700384 and 2 Rotate propeller shafts and inspect the following
J0M83AC701781 may have been assembled with other U-joint to yoke attaching clamp bolts with Thrx heads.
than specified universal joint to yoke attaching clamps
and bolts. As a result, these bolts may not hold torque 1979 CJ Models Inspect bolts and clamps at both
-
due to interference between the bolthead flange and the front axle yoke and rear axle yoke.
clamp. This could result in the loosening of the bolts,
uncoupling ofthe propeller shaft U-joints and yokes and 1980 CJ Models - Inspect bolts and clamps at all
loss of drive to the front and/or rear wheels. yokes.
Service correction involves inspecting the subject ve If all bolt heads have small flange Fig. 1 and there is no
hicles for the proper universal joint to yoke clamps and interference with clamp, clean yoke using wire brush
bolts and replacing the substandard components. Refer and shop cloth with solvent. Color every yoke with dab
to the Inspection Procedure. of light colored paint where screws and clamps were
correct to note campaign completion, and return vehicle
The Zone will provide a YIN list to each dealer with to owner.
vehicles involved. However, the campaign procedures
apply to all dealers. On all undelivered campaign-
involved vehicles, the inspection/correction must be
made hefore the vehicle is sold or otherwise put in
CLAMP
service.
The parts required for this campaign have already been

shipped to all dealers on a no-charge basis. Each dealer
has received bolts and clamps for every vehicle on his
YIN list. Additional parts may be ordered as needed
from your Zone Parts Distribution Centeit

iO
0.355 -
Inch
0.375
Correct
Part
Description Qt No. Group Fig. 1
BOLT, Propeller
Shaft to Yoke A/R 4006363 9.100
If any bolt heads have large flange Fig. 2, then clamp
CLAMP, Propeller and bolts must be replaced. Refer to the Replacement
Shaft to Yoke AIR 3235473 9.100 Procedure.

Service Engineering Department * 14250 Plymouth Road * Deirelt, MIthigan 48232
79-43
INSPECT
1 Remove and discard propeller shaft yoke bolts and TIllS POINT CLAMP
clamps identified as faulty during inspection. FOR INTERFERENCE
NOTE: These torx head bolts require a thin wall, E8

lbrx-driue socket as found in the J-2&359-02 Thrx bit
and socket set.
2 Install new bolts and clamps and tighten replace
ment bolts to 15 ft. lbs. 19N.m torque. -i-s
t418 - 0.438
Inch
3 Clean yoke using wire brush and shop cloth with
solvent. Incorrect
Fig. 2
4 Color every yoke with dab of light colored paint
where screws and clamps were replaced to note cam
paign completion.
5 Lower vehicle.
ALPHA
BOLTS/CLAMPS, Propeller Shaft to ke - Inspect

Includes Drive-iNfDrIve-out A 03-93 0.2 M
Replace Includes Drive-In/Drive-out and
Inspection Time Allowance
One a 0.4
Two C 0.5 i
Three 0 0.6
All E 0.7
CLAIM HANDLING AND CAMPAIGN REPORTING Factory Copy: to be used as a packing copy for return
able parts when required.
Beginning with this campaign, owners of record will be
Deider Accounting/Dealer Service/Owner File
mailed a new AMC and Jeep combined Product Recall Copy: this copy is for the dealer file.
Campaign Notice and Claim Form Fig. 3. This new
form is to be used in place of a warranty claim and a Customer Copy: to be given to the customer as a record
campaign reporting card. of the campaign service performed.
Reply Card: to be used by the owner if he or she no
This new Product Recall Campaign Notice and Claim longer owns the vehicle or has moved.
Form is a six-page form that is pre-printed with the
customer’s name and address and the campaign name Upon presentation of this form by an owner, the dealer
and number. The entire form will be mailed to the owner should:
of record along with a cover letter outlining the defect
and instructions to present the complete form to the * Imprint the combined notice and claim form in the
dealer at the time the vehicle is serviced, upper right hand corner with his dealer plate and re
move the cover sheet.
The six copies are: * Complete the header information boxes.
Cover Sheet: contains instructions for the owner and * Have the owner sign the form on the owner signature
shows the dealer where to imprint his dealer plate. line.
CCD Copy: to be submitted to CCD for campaign * Perform the required campaign service as outlined in
reporting and crediting. the DRB.
79.44
* Complete the form by entering the RO. date, mileage provided and t5X" the appropriate service box as outlined
and placing an X in the appropriate alpha code box in the Diagnosis and Repair Bulletin.
indicating the campaign service which was performed.
The alpha code, which takes the place of the cost code Based on the alpha box checked, the dealer will auto
and operation number, can be found in the 550 Block of matically be credited on the mid or end-of-month
this DRB. memorandum of warranty transactions code 40 re
ferencing the claim number on the form. The single
* Sign the form in the area provided and mail the CCD claim credit will include Drive-in/Drive-out, corre
copy to CCD in Milwaukee. sponding labor, parts cost at dealer net and applicable
parts mark-up.
In the event the owner misplaces or neglects to bring in
the campaign notice and claim form, the dealer should Although it will no longer be necessary for the dealer to
use a blank Campaign Notice and Claim Form. A small enter the parts and labor costs for processing of the
supply is included with this DRB. Should you need more recall claim, the dealer may wish to complete the inter
forms, they are available from your Zone Service De nal records box in the lower left hand corner of the
partment. claim. The figure shown in this box should be entered on
the dealer’s claim register along with the claim number.
If an owner fails to present the campaign notice and
claim form, the dealer must check the Vehicle Identifi Starting with this UJOINT Campaign, it will no longer
cation Number VIN against his Campaign VIN List or be necessary to complete a warranty claim form and a
the total campaign VIN range contained in the Cam campaign reporting card after servicing an AMC or
paign DRB to ensure the vehicle is eligible to receive Jeep vehicle involved in a product recall.
campaign services.
PLEASE NOTE: All prior campaign service claims
When it is necessary to use a blank campaign form, be must be handled as in the past, using a warranty claim
sure to enter the owner’s name and address, yIN, Zone form properly completed for the campaign repair.
PUC and Dealer Code, campaign name or number, date
of campaign service and dealer’s signature in the areas
fl Sales American Motors

Corporation
SERVICING DEALER:
4aeqaqi
SERVICING DEALER IDENTIFIcATIoN
PRODUCT RECALL AiIer the required campatgn service has teen peilormed,
CAMPAIGN NOTICE AND please imprint your plate to the right and sign the claim and huSh
CLAIM FORM complete the applicable inFn,malion below. Follow t°te in
structions in rIse Oiagnoais and Repair Bulletin {DRB} For this
campaign. Please be accurate and legible since toils intortna
I aulhoeue that tie taper cot be
rertotisied on ate descroed tonm, hen will be used for campaign reporting and crediting. Mail till i:Attlt.YF titilu 1115
vehicle The tehicle may be operaled by thu claim to CCD in Milwaukee. It returnable pails axe ,1U111l 0,’
you or your persotwel for tell 1d involved follow the applicable butetini ristructions ANlllllt . Ut thhhIllutti
nspecboii purposes
Omit, S Sigojiure
Fee
3 51
*fo
DATE
Isa,
Authorized
50
Yea
*4ed
%O
0iiitSl r- jtooMs4? J00000ls
lie
I
C eerie,
81102
OWNER INFORMATION
reeiliatuiatveO.llSlaStiiiii.ivd,v
1levOidQeOvSSetuela,l fact,-
h&
t
r-
B C
-><
0 5 !.... G
I
ji
I
Dealer Signature X ---

- NME ANN 5t1501&
The it to certity total the required campaign service has been ADDRESS I 234 CIZILMIS till-Ui
perlern,ed tree of chaige lo the owner or she above vetsele- AsrIttOl, USA I? 1S
CITY. STATE. ZIP
VEHICLE IOENTIFtCATIDH NO jüit tNloOOhioai
Upon completion this Form should be submitted wllh your
Warranty Claims to CCO.
cseospoasiiit e.id It lUhlINI 8002
Fig. 3 - Completed Combined Product Recall Campaign Notice and Claim Form
The above is a sample claim illustrating Drive-In/Drive-Out and inspection plus replacement of 3 bolts/clamps.
79-45
Subject: Rear Axle Housing Cover Service Application: 1977-79 Ci Models File: CHASSIS
No- 9-02 May IS, 1979
be aligned prior to installing it.
whether it extends below the bottom edge of the axle cover is rotated, to determtne if cover no longer extends
axle housing.
2 Inspect rear axle cover for ahgnment as follows:
axle housing, realign cover by moving it upward. If bolts to 20 ft. lbs. 27 N’m torque.

PERA SKILL
OPERATION DESCRIPTION REPORTING QNuMTI MODEL
SE LEfl
77 7 79
COVER, REAR AXLE - MODIFY 9.007 9051 83-93 0.1 0.1 0.1 C
9-073-093

S.rvlc. Enginnrlng Dartm.nt * 14250 Plymouth Road * Dtroit, MIchigan 48232
Additional copies of this bulletin are available through your zone of lice.
79-46
Subject: Revised Ball Stud Preload Correction Application: All 19 78-79 Jeep Models File: CHASSIS
and Front Wheel Shimmy Procedures Axles - Propeller Shaft
No. 9-01 January 25,1979
Service procedures and related specifications for Front FRONT WHEEL SHIMMY
Wheel Shimmy inspection/correction and front axle Ball Refer to step 7 under Front Wheel Shimmy on page
Stud Preload Correction in the 1978 and 1979 Jeep Tech 2M-5 and change substep b. and substeps g through
nical Service Manuals have been revised. k to read:
These revisions apply to both the 1978 and 1979 Jeep b Loosen lower ball stud jamnut and remove cotter
Technical Service Manuals and are outlined separately pin and slotted nut from upper ball stud.
as follows.
g Install and tighten upper ball stud slotted nut to 10-
20 foot-pounds 13-27 N.m torque to draw lower ball
BALL STUD PRELOAD CORRECTION stud into tapered hole in axle yoke. Do not install upper
ball stud split ring seat at this time.
Refer to Ball Stud Preload Correction on page 2F-5 and
change steps 2, 3, 9, 10, 11, and 12 to read: h Tighten replacement lower ball stud jamnut to 80
foot-pounds 108 N.m torque.
2 Loosen lower ball stud jamnut.
i Remove upper ball stud slotted nut and install
3 Remove cotter pin and slotted nut from upper ball replacement split ring seat using tool J-25l 58. Tighten
stud. seat to 50 foot-pounds 68 N.m torque. Install and
tighten upper ball stud slotted nut to 100 foot-pounds
9 Install and tighten upper ball stud slotted nut to 10- 136 Nem torque. Align and install cotter pin without
20 foot-pounds 13-27 Nem torque to draw lower ball loosening slotted nut.
stud into tapered hole in axle yoke. Do not install upper
ball stud split ring seat at this time. Imeasure
Loosely install axle shafts and steering spindles and
turning effort of each steering knuckle.Refer to
10 ‘lighten replacement lower ball stud jainnut to 80 Ball Stud Preload Measurement in Chapter 2F Axles, -
foot-pounds 108 N*m torque. page 2-F4. If turning effort is less than 10 foot-pounds
14 N.m torque, proceed to next substep. If turning ef
II Remove upper ball stud slotted nut and install fort is more than 10 foot-pounds 14N.mtorque, replace
replacement split ring seat using tool J-25 158. Tighten upper and lower ball studs and repeat Ball Stud reload
seat to 50 foot-pounds 68 Nm torque. Correction procedure in Chapter 2F Axles. -
12 Install slotted nut on upper ball stud. Tighten nut to k Install axle shafts and repeat procedure outlined in
100 foot-pounds 136 N.m torque. Align and install step 7.
cotter pin without loosening slotted nut.
I Install wheels and lower vehicle.
Refer to the Torque Specifications Chart on page 2F-12
in the 1978 manual and on page 2M-6 in the 1979 manual.
Change the lower ball stud jamnut set-to torque to 80 The current operations and standard work times are not
foot-pounds 108 Nem torque. The upper ball stud affected by this bulletin.
retaining nut remains at 100 foot-pounds 136 N.m.
l2-SGJ
VU American Motors Sales Cosporatlon

S.rvic. EnglnnrIng Dpovtun.nt * 14250 Plymouth Road * D.trolt, Michigan 41232
Additional copies of this bulletin ar available through your tone office.
79-47
DiagnoSis and Repair Bulletin
Subject: Brakedrum and Rotor Repair vs Applicatlom All 1976-79 Jeep Vehicles File: CHASSIS
Group t000
It is not necessary to replace drums or rotors ii he 8 Install bearings and seal in rotor.
dimensional specifications. Instead of replacement. re 9 Install rotor on steering spindle and check runout
to ensure proper brake operation, correct service pro a Mount dial indicator on support stand or steer
cedures are very important. The specifications and pro ing spindle.
of rotor lining contact area and zero iidicator.
d Refinish rotor if runout exceeds stated limit.
I Raise and support front of vehicle. Replace rotor if runout is so severe that machining
would cause rotor to fall below minimum replace
cations.
3 Remove caliper do not disconnect brakeline. e If runout is within limits, proceed to step 42.
4 Inspect rotor braking surfaces. If surfaces are only

NOTE: Excessive lateral runoul will cause rotor
lightly rusted or scored, proceed to step 5. If surfaces wobble resulting in chatter, vibration, and pedal pulsa
are severely scored, cracked, chipped, excessively lion.
5 If rotor surfaces are only lightly scaled, rusted or -a Measure variaQon using micrometer or two
Clean rotor hub bearing surfaces and mount rotor in h Take readings at four or more equally spaced
tions.
7 Check rotor thickness at center of lining contact dl Refinish rotor if thickness variation exceeds
refinishing if necessary. If rotor is within limits, pro below minimum thickness specification.
ness specification or refinishing would leave it below NOTE: Excessive thickness variation will cause pedal
minimum thickness specification. replace rotor. pulsation and vibration when the brakes are applied.
OVER

S.rvlc. Engkinrlng D.partnwnt * 14250 Plymouth Rood * D.tralt, MIchIgan 41232
79-48
Rotor RefinishIng 1978 Models

equipment that will machine both of the rotor surfaces Ci 11.7 in. 29.7 cm
duce a tapered rotor. The correct surface finish is 15 Cke. Wag. J10 Trk 12.0 in. 30.48 cm
to 80 microinches for Ci models; 20 to 60 microinches
for Cherokee, Wagoneer, and Truck models and must 1-20 Trk 12.5 in. 31.75 cm
NOTE: If a rotor is glazed or highly polished, sanding
the rotor may not produce the required rotor finish. Rotor Lateral Runout All 0.005 in. 0.12 mm
It may be necessary to turn the rotor to meet the
finish requirements. Rotor Minimum Replacement I Thickness:
Ci 1.l2Oin.28.45mm
manufacturer’s recommendations for feed and speed Cke. Wag, Trk 1.215 in. i30.86 mm
before machining rotor. Rotor Thickness Variation All. 0.00! in. 0.02 mm
1 Remove rotor from steering spindle. 1977 Models
2 Remove bearings and seal from rotor and clean Rotor Diameter:
bearing surfaces in rotor hub thoroughly. CJ 11.7 in. 29.7 cm
3 Mount rotor in lathe according to manufacturer’s Cke. Wag. J10 Trk 12.0 in. 30.48 cm
J-20 Trk 115 in. 31.75 cm
Rotor Hub Bore Runout All. .0.010 in. 0.254 mm
manufacturer’s instructions only. Make two cuts if re- Rotor Lateral Runout All 0.003 in. 0.076 mm
CAUTION: Do not attempt to refinish rotor if ma
chining would cause the part to fall below the minimum Rotor Thickness Variation All. 0.0005 in. 0.OL mm
NOTE: If one disc brake assembly requires a new set Rotor Diameter:
of shoes, the shoes on the other assembly must be Cke, Wag. 1-10 Trk 12.0 in. 30.48 cm
replaced to ensure even braking.
Rotor Hub Bore Runout All. .0.010 in. 0.254 cm
.

All 1.125 in. 28.5 mm
Rotor Diameter:
Ci 11.7 in. 29.7 cm Rotor Thickness Variation All 0.0005 in.O.0l3 mm
Cke. Wag. J-I0 Trk 12.0 in. 30.48 cm

BRAKEURUM SERVICE
J-20 Trk 12.5 in. 31.75 cm
Inspection and Measurement
RotorHubtoBoreRunout All. 0.010 in. 0.254 mm
II Raise and support vehicle.
Rotor Lateral Runout All. . . .0.005 in. 0.12 mm
2 Remove wheels.
Cke, Wag. Trk 1.215 in. 30.86 mm 4 Clean drums using soap and water solution. If
2
79.49
Si Inspect drums for cracks, severe scoring. distor- BRAKEDRUM SPECIFICATIONS
tiui. or hard spots a series of shiny or dark colored
these conditions. If drums appear in good condition. 1979 Models
proceed to next step,
Maximum Drum Diameter:
6 Refer to Brakedrum Specifications then measure
CJ 10.060 in. 25.5 cm
refinishint would not create an oversize condition, pro- Cke. Wag. Trk 11.060 in. 28.09 cm
needs refinishing hut would exceed allowable size limits J-20 Trk 12.060 in. 30.6 cm
after machining, replace drum.
Maximum Drum Radial Runout. 0.005 in. 0.12 mm
7 Mount drum in lathe according to lathe manu -
fact urer’s instructions.

1978 Models
CJ 10.060 in. 25.3 cm
a Rotate drum 3bOdegrees and observe readings. Cke. Wag. Trk 11.060 in. 28.09 cm
Ib Move indicator stylus until readings have been
taken across entire contact surface of drum. J-20 12.060 in. 30.6 cm
tc Drum runout must not exceed 0.003 inch 0.12
mm total indicator reading at any point. Also note if Maximum Drum Radial Runout. OAE5 in. 0.12 mm
cate tapered or hell-mouthed drum. 1977 Models
10 If drum is within limits and does not need refin- Maximum Drum Diameter:
ishing. install drum. If drum is not within limits or is Ci 10.0W in. 25.5 cm
finishing. Cke. Wag. Trk I 1.0W in. 28.09cm
Brakedrum Relinishinu J-20 Trk 12.06 in. 30.6 cm
ti Sharpen or replace cutting tool hit if necessary. Maximum Drum Radial Runout. 0.007 in. 0.18 mm
2 Install anti-chatter hand on drum.

1976 Models
recommendations for feed and speed. Do not remove Maximum Drum Diameter
more than 0.010 inch 0.25 mm of slack during any cut. Ci 10.0W in- 25.5 cm
4 Check drum radial runout again after completing Cke, Wag. Trk 11.0W in. 28.09 cm
J-20 12.060 in. 30.6 cm
NOTE: When brake shoev are replaced on one wheel.
the;’ must also he replaced on the opposite wheel Maximum Drum Radial Runout. 0107 in. tO.18 mm
79-50
CODE NUMBER MODEL 76 77 78 79 LEVEL
SHOESET,FRONTDISCBRAKE-REPLACE 8.152 8060 0.5 0.5 0.5 0.5 G
Disc Assembly-Clean A 0.1 0J 0.1 0.1 G
Disc Assembly-Resurface One &163 B 0.5 0.5 0.5 0.5 P

Both 8.163 1.0 1.0 1.0 1.tl p
Includes clean, inspect and repack wheel bearings.

listed for operation Brake Shoes, Four Wheels-
BRAKE SHOES, TWO WHEELS REAR-

REPLACE 8.202 8020 0.8 0.8 0,8 0.8 G
Brake Drum-Reface Roth 8.222 A 0.3 0.3 0.3 0.3 P

Rear Axle 9.073 H 0.4 0.4 0.4 0.4 G
Material allowance for hearing lubricant is $0.30.

listed/or Operation Brake Shoes. Four Wheels-
Replace 80008050 as they apply

WHEELS FRONT-REPLACE 8.102 8010 *3.93 0.7 0.7 C
Front Wheel Bearings-Repack 8.909 A 0.4 0.4 G
Remove, wash, inspect, repack. install new seals
and adjust.
Drum-Reface-Both 8.127 8 0.3 0.3 P

9-036M1A/J
79-51
Replacement Vehicles Equipped with Power Steermg Steering and Suspension
1977 Group 10.000
Revised
No.9-01 January 16,1979
step D under "1977 Jeep Technical Service Manual" "ASSEMBLY STEERING GEAR HOUSING
-
and step E under "1979 Jeep Technical Service COMPONENTS," step 12 should be changed to read
Manual." Please remove and discard DRB No. 9-Cl, Install end plug in rack piston. Tighten end plug to 75
November 20, 1978.
The Warranty Administration Manual states that partial "WORMSHAFT BEARING PRELOAD," step 3
or complete overhaul of an assembly shall take should be changed to read: Measure counterclockwise
precedence over replacement of that assembly; except one-half inch 13mm from first index mark and remark
when the sum total of replacement parts and labor costs housing. Refer to Figure 1 below.
at RFC values to repair the assembly would amount to
80 percent or more of the sum total parts and labor costs D. On page 11-58 under the subtitle
at RFC values to replace the assembly. "PITMAN SHAFT OVERCENTER DRAG
TORQUE," step 1 should be changed to read: Loosen
The appropriate Jeep Technical Service Manuals state locknut, turn pitman shaft adjuster screw counterclock
that adjustment of the steering gear must be done with the wise until fully extended, then turn it back clockwise
gear assembly removed from the vehicle. one full turn. Step 7 should be changed to read: Tighten
On the other hand, the Standard Servicing Operations 27 N* m torque after adjusting overcenter drag torque.
Manual 550 has an operation and time for steering
the vehicle.

are necessary, Also, note the changes in the Standard

MANUAL
Fig. 1 Indexing Gear Housing
A. On page 11-47 of the SERVICE
"CONDITION" and after subtitle "POOR RETURN II, 1978 JEEP TECHNICAL SERVICE
OF STEERING WHEEL TO CENTER," add step II. MANUAL
Correction A. On page 2L-8 of the SERVICE
Possible Cause DIAGNOSIS CHART under the heading
"CONDITION," add step II to subtitle "POOR
Ii Kink in Return Hose II Replace Return Hose

S.rvlc* Englnnrlng Dsportm.nt * 14250 Plymouth Rood * D.t,-olt. MIchIgan 48232
79-52
Possible Cause Correction C. On page 2L-32 under the subtitle
"STEERING GEAR ASSEMBLY AND
II Kink in Return Hose II Replace Return Hose ADJUSTMENT," step 19 should be changed to
read: Install end plug in rack piston. Tighten end plug
B. On page 2L-12, fig. 2L-7, View A, the to 75 foot-pounds 102 N. m torque.
shown in fig. 2. D. On page 2L-34 under the subtitle "WORM
BEARING PRELOAD," step 3 should be changed to
C. On page 2L-3 2.under subtitle "STEERING yead: Measure counterclockwise one-half inch 13mm
GEAR ASSEMBLY AND ADJUSTMENT,"stepl9 from first index mark and remark housing. Refer to
should be changed to read: install end plug in rack Figure I.
piston. Tighten end plug to 75 foot-pounds 102 N m
torque. E. On page 2L-35 under the subtitle
D. On page 2L-34 under the subtitle"WORM TORQUE." step I should be changed to read: Loosen
BEARING PRELOAD," step 3 should be changed to locknut. turn pitman shaft adjuster screw counterclock
read: Measure counterclockwise one-half inch 13mm wise until fully extended, then turn it back clockwise
from first index mark and remark housing. Refer to one full turn. Step 7 should be changed to read: Tighten
fig. I. pitman shaft adjusting screw locknut to 20 foot-pounds
SHAFT OVERCENTER DRAG TORQUE." step I
one should be changed to read: Loosen locknut, turn IV. STANDARD SERVICING OPERATIONS
In the October 9, 1978, printing at the bottom of
7 should be changed to read: Tighten pitman shaft
adjusting screw locknut to 20 foot-pounds 27 Nm page 2-08-5 is the operation description GEAR, POWER
torque after adjusting overcenter drag torque fig. 2H- STEERING - ADJUST ON-VEHICLE with operation
115. number 10290. DO NOT USE THIS OPERATION
NUMBER.
111. 1979 JEEP TECHNICAL SERVICE
MANUAL
TION." add step II to subtitle "POOR RETURN OF
STEERING WHEEL TO CENTER." StepIlwill read
as follows:
B. On page 2L-l2, figure 2L-7, View A, the
shown in fig. 2.
Seat bail in housing with blunt-nosed punch. Spray ball

compressed air. Cover bait with Loctite adhesive 290. Let
/
View A
OPERATION DESCRIPTION REPORTING OPERATIO N MODEL SKILL
NUMBER LEV E I
CODE 78
GEAR ASSEMBLY, POWER STEERING -
R& R 10.500 10310 WAG-CKE-TRK 0.6 0.6 0.6 6

83-93 0.8 0.8 0,8
With snow plow Add - 0.1 0.1 0.1
Gear assembly Adjust
- 10.959 A 0.2 0.2 0.2 6
Gear assembly - Replace 10.501 B 0.1 0.1 0.1
Gear assembly Overhaul
- 10.502 C 1.2 1.2 1.2 6
Adjuster Plug Replace
- 10,555 D 0.3 0.3 0.3 6
- 10.615 E 0.5 0.5 03 6
NOTE: Combinations D and E include a4ha:-
operation.
9-OOS-IOA/JC
79-53
VUJeep
Subject: Br - at .5 and CJ-7 File: CHASSIS
4Type"S"P B Beti IN Numbers Steering-Suspension
Campaign H 07
Connecting 8 34
Clamp Bolts: No. 9-02 December 1, 1978
This is a Type "5" Product Recall Campaign subject 5. If both clamp bolts are loose but steering wheel align
to all campaign procedures and involving safety-related ment is correct, tighten bolts to 12 foot-pounds 16.Nm
elements. A copy of the combined owner notification torque and return vehicle to owner or to stock. If both
and correction reporting card for this campaign is shown clamp bolts are loose and steering wheel alignment is
in Figure 2. incorrect, proceed to next step.
Some 1979 Jeep CJ-5 and CJ-7 model vehicles between 6. Place steering wheel in aligned position and secure
VIN’s J9A93EH800007 and J9F93EC801734 may have wheel using steering wheel holder.
clamps on the adjuster tube that are not properly
tightened. Loose clamp bolts could allow the adjuster 7. Turn adjuster tube until front wheels are in straight’
tube to move or separate from the connecting rod or pit- ahead position. Verify wheel position using alignment
man arm end assembly causing a shift in steering wheel rack.
position or complete loss of steering.
8. Tighten adjuster tube clamp bolts to 12 foot-pounds
Service correction involves checking and correcting 16.Nm torque.
clamp bolt torque and steering wheel alignment as
necessary. 9. Remove vehicle from alignment rack and return
vehicle to owner or to stock.
Under separate cover, the Zone should have already pro
vided a VIN list to each dealer with vehicles involved.
However, the campaign procedures apply to all dealers. PITMAN ARM
On each undelivered campaign involved vehicle, the AND ASSEMBLY
inspection/correction must be made before the vehicle
is sold or otherwise put in service. CLAMP BOLT NUTS
PROCEDURE
1. Place vehicle on alignment rack.
2. Check adjuster tube clamp bolt torque using foot-

pound torque wrench. Refer to Figure 1 for clamp bolt
location.
CLAMP
ADJUSTER TUBE
3. if both clamp bolts register 10 foot-pounds l4Nm
CLAMP BOlTS
torque or more, return vehicle to owner or to stock.
ROD
4. If only one damp bolt is loose, tighten this bolt to
12 foot-pounds 16.Nm torque and return vehicle to
owner or to stock. FIg. 1 Adjuster Tube Clamp Bolt Location

SiMs, Enginoorlng D.partmtnl * 14250 Plymouth Road * Detroit. MIchigan 48232
79-54
__________

OPERATION OESCRIPTION REPORTING OPERATION MODEL * SKILL
CLAMP, ADJUSTER TUBE

Inspect end Torque One or Both. 10.230 10183 83-93 .1 S
Center Steering Wheel 11L23 1 A .2
Applicable Defect Code: 56

CLAIM HANDLING
Several vehicles may be listed on a single Warranty Claim, Reference Warranty Administration Manual WAM,
Section 7, Product Recall Campaign.
Complete and mail the reporting half of the notification card Figure 2 for each vehicle as soon as campaign
CAUTION: On multiple-vehicle claims, do not delay any claim so that we will receive it beyond the time limit
outlined in the WAM.
j", National Trait ic and Motor Vahici. Safaty Act of 1980

Notic. of Product Rcd Campaign InvoMng Your Vdiid. Product Racall Campaign R.porting Card
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II y., R S_ISd S ,,.bl, I. 5 554’_iS ..,*le -4-4*. pA... iS. I_ni An,s M...,.
&‘__..I__ Ze. .44., li-S 4. , 0,_n. M...aI - A__I_n Mit_s ..jo..d... 40..., P.554_i. 1411.
i_si - .1_i,.. I’M2 *RAM8TER 788
My-a P_id. On,ao. MI 4 IIo_...na ...M. t Si-A .54. P,l
5h* 44_AM_n.,. i_n.4 hAl_n t..e, s_aty 445%ntt.. W5n_. lkIfl Sil.
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w,o, pot, wAirk jot. rot IS. .q.nA .iI..Ia P5. -. tIM i_Tat, ..4mad.. - - .,AI - -
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pin.. cid.. IS. ‘Cbs. .1 O*.nSl minisn,. ns,l it: or’s otS. - -
- - nf-. Cats,. ISV Ri’aS. tics..
-
- tt9t 140!M3IW 1104110
a
- pn ‘anowAw OSnI Notia of Product R.c.ll campaign Involving Your V#iid*
-
- uo.*a.g 0,1t0d4u n.o uS.dw.
- - - I.
-
a uotaiod.oo dnr
-
a .101na4"tA onslod
YIN 101111014 IOtnM,I,c.lIoR 5on44.11
-
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Fig. 2 Owner NotIficatIon and Correction Repoeting Card
79-55
Subject: Improved Method For Retaining Application: 1979-81 Cherokee and File: BODY -
Electrically Operated Tailgate Glass In Wagoneer Models With 5/32-Inch Body General
Lower Channel Thick Electrically Operated
Tailgate Glass
No. 81-3 July 3.1981
This bulletin supercedes Diagnosis and Repair Bulletin 4 Cut two 53-1/2-inch long strips of sealer from roll.
Number 9-01, filed under BODY - Body General, and Place one strip of sealer over the other with ad
dated May 15, 1979. Discard all copies of bulletin 9-01 hesive sides together to form one double thickness
and replace it with this current bulletin. strip of sealer that is 53-1/2 inches in length.
On some 1979-81 Cherokee and Wagoneer models equip 5 Position tailgate glass so bottom edge of glass
ped with electrically operated tailgate glass, the tailgate faces upward. Support opposite edge of glass on
glass may separate from the channel. This bulletin pro cushioned surface to avoid damaging glass.
vides an improved method of retaining the glass in the
channel. 6 Remove silicone treated liner from one side of
Service correction involves inspecting the tailgate glass double thickness sealer strip.
assembly, replacing any damaged components if
necessary, installing a double coated foam tape sealer to 7 Center sealer strip over bottom edge of tailgate
retain the glass in the channel, and installing a stop glass. Starting at one end, install sealer along
bumper and bracket at each side of the lower channel. entire length of glass. Be sure to keep sealer
centered on edge of glass during installation.
the week of July 27, 1981. Do not order parts before this 8 Remove silicone treated liner from opposite side of
date. sealer strip and install channel on bottom edge of
Quantity Part No. Group tailgate glass. Press or tap channel into position
Description carefully. Be sure channel is fully seated before
CHANNEL, Tailgate continuing.
Glass, Lower 1 5455959 25X133
SEALER, Tailgate 9 Drill two 1/4-inch mounting holes for stop bumper
1 8130418 25.033 brackets at each lower corner of tailgate inner
Glass
BRACKET, Stop 2 959614 25.054 panel as follows:
BUMPER, Rubber Stop 2 968734 40.088
SCREW, 10-24 x 112" a Position right side template on driver side
G0159920 17.598 lower corner of tailgate inner panel Fig. 1.
Pan Head 2
SCREW, 1/4-20 x 3/4" Align template edges with bottom and side of
Flat Head 4 G0156253 17.586 tailgate inner panel, and tape template in place.
NUT, 10-24 2 G0271166 17.412 Mark hole locations indicated on template using
centerpunch and remove template.
PROCEDURE
b Turn template around and position left side
1 Remove tailgate glass. Refer to appropriate Jeep template on passenger side lower corner of
Technical Service Manual for procedure. tailgate inner panel. Align template edges with
bottom and side of tailgate inner panel and tape
2 Inspect tailgate glass operating components. Re template in place. Mark hole locations indicated
place any components that are bent or damaged. on template using centerpunch and remove
template.
3 Clean lower portion of tailgate glass using
isopropyl alcohol. c Drill two 1/4-inch holes at each lower corner of
tailgate at locations marked with centerpunch.
CAUTION: If the vehicle is equipped with a rear window
defogger, do not wipe or rub the defogger grid and do not d Remove metal chips generated by drilling
allow the window cleaning agent to contact the grid. operations using magnet.
S.rvlc. Englnnrlng D.partne.nt . 14250 Plymouth Road * D.troit, MichIgan 48232

79-56
TEMPLATE 12 Loosen original tailgate glass center stop, move
INSTALLED ON
DRIVER SIDE stop to lowest position, and tighten stop.
OF TAILGATE
INNER PANEL
13 Install tailgate glass but do not install access or

trim panel at this time. Refer to appropriate Jeep
Technical Service Manual for glass installation
procedure.
14 Lower tailgate glass and verify proper channel-to-

stop-bumper contact. Reposition rubber bumpers
as necessary to obtain proper contact.
15 Install tailgate access and trim panels.
Fig. 1 Positioning Template on

Tailgate Inner Panel
10 Install rubber bumpers on stop brackets Fig. 2.
Use 10-24 x 3/4-inch pan head screws and nuts to
attach bumpers to brackets.
NOTE: The stop bracket may have a rubber or plastic in

sert in the screw slot at the top of the bracket. Remove and
discard this insert before installing the rubber stop
bumpe -
11 Install one bumper and bracket assembly at each

lower corner of tailgate inner panel Fig. 2. Work
through the tailgate access panel opening to install SIDE VIEW
brackets and secure brackets to panel using 1/4-20
flat head screws. Fig. 2 Stop Bumper Installation
The following standard servicing operation and work time will apply.
YEAR AND TIME

OPERATiON DESCRIPTION MODEL
CODE NUMBER LEVEL
79 80 01
STOP BUMPER Assembly, 25.033 25157 Cke-Wag 0.5 0.5 0.5 G

TAILGATE GLASS INSTALL -
S1-089-BSJ
79-57
____
I
99-61
13NYd H3NNI
JIVO1IYi 403003
wouoa HuM NEWlY
13NYd
U3NNI 3IYO1IYL
40 300] 3019
HUM NOI1Y
I 3iVldVl3i
aais IHDIU I
383 H
9310K 83JSVIYIO
.411 11180 0NY
HONfldLJ3LN3O
CENTERPUNCH
AND DRILL 114"
DIAMETER HOLES
HERE
ALIGN WITH SIDE

EDGE OF TAILGATE
INNER PANEL
LEFT SIDE
TEMPLATE
ALIGN WITH BOTTOM

EDGE OF TAILGATE
INNER PANEL
Subject: Electrically Operated Tailgate Glass Application: 1979 Cherokee and File: BODY
to Lower Channel Retention Wagoneer with 5/32-inch Thick Body General
Tailgate Glass
No. 9-07 May IS. 1979
Some 1979 Cherokee and Wagoneer models may have an NOTE: Do no wipe or rub grid area when eleaning glass.
electrically operated tailgate glass that has separated
from the lower channel. An improved method of 3 Cut two pieces of tailgate glass bottom sealer 53½-
retaining the glass has been developed. inches long from roll. Place one piece on top of other with
adhesive sides together forming a 0.O90-iich thick strip
Service correction involves checking the assembly, 53½-inches long.
replacing any damaged components and using a double
coated foam tape sealer to hold the glass in the lower 4 Position glass with bottom edge facing up and top
channel. edge on cushion to prevent damage to glass.
NOTE: Vehicles with 5/32-inch thick glass must have
the correct tailgate lifter channel described below for 5 Remove silicone treated liner from one side of new
proper retention. sealer. Starting at one end, center sealer over edge of
glass. Lay sealer along complete length of glass. keeping
The following parts are required and will be available sealer centcred over edge of glass.
May 28. 1979. Do not order parts before this date.
Description Quantity Part No. Group No. NOTE: Do not wrap sealer around the bottom edge of
the glass at this time-
CHANNEL, Tailgate
Glass Lower Lifter I 5455959 25.033 6 Remove second silicone liner and wrap sealer
around bottom edge of glass.
SEALER, Tailgate
Glass Bottom I 8130418 25.033 7 Install new bottom channel on glass by pressing or
tapping channel into position. Be sure channel is fully
seated on glass.
PROCEDURE
8 Install tailgate glass as outlined in 1979 Jeep
I Remove tailgate glass as outlined in 1979 Jeep Technical Service Manual.
Technical Service Manual. Check tailgate glass operating
mechanism for bent or damaged components. Replace as The Standard Servicing Operations and work times as
necessary. published in the current SSO manual are not affected by
2 Using a low strength solvent i.e, isopropyl alcohol, this bulletin.
etc., clean lower section of glass.
9-076-BSJ

S.rvlc. Englnoring D.pcrtm.nt * 14250 Plymouth Rood * D.trolt, Michigan 48232
79-59
Subject: Hood Release Handle Binding or ApplicatIon: 1979 Wagoneer, Cherokee Eli.: BODY
inoperative and Truck Models Built Prior to V1N Body General
J9A15NN060233
No. 9-06 February 28. 1979
On some early built vehicles, the hood release handle may

bind or the latch paddle may move behind the release
handle. Once the latch paddle has moved behind the
release handle, the hood cannot be opened.
Service correction involves removing the hood release

handle, lubricating the shoulder bolt, and reinstalling the
handle and shoulder bolt with an additional steel and
nylon washer. In addition, hood release handle spring
tension can be increased by drilling an additional hood
release handle spring attaching hole.
WASHER. Flat I 664596 29. 105

WASHER, Nylon 1 3613467 23.104
PROCEDURE
I Open hood.
NOTE: flood will not open. put apiece ofmasking tape

on either side of the hood center to avoid scratching
paint. Using a small screwdriver, remove the Phillips-
head screws that attach the upper center section of the
grille to the radiator splash paneL
2 Remove grille from grille face panel and radiator

grille support and baffle assembly.
Hood Release Handle
3 Remove hood release handle assembly using Ton Assembly and Spring
Bit Tool J-25359-02 and raise hood if not already done by Tension Modification
pulling latch paddle forward.
9 Refit assembly making sure wave washer on
4 Drill a 1/8-inch hole, 1/4 inch outboard on hood shoulder bolt is located on bottom side of handle.
release handle spring locating bracket see illustration.
- . JO Tighten shoulder bolt using Torx Bit Tool
5 Install spnng m new hole on locating bracket. J-25359-02 and check handl assembly for proper
operation.
6 Lube hood release handle shoulder bolt and washers
using Lubriplate 8990685 or equivalent. 11 Install grille to sheet metal. If vehicle is equipped
with cold climate package, loosely position block heater
7 Install nylon washer on upper side of handle see cord in radiator opening before installing grille.
illustration.
12 Close hood and verify that handle is returning to its
8 Install steel flat washer on top of nylon washer. proper position.
OVER
‘l American Motors Sales Corporation
S.rvlc. Englnnrlng D.pou-ttn.nt * 14250 Plymouth Rood * Detroit. Michigan 43232
79-60
WARRANTY YEAR AND TE
OPERAtION SKILL
OPERATION DESCRIPTION REPORTING MOOR -
NUM8R 77 LEVEL
CODE 78 79
HANDLE, HOOD RELEASE REMOVE AND
-
INSTALL SPACER AND SPRING 12.060 12045 WAG-CKE-TRIC 0.4 6
9-055-BS.J
79-61
Subject: Wagoneer Limited, Front Fender ApplicatIon: 1978-79 Wagoneer Models File: BODY
Woodgrain Moulding Retention with Limited Trim Option Body General
No. 9-05 February 2, 1979
A procedure has been developed for repairing loose vinyl MOULDING

woodgrain moulding on the front upper corner of the
POP RIVET
front fender on Wagoneer Limited models. FENDER
PLUG
The service correction involves drilling and counter-
boring a hole in the moulding, installing a pop rivet, and
inserting a color-coordinated vinyl plug to fill the re
maining recess.

February 2, 1979. Do not order parts before this date. 0.156-INCH
DEPTH
Description Quantity Fart No, Group No.
RIVET, Pop 2 4004962 12.078
PLUG. Moulding 2 5750596 12.078
PROCEDURE
1 Measure up from bottom edge of miter joint 1-3/4
inches along center of miter joint and make a mark at
this point see illustration.
2 Push moulding flush against fender and drill 0. l25-

inch hole through moulding and lender at mark.
CAUTION: Care should be taken to prevent the dr//l Wagoneer Limited

chuck from contacting the moulding when drilling Moulding Retention
through the fender.
3 Counterbore a 0.250-inch diameter hole to a depth 5 Apply adhesive to moulding plug, align woodgrain
pattern and install plug in counterbore see illustration.
of 0.156 inches at original 0.125-inch diameter hole see
illustration.
NOTE; Rcfore applying adhesive to the plug it mar be
4 Push moulding flush against the fender and install necessary to trim the plug to fIt flush with the moulding
pop rivet through fender and moulding. surface.

OPERATION SKILL
CODE
NUMBER 77 78 I LEVEL
MOULDING, WOODGRAIN
Both sides
- REPAIR 26.030 26009 WAG
0.2
I 0.2
C
9-031-BSJ

ServIce Englnnrlng D.portm.nt . 14250 Plymouth Rood * Detroit. MIchigan 48232
Addit,onal copies of this bu1letrj are available through your zone office.
79-62
Subject: Tailgate Window Overtravel Application: 1979 Wagoneer and File: BODY
Cherokee Models Built Prior to Body General
J9XXXXXOS62S3
No. 9-04 January 26, 1979
Early production Wagoneer and Cherokee power PROCEDURE

tailgate windows may overtiavel in the up position,
causing a noise when the window lift channel contacts the
upper inner weatherseal just before the tailgate glass seats I Cut three pieces of hose 3-1 /2-inches long from bulk
in the closed position. hose.
Service correction involves installing three pieces of 3/8- 2 Lower tailgate glass completely.
inch O.D. vacuum hose in the upper tailgate glass run
channel to limit the upward travel of the tailgate glass. 3 Insert three pieces of hose in upper tailgate glass run
channel. One piece of hose is to be located at each top
The following pans are available and required: corner and one piece is to be located in middle. Roll edge
of tailgate glass run channel window seal over hose to
Description Quantity Part No. Group No. hide it from view.
HOSE, 4 Raise tailgate glass to seat vacuum hose.

3/8-inch OD. x
3-1/2-inch long 3 8125812 4.701
Bulk

OPERATION SKILL
OPflATION DESCRIPTION REPORTING MODEL
NUMBER LEVEL
CODE 77 78 79
STOP, TAILGATE CLASS RUN CHANNEL -
INSTALL 25J41 25191 WAG-CKE 0.2 C
9-039-BSJ

ServIce Engineering Deportment * 14250 Plymouth Road * Detroit, MIchigan 48232
79-63
Subject: Windshield Cracking During Extreme Application: 1978-79 CJ Models Built File: BODY
Cold Weather Prior to J9XXXXHO3S3I9 Toledo Body General
and J9XXXXHSO4O1S Bra.npton
No943 December 8.1978
Some subject vehicles may exhibit windshield stress PROCEDURE

cracks in extremely cold weather. When this condition
occurs, the crack originates at the bottom of the
windshield at or above the defroster opening. 1 Using windshield removal and installation
procedures as outlined in appropriate Jeep Technical
Service correction involves replacing the windshield as Service Manual, remove defroster air deflectors.
outlined in the appropriate Jeep Technical Service
Manual and installing new defroster air deftectors. 2 After rearview mirror has been installed on
replacement glass bracket, install new deflectors on
The following parts are available and required: windshield frame.
Description Quantity Part No. Group 3 Complete windshield installation procedure as

outlined in Technical Service Manual.
DEFLECTOR. Windshield
Defroster Air, LII 1 5750339 25M04
DEFLECTOR, Windshield
Defroster Air, RH I 5750340 25M04

WARRANTY YEAR AND liME
OPERATION - SKILL
coo NUMOER LEVEL

77 78 79
GLASS, WINDSHIELD - REPLACE 25.001 25130 83-93 0.8 0.8 C

Includes sealing
Material allowance for sealant is $0.90

Minor mounting support kit Install
- 25.001 A 0.1 0-I C
Deflectors, windshield defroster Replace
- 13.115 C 0.1 0.1 C
NOTE: Combination B is not applicable.
8-I 15-BSJ

Seivice Enginnring Department * 14250 Plymouth Road * Detroit, Michigan 48232
79-64
Subject: Door Lock and Latch Mechanism Application: All 1978-79 Cherokee, File: BODY
Freeze-Up Wagoner and Tnick Models Body Central
No.9-fl November 10,1978
In an effort to minimize the annual door lock! latch

freeze-up complaints during adverse winter weather, a
service procedure has been developed to help prevent
recurrence.
Service correction involves removing the door trim

panel, blowing any accumulated moisture out of the
affected mechanism, and lubricating the lock or latch
mechanism.
LUBRICATE AT
NOTE: If a dcicing fluid containing akohol is used on a .
?OP’ff S INOICATED
lock or latch mechanism, the lock or latch mechanism
must be lubricated to prevent further freeze-up.
PROCEDURE
I Remove door latch remote control handle and door
window regulator handle.
2 Remove armrest overlay and armrest from door

trim panel.
3 Remove ash receiver screws and ash receiver, if

equipped.
4 Remove lower door trim panel screws and pry door

trim panel nylon spring clips loose with tool J-263 1-01 Door Latch Mechanism
and remove panel. Lubrication Points
5 Cut upper rear portion of water shield dam paper
and fold paper back to gain access to lock and latch 10 Position water shield dam paper and fasten in
mechanisms. place with masking tape. Tape all edges or areas cut or
loosened when removed.
6 Remove moisture from lock assembly by applying
moderate air pressure through face of lock cylinder. 11 Position trim panel on door and install nylon spring
clips in holes of inner door panel.
7 Spray AMC/Jecp Silicone Lubricant 8993542 or
equivalent into keyhole of lock cylinder. 12 Install lower door trim panel screws.
8 Remove moisture from latch mechanism using 13 Install ash receiver and screws, if so equipped.
moderate air pressure to avoid removing lubricant
present on latch mechanism. 14 Install armrest and armrest overlay.
9 Lubricate designated latch areas with AMCJJeCp 15 Install door latch remote control handle and door
Lubriplate 8990685 or equivalent see illustration. window regulator handle.
OVER

ServIce Engineering Department * 14250 Plymouth Road e DetroIt, MichIgan 48232
79-65
WARRANTY ‘ YEAR AC TIME
REPORTING OPERATION - SKILL
OPERATION DESCRIPTION - -
CODE NUMSER MODEL 77 78 79 LEV!L
LOCK AND LATCH - DOOR - EACH -
LUBRICATE 23185 CKE-WAG-TRK 0.3 0.3 03 M

Front 23.050
Rear 23.051
9-015-OS
79-66
Subject: 1979 Wagoneer, Cherokee, and Application: Early Built 1979 File: BODY
Truck Plactic Radiator Grille . Wagoncer, Cherokee, and Truck Body General
Models
No. 9-01 September 15, 1978
Some early built I979 Wagoneer, Cherokee, and Truck HOOD RELEASE HANDLE
Models may have a visible ridge on the plastic radiator IN OPEN POSITION
grille bars directly above and below the hood release FILE UPPER AND
handle. This condition can be corrected by filing the ridge
oft’ the grille bars with a flat or mill file.
PROCEDURE - -
--
-____________
‘ L-
r
- L_____ *‘
I Pull hood release handle to fully opened position. -i
IL____ ‘ L I
c ‘I
2 Angle file so that it is parallel with hood release
han die see illustration. -Il
-I-
3 Remove ridge by filing lower grille bar area until bar nri I flU {-
isfiat. - -
4 File upper grille bar as necessary. -_________ -
5 Open hood fully, and close hood securely.

1979 Wagoneer, Cherokee, and Truck
Model Radiator Grille
CODE NUMBER MODEL 79 LEVEL
GRILLE, RADIATOR - MODIFY 2.050 2081 10-20-40 0.1 C
9-003-BSJ

Additional copies of this bUlletin are available through your zone office.
79-67
FILE: Body/Chassis
Jeep
-
Electrical BODY Body -
F
Electrical
No. 8-05-HZ Spnt. ilL 1982
TECHNICAL BULLETIN
PROBLEM AND Oil pressure gauge needle flutters during engine operation on some
APPLICATION; 1979-82 CJ and Scrambler models.
CORRECTION: Install the improved gauge that was phased into production on
February 24, 1982. The improved gauges are date coded be
ginning with code 5201 2-1-82.
PAK 5: Description Quantity Part Number Group
GAUGE, Oil 1 5750279 3.605

Pressure
S.R.T. INFORMATION
Operation
Operation Description T.I.C. Number S.R-T.
CO. GAUGE, OIL PRESSURE

REPLACE 8-352 8999 0.3
DEALER Reimbursable within the provisions of the applicable warranty.

REIMBURSEMENT:
PROCEDURE:
1. Remove tbe original oil pressure gauge as outlined in Chapter 1L of the appro
priate Jeep Technical Service Manual.
2. Obtain a replacement oil pressure gauge and check the gauge date code before in
stallation to be sure it is one of the improved gauges. The code must be 3201
2-01-82 or later.
NOTE: Code 1-etter B indicatesthe month, such as B for February, C for March, or
B for April. The firstnumber indicates the year, which in this case is
1982. The last two numbers represent the day of the month. For example,
code C217 would represent March 17, 1982 and code D2O8 would represent
April 8, 1982. Letter I is not used as a code letter.
3. Install the replacement oil pressure gauge as outlined in Chapter lL of the appro
82-O64-J

Additional copies of this bulletin are available thtough your zone office
79-68
* 4
*
Diagnosis and Repair Bulletin 4:.
1e
Subject: Moisture Entering Parking and Application: 1976-80 Cd Models File: BODY
Body Electrical
No, 80-2 Dec. 7, 1979

Some 1976-80 CJ models may have moisture entering MOUNTING
the parking and front directional signal lamp assem GASKET
side of the lamp housing,
Service correction invOlves repositioning the lamp


LAMP, Assembly
Parking and Front
HOUSING
BEZEL ASSEMBLY
GASKET, Directional
LENS
PROCEDURE
The following operations and standard work times will apply
OPERATION DESCRIPTION COST OPERATION MODEL YEAR AND TIME SKILL

CODE NUMBER 76-80 LEVEL

AND/OR REPOSITION 3.292 3403 CJ 0.1 G
Replace One or both &292 A CJ 0.1 U
8O-032-BSA

Service Engineering Department e 14250 Piymouth Road * Detroit, MIchigan 48232
Additional copies at this bulletin are available Through your zone office.
79-69
Subject: Tailgate Glass Defogger Wire Repair Application; 1977-79 Wagoner and File; BODY
Cherokee with Tailgate Glass Repair Body Electrical
No.9-01 June 7, 1979

defogger is found to be broken or chafed adjacent to the

KIT, Rear I 8l29876 3.774 5 Trim insulation from feed or ground wires to
Window expose approximately 1/4 inch of bare wire.
Defogger
wires.
PROCEDURE NOTE: Use 60/40 solder or equivalent such as Eutec Rod
157B for this solder joint.
keeping joint as small as possible. & sure solderjoint is as
lower channel see fig. I. 8 Slide heat shrinkable tubing over the solderjoints
see fig. 3.
WIRE
WiRE
Fig. 1 Defogger Wire Interference Fig. 3 Tailgate Glass With Defogger Wire In
Position
3 Remove any excess channel sealer that protrudes
from end of channel see fig. 2. 9 Shrink tubing with low heat soldering gun.
OVER
ServIce Engineering Department e 14250 Plymouth Road e Detroit, Michigan 48232
Additional copies of this bulletin are available through your Zone oltice.
79-70
ID Secure feed or ground wires with nylon strap to II Install tailgate glass and channel assembly as
inside of square loop located on channel. outlined in appropriate Technical Service Manual.

OPERATION KILL
OPERATION DESCRIPTION REPORTING MODEL EVEt
NUMBER
77 7 79
GLASS, TAILGATE - R& R 25.127 25150 WAG-CKE 0.4 0.4 0.4 G

Replace 25.127 A 0.1 0.1 0.! C
WIre, Defogger - Repair
One side 3.807 B 0.1 0.1 0.! C
9-ugh- BSJ
79-71
_______

Subject: Air Control Cable Operation Application: 197841 CJ-5 and CJ-7 File; BODY
Models Heater -Air
Conditioning
No. 81-1 April 13, 1981
cable and intake duct vent operation and can also be 11 Disconnect heater control cables.
used on all 1978-81 CJ.5 and CJ-7 models.
Installation
PROCEDURE
Removal
5 On models with air conditioning, remove screws 11 On models with air conditioning, connect wires to
bracket.
14 Refill radiator.
compartment side of dash panel. 15 Connect battery negative cable.
8 Disconnect speedometer cable. The standard servicing operations and work times
9 Remove glove box. affected by this bulletin.
Hi-OGO. 133

Service EngineerIng Department e 14250 Plymouth Road e Detroit. Michigan 48232
79-72
Subject: Heater Diagnosis and Repair Application: All 1978-79 Jeep Vehicles File: BODY
Heater-Air Conditioning
No. 9-01 April 19, 1979
For all heater repairs, the logical and proper procedure is 4 Check engine coolant temperature. If coolant does
diagnosis before disassembly. Never assume any not achieve proper operating temperature 189°F;
component to be the cause of a problem without 87°C after engine warm-up, thermostat may be staying
verification. A systematic diagnosis procedure is open or radiator cap may be leaking or developing
extremely important in avoiding time consuming and insufficient pressure.
costly repair delays caused by incorrect or unnecessary
repairs. The most effective approach to any heater 5 If problem was revealed during initial inspection,
malfunction involves four basic procedures which are: repair as necessary and return car to owner. But, if initial
problem definition and initial inspection, coolant flow inspection did not reveal problem, refer to next
checks, vacuum system checks, and a check of all heater procedure in diagnosis sequence- Coolant Flow Checks.
system mechanical components. The four procedures
should be performed in the sequence outlined and as
described in the following paragraphs.
COOLANT FLOW CHECKS
PROBLEM DEFINITION AND
INITIAL INSPECTION I Check thermostat operation. Perform this check
only when coolant is well below operating temperature of
Problem definition is the first and most important step in 189°F 87°C. Remove radiator cap and start engine.
resolving any heater malfunction. Have the owner Increase engine speed momentarily and observe coolant
describe and, if possible, demonstrate the problem motion in radiator top tank. There should be no
condition before proceeding any further. appreciable flow through tank. If pronounced flow
occurs, thermostat is inoperative and should be replaced.
I Have owner describe and demonstrate problem. If flow was negligible, proceed to next step.
Problem may simply be misundertanding how heater
controls work. If owner knows how to operate controls, 2 Place heater controls in MAX heat position and
proceed to next step. If owner does not know how operate engine until it reaches operating temperature. If
controls operate, demonstrate proper usc and return car engine coolant reaches proper operating temperature but
to owner. heat output is still insufficient, proceed to next step. If
heat output is sufficient, return ear to owner.
2 Raise hood and inspect heater system underhood
components. Look for: loose or missing hose clamps,
collapsed hoses, loose or missing radiator cap, WARNING: The engine coolant is hot and under
insufficient coolant in radiator, damaged or loose fan pressure. Wear safety goggles, cover the radiator cap with
belt, disconnected vacuum hoses, and visually observable a shop towel and remove the cap slowly to prevent
coolant leaks. On CJ Models, check for evidence of coolant surge out of the radiator.
coolant in the heater housing drain tube.
3 Remove radiator cap slowly and note coolant
3 Inspect interior components and controls. Be sure
heater controls operate correctly and do not bind. Also level.
be sure control cables and vacuum lines are securely If coolant level is OK, install cap and proceed to next
attached and are not kinked. On Cherokee, Wagoneer step. If coolant level is low, add coolant as necessary and
and Truck models, signs of coolant on the passenger side check heater output again. If output is now OK, return
floormat or carpeting may indicate problem with heater car to owner. If output is still insufficient, proceed to next
core or related components. Refer to Mechanical step.
Component Checks, step 6.
OVER

Service Engineering Deportment e 14250 Plymouth Road e Detroit, Michigan 48232
Additional copies of ttpis bulletin are available through your zone office.
79.73
4 Bleed air from system. Loosen clamp attaching 3/4- MECHANICAL COMPONENT CHECKS
inch I.D. return hose to heater core and allow air that
may be trapped in cooling system to bleed off. Check
heater output again. If OK, return car to owner. If not A malfunction of the cable operated heater doom can
OK. proceed to next step. also restrict or completely block heater air flow. In
addition. misadjusted door cables or a cracked or
5 Stop engine and remove radiator cap. Test cap for damaged heater housing can restrict or diffuse air flow.
leakage and capacity using cooling system pressure
I Check cable operation. Cables must be securely
tester. If cap is OK. proceed to next step. If cap is faulty.
replace cap and check heater output again. If output is connected and not binding. Adjust cables if necessary.
now OK return car to owner. If not OK. proceed to next
step. 2 Check heater air intake for foreign material. On
Jeep vehicles, the intake is located on cowl between hood
and windshield.
WARNING: Coolant is hot and under pressure. Wear
safety goggles and be sure the hose end is directed into the
3 Check air flow from outlet ducts. Be sure that
bucket or drain pan. carpeting is not blocking ducts.
6 Check for system restrictions. Remove heater return
hose from heater core outlet. Attach length of heater hose 4 Check heater housing for cracks. Operate fan at
to outlet and secure end of hose in bucket or drain pan. intermediate speed and listen for escaping air. Wet
Have helper start and operate engine while you observe fingers and probe around housing to further detect any
flow from hose into container. possible cracks or voids.
NOTE: Small cracks or voids in the heater housing can

7 If coolant flow is restricted, check flow out of water be repaired using 3-M Strip Caulk 8578 or equivalent.
pump, inlet hose, and through water valve using a length
of heater hose and a container as described in step 6. 5 If above components are OK, verify system
operation and check for internal obstructions in heater
NOTE: & sure to inspect the heater core inlet and outlet
housing by comparing performance with known good
tubes and the water pump and thermostat housing inlet car. If air flow is not comparable to known good car,
and outlet necks for cast ingflash which can also restrict
flow. check and repair heater housing as necessary.
6 If coolant was observed on passenger side carpeting

8 If flow is restricted at any point, repair or replace on Cherokee, Wagoner, Truck models or in heater
components as necessary. If coolant flow was OK at all housing drain tube on Ci models, remove heater core and
points, proceed to next procedure in diagnosis check for leaks. Cap one outlet tube in core, apply 15 psi
sequence- Vacuum Checks. air pressure to core, and immerse it completely in
container filled with water. Bubbles at any point on the
VACUUM CHECKS core indicate leak. Replace or repair core as necessary if
leak is evident.
Improper vacuum assisted heater door operation or
coordination can restrict or completely block heater air NOTE: Check Cherokee, Wagoneer and Truck model
flow. The vacuum motors, hoses, and reservoir can be heater core end caps for proper positioning see
checked using Vacuum Tester J-23738 or applying illustration.
vacuum by connecting a hose to an intake manifold TOP
fitting and operating the engine. Refer to Chapter 3D -
Heater in the appropriate Jeep Technical Service Manual IN

for system operation and component location.
1 Check operation of each vacuum motor using

Tester J-23738 or by apply engine vacuum.
out
2 If tester indicates a motor or hose will not maintain
steady vacuum, replace as necessary and check operation
* of replacement component.
3 If vacuum m.nor and hoscs test OK, chcckvacuum

reservoir if equipped. If reservoir will not hold vacuum,
replace it. If reservoir is OK, proceed to next step. HEATER CORE TUBE LOCATION
4 Check vacuum assisted heater door operation. If
doors are binding or stuck, repair as necessary and check The Standard Servicing Operations and work times as
operation again. If doors operate correctly, proceed to published in the current SSO Manual are not affected by
next sequence in diagnosis procedure Mechanical
-.- this bulletin.
Component Checks. 9-041-I 3A/ 3
79-74
Subject: Sun Roof Arm Operator Application: 1979-80 CJ-7 File: BODY
Hardtop Models With Type-i Headlining-Hardtop
Sun Roof Enclosure-Exterior
Decals and Overlays
No. 80-2 Jan. 14, 1981

A new metal arm operator for the Type-i sun roof used
on 1979 and some 1980 CJ-7 hardtop models has been
released. The new arm operator provides increased
sealing ability by applying additional compression force
on the sun roof weatherstrip improving sealing against
water leaks.
If it becomes necessary to replace the arm operator on a
Type-i sun roof, the following new part should be used.
OPERATOR, Sun Roof

Ann Metal 1 8129249 28.806
PROCEDURE
Close sun roof.
Type-i Sun Roof Assembly

2 Remove ann operator attaching screws and nuts
see illustration.
4 Insert replacement arm operator into channel
opening and position arm operator on sun roof.
3 Move arm operator into channel opening and
remove arm operator. 5 Install arm operator attaching screws and nuts.
The following standard servicing operation and work lime will apply:
YEAR AND TIME

OPERATION DESCRIPTION MODEL , I
CODE NUMBER I I LEVEL
19 I 50 I SI
OPERATOR, SUN ROOF ARM

REPLACE
-
28.416 25.204 93 0.2 0.2

I G
SO-164-BSJ

S.rvlc. Engineering Department * 14250 Plymouth Road * Detroit, Michigan 48232
Additional copies at this bulletin are available through your zone ott/ce.
79-75
Subject: 1979 Phase-Out/1980 Phase-In Application: 1919 Jeep Vehicles File: BODY
Program Paint Information Metal Repair Painting
-
Water Leaks/Wind
Noise
No. 9-04 July28, 1979
As part of the 1979 Phase-Out /1980 Phase-In program, eight new 1980 exterior colon may be used on 1979
models. They are:
1980 Paint Code Color Replaces
OB Smoke Gray Metallic 9J

OE Dark Green Metallic 9H
OH Navy Blue 9T
OJ Teal Blue 9E
OK Cameo Tan 9N
OM Dark Brown Metallic 9K

OP Cardinal Red 6P
OR Caramel New Color
NOTE: Some intermix formulas are marked N/A because they were not available at time of publication.
Contact your local paint jobber for information not contained herein.
SMOKE GRAY SMOKE GRAY SMOKE GRAY SMOKE GRAY

DITZLER SHERWIN-WILWJsIS
DAR3239 SHERWIN-WILLIAMS
35-30716 34-30716
Mixing 1 Quart Mixing 1 Quart Mixing 1 Quart
DMR475 24 F5P-92 9.6 L4M-32i 5.8
DMR414 48 FSM-78 24.0 L4N-342 29.4
DMR433 108 F5L-68 38.4 L45-345 79.2
DMR435 152 F5B-Si 250.0 L4B-302
DMR49O 296 314.0
V6V-175 295.0 L45-343 584.0
DXR495 316 F5S-101 900.0
DMR499 T1C-324 878.0
996

Ss.vta Engineering Deportinsit * 14250 Plymouth Rood * Detroit, Midilgon 48232
Additional copies of this bulletin an, available through your zone oft/ce.
79-76
DARK GREEN DARK GREEN DARK GREEN DARK GREEN
METALLIC METAWC METALLIC METALLIC
DAR3242 35-30719 34-30719
Mixing 1 Quart Mixing 1 Quart Mixing 1 Quart Mixing 1 Quart
DMR435 2 F5L-70 54.0 L4S-345 48.0
DMR433 26 F5B.81 246.0 L4S-335 96.0
DMR415 56 F5S-101 506.0 L4B-302 240,0
DMR49O 122 V6V-175 551.0 N/A T1C-324 432.0
DMR441 562 F5G-90 903.0 MG-Sit 882.0
DXR49S 582
DMR499 982
NAVY BLUE NAVY BLUE NAVY BLUE NAVY BLUE

DAR3243 35-30720 DDL3243 34-30720
DMR400 26 P5W-SO 73.0 DMA359 110 L4W-301 77.6

DMR49O 196 FSR-100 238.0 DMA321 150 L4B-320 216.0
DMR4SO 686 F5B-81 535.0 DMA311 194 L4M-321 364.0
DXR495 706 V6V-175 580.0 DMA32O 374 L4L-339 882.0
DMR411 1016 F5L-70 910.0 DMA3O4 784
DMA31O 1004
TEAL BLUE TEAL BLUE TEAL BLUE TEAL BLUE

DAR3244 35-30721 DDL3244 34-30721
DMR490 56 F5P-92 51.0 DMA35I 26 L4Y-303 4.6
DMR41O 132 F5B-81 143.0 DMA35S 94 L4B-320 41.8
DMR400 422 F5L-68 283.0 DMA37S 234 L4M-321 106.8
DMR414 822 V6V-175 328.0 DMA311 784 L4L-309 218.0
DXR495 842 F5W-80 973.0 DMA31O 994 L4W-301 934.0
DMR499 1092
CAMEO TAN CAMEO TAN CAMEO TAN CAMEO TAN

DITZLER SHERWIN-WILLIAMS DITZLER SHERWIN.WILLIAMS
DAR3245 35-30722 DDL3245 34-30722
DMR49O 20 P58-81 31.3 DMA358 16 L4B-320 16,0
0MR475 92 F5E-86 68.3 DMA333 46 L4E-317 45.8
DMR486 396 F5Y-93 230.0 DMA329 306 L4Y-303 254.0
DMR400 886 V6V-175 275.0 DMA311 946 L4W-301 940.0
DXR495 906 P5W-SO 996,0 DMA31O 1076
DMR499 1266
79-77
DARK BROWN DARK BROWN DARK BROWN DARK BROWN
METALLIC * METALLIC METALLIC METALLIC

DAR3247 35-30724 34-30724
DMR433 12 P5W-SO 4.4 L4M-321 23,8
DMR435 24 F5P-92 26.1 L45-345 59.6
DMR4S3 76 FSM-71 91.0 L4S-343 119.4
DMR452 128 F5B-81 331.0 N/A L4M-341 203.0
DMR482 198 F5S-101 592.0 L4B-320 358.0
DMR49O 308 V6V-175 637.0 T1C-324 596.0
DXR495 328 P5N-76 909.0 L4N-342 882.0
DMR476 1028
CARDINAL RED CARDINAL RED CARDINAL RED CARDINAL RED

DAR3248 35-30725 DDL3248 3430725
DMR400 4 P58-81 7.7 DMA311 4 L4B-302 1.8
DMR491 36 F5P-92 416.0 DMA3S6 404 L4M-321 400.0
DMR464 186 V6V-175 461.0 DMA360 974 L4E-317 920.0
DXR495 206 F5E-86 954.0
DMR451 1086
CARAMEL CARAMEL CARAMEL CARAMEl

DAR3249 35-30726 DDL3249 34-30726
DMR49O 26 P5w-SO 10&0 DMA3O9 8 L4B-32O 72.8
DMR4O1 76 F5Y-87 283.0 DMA311 14 L4W-301 180.0
DMR486 386 F5B-81 467.0 DMA333 324 L4Y-333 448.0
DMR47S 736 V6V-175 512.0 DMA329 754 L4R-304 926.0
DXR495 756 F5E-99 972.0 DMA31O 1004
DMR499 1036
9-102-21A/J
79-78
Subject: 1979 Silver Anniversary CJ-5 Application: 1979 CJ-5 Model File: BODY
Model Paint Information Metal Repair Painting
- -

RE VISED
No, 9-03 July 6, 1979
The June 18, 1979 issue of this bulletin was mad- metallic 8C color coat. The Ditzler and Sherwin
vertantly issued with the incorrect paint formulas. Williams intermix formulas are listed below. If a
Please remove and discard that bulletin and insert local jobber has difficulty in locating a formula,
this revised bulletin, take this bulletin to the jobber for intermix
The CJ-5 Silver Anniversary Model has Quick Silver formulation.
QUICK SILVER QUICK SILVER QUICK SILVER QUICK SILVER


P/N DAR3O3O P/N F11A3909 P/N DDL3O3O P/N L11A3909
DMR414 3 F5L681 1.2 DMA3I I I0 L4W301 4. I
DM R49 I S FSYS9 3.0 DMA373 12 L4S 316 108.0
DMR433 253 F5P92 6.6 DMA395 82 L4S345 212.0
DXR495 273 F5WSO 21.5 DMA358 88 Ti C324 876.0
DMR499 1030 V6V 175 66.0 DMA323 ISO
FSSIOI 902.0 DMA3IO 1010
9M94A/J
Fl American Motors SSes Corporation

Ssnic* Engin.srlng D.pou’tm.nt * 14250 Plymouth Road . Ostroit, MIchigan 45232
79-79
Subject: Wind Noise or Water Leaks at Door Application: 1979 Wagoneer, File: BODY
Glass Cherokee, and Truck Models Metal Repair Painting
- -
No. 9-02 February 2, 1979
Some vehicles may have wind noise or water leaks NOTE: The inspeclion and possible repositioning
around the door glass and glass slide channels. This may applies to front door glass on/v.
be caused by loose fitting door glass or a front door glass
that may have been installed backwards, If repositioning of the front door glass does not correct
the problem, proceed to "DoorGlassShimniingProcedure."
Service correction involves inspecting the door glass for
proper installation, correcting the door glass installation
if necessary, and shimming the glass slide channel to limit DOOR GLASS SHIMMING
the amount of glass-to-channel travel if necessary. PROCEDURE
The following part is required and will be available after
February 5, 1979. Do not order parts before this date.- I Lower door glass completely.
2 Pull glass slide channel loose from door frame so
SHIM, Glass that shim may be installed on vertical portion of door
Slide Channel AR 8130721 25.020 frame.
INSPECTION/REPOSITIONING 3 Install shims to rear, inner portion of front door
PROCEDURE frame and to forward, inner portion of rear door frame as
required. Push glass slide channel back into door frame.
Inspect the window glass for the manufacturer’s imprinted
identification, L.O.F. If the identification is at the front
4 Raise glass midway in slide channel and check fore/aft
of the glass by the vent window, the door glass must be
repositioned so the identification is properly positioned at movement. Install additional shims if necessary.
the rear of the glass above the inside door lock. Refer to
page 3J-5 of the 1979 Jeep Technical Service Manual 5 Raise glass completely in slide channel.
for removal and installation of door glass.

MODEL -
NUMBER LEVEL
CODE 77 78 79
DOOR CLASS - INSPECT 25.014 25041 WAG-CKE-TRJ 0.1 C

Door Glass Front - Reposition 25.014 A 0,6
Shim, Door Glass Channel B
Front 25.036 WAG-CKE-TRI 0.2
Rear 25.038 WAG-CI[ 0.1
9O37-BSJ

Service Engineering Deportment e 14250 Plymouth Rood e Detroit, MIchigan 48232
79-80
_______________________________________

Subject: Paint Information All 1979 Jeep Application: All 1979 Jeep Vehicles File: BODY
Vehicles Metal Repair Painting
-
No.941 October 6, 1978
Attached is the DuPont color chart for all 1979 paint This bulletin was sent to all Jeep dealers in reduced
colon. Color name and code numbers are included in quantities. If additional quantities are required, contact
each chart. your Zone Service Manager, or Service Representative.
941 I-21A/J

Service Engineering Deportment e 14250 Plymouth Rood e Detroit, Michigan 48232
79-81
Service Technical Letter I File: Service General
lNo.80-l8Sept.25,19801
Subject Information
Sun Roof Sealer - 1980 Jeep On smne late production Jeep vehicles equipped
Vehicles with a manually operated sun roof, a black butyl
sealer was used to seal the area between the sun
roof frame and roof panel.
Whenever the sun roof frame has been removed, a

butyl or silicone sealer may be used to seal the
area between the sun roof frame and roof panel.
Apply an even bead of sealer to the roof panel
surface approximately 1/8 inch from the edge of
the roof opening.
Standard Oil Filter Damaged During 4 new oil filter, part number 3240511, has been
Severe 0ff-Road Operation - released for use on 1974-80 Cherokee, Wagoneer,
1974-80 Jeep Cherokee-Wagoneer- and Truck models. The filter is longer in length
Truck Models With Six-Cylinder and has a smaller diameter for additional filter-
Engine to-engine mount area clearance during severe of f-
road operation.
Fl AmerIcan Motors Sales Corporation

Service EngIneering Dept. * 14250 Plymouth Rd. * Detroit, Mich. 48232
79-82
i
I
July 28, 19801
Subject Information
Two-Stage Power Valve - Carburetor Some of the two-stage power valves used in subject
Models 2100 and 2150 1978-80 model carburetors have been replaced for what
Jeep Vehicles appears to be a leakage problem. Although a
small amount of fuel may enter the power valve
cover via the carburetor manifold vacuum chamber,
it does not constitute a leak problem. This
condition is normal and will not effect performance
or economy.
Tire Vibration - 1979-80 131-Inch The subject tires may be the cause of unexplained
Wheelbase J-lO Truck Models vibration problems on 1979-80, long wheelbase
Equipped With 1478-15, Load Range B J-l0 trucks. If diagnosis and test procedures do
Firestone Town and Country Tires not reveal any type of runout or imbalance
condition, install a set of test tires other than
Firestone on the vehicle and road test again. If
the vibration is now corrected, contact the
nearest Firestone regional service center.

79.83
Service Technical Letter lFIle;$eMceGeneral
No. 80-7 March 27, 1980
Subject Information
Camshaft Spring Pin Correction - When performing the camshaft pin replacement
Six-Cylinder Camshaft Pin Breakage procedure, order spring pin 0456384. Do not
on 1977-80 Jeep Vehicles - order pin GM456384.
DRB 80-3 dated February 4, 1980,
Filed Under POWER PLANT-Engines

79-84
No. 80-5 Dec. 7,1979
Subject Information
Difficult Starting After Parking Some 1978-79 models with 6-cylinder engine and
Overnight - Expanded Application model YF carburetor may be difficult to start
of DRB 9-03, Power Plant, Fuel long crank 8-12 seconds after the car has been
and Exhaust Systems parked overnight. This is caused by fuel
evaporating from the fuel bowl and lowering the
fuel level.
Installing a 115°F thermal check valve, part

number 8129872, in the charcoal canister-to
carburetor vent hose will shorten the cranking
time to an acceptable lever approximately 2-3
seconds.
Refer to Diagnosis and Repair Bulletin No. 9-03,

dated August 14, 1979. FILE: Power Plant, Fuel
and Exhaust Systems for repair procedure and
standard work time.
NOTE: DRB 9-03 originally applied to 1979 models

with a 232 CID 6-cylinder engine and 49-state
emission controls. It now applies to all 1978
and 1979 models with 232 or 258 CID engines with
model YF carburetor and 49-state or California
emission controls.
Correction to Exploded View of The exploded view of the power steering pump in
Power Steering Pump the 1977 through 1980 ANC Technical Service
Manuals shows the flow control valve facing in
the wrong direction. The hex end of the flow
control valve should be facing the valve spring
and pump body. Circle the flow control valve
and write "shown backwards" below it on the
following Technical Service Manual pages.
T SN Figure Number Page Number
1977 21-1-181 211-117

1978 2K- 116 2K- 77
1979 2K-ll6 2K-78
1980 2L-1l4 2L-75

79-85
I Flit Service General I
Service Technical Letter INO.913 A.31,1979J
Subject Information
New Exhaust Manifold Gasket- A new exhaust manifold gasket, part number
Eight-Cylinder Engines 3237270, has been released for service and will
be available after October 12, 1979. The
gasket was designed for 1979-SO eight-cylinder
engines which have 5/16-inch bolts at the two
outer holes of each exhaust manifold the inner
bolts are 3/8 inch. This gasket may be used
on 1971-78 eight-cylinder engines if the outer
5/16-inch holes in the gasket are enlarged to
3/8inch with a round file. When using this
gasket on 1971-78 engines, tighten the *outer bolts
to 20 ft. lbs. 27 N.m torque.
Note: This gasket is included in the 1980 Jeep

advance parts order program.

Additional comes of this letter are available through your zone office.
79-86
INO.9-12
Subject information
1979 CJ Model Revised Clutch During mid-April production, the clutch linkage
Linkage Components components for all CJ models were revised to lower
the clutch pedal effort on V-8 engine equipped
vehicles which have a previously released 2000 lb.
clutch pressure plate.
The new clutch linkage components will be found in

Toledo built vehicles built after VIN
J9XXXXXI24YoI and in I3rampton built vehicles built
after J9XXXXX837434.
Part numbers for the clutch linkage components are

listed below and are not interchangeable with the
previous used components.
Description Part Number Group Number
BELLCRANK, Clutch
Release Idler 5360104 5.168
PEDAL, Clutch 5359856 5.135
SPRING, Clutch 5357515 5.155
RETAINER, Brake 8130726

Pedal Sled Bracket 8.164

79-87
Service Technical Letter I’!ttti
Subject InformatiOn
Improved Door Rain Shield Rivet- An improved Delrin rivet for better retention of
1979 and Prior Cherokee, Wagoneer the rain shield located above the doors in the
and Truck Models body opening entered production in July. The
Delrin rivet is approximately 0.050-inch thicker
in diameter than the previously used nylon rivet.
Delrin rivets will be available as a replacement

part after August 20, 1979. Do not order parts
before this date.
The part number is as follows:
Description Quantity Part No. Gro!p
RIVET, Rain Shield AR 4006637 23.012

Attaching
1979 Jeep Warm Engine Operation Diagnosis and Repair Bulletin number 9-01, dated
Bulletins November 10, 1978 and filed under Power Plant/Fuel
and Exhaust Systems outlines a procedure to
install an EGR and Spark Control Kit on certain
1979 Jeep models. A supplement, Diagnosis and
Repair Bulletin number 9-02, dated January 25,
1979, and filed under Power plant/Fuel and
Exhaust Systems, limits the use of the kit to
vehicles built before VINs J9X15XX047200 and
J9X25XX042459. Vehicles built after the
published VINs were assembled with the kit
components and neither of the referenced
bulletins apply.

Service Engineering Dept. * 14250 Ptymouth Rd. * Detroit, MIch. 48232
79-88
Service Technical Letter I
Subject Information
1977-79 Cherokee-Wagoneer.-Truck panel and watershield paper, the paper becomes
Models damaged and must be replaced to prevent water
leaks.

Description Qty. Part No.

Rear Door, Left
Paper, Watershield 1 5464554 23,012

Rear Door, Right

Front Door,Left

Front Door, Right

Sufficient for
One Door

as published in the current SSO Manual are not
affected by this bulletin,

79-89
[No.O9 June2S,19791
1
Subject Information
1979 Jeep Models - Severe Engine Severe engine spark knock may occur when towing
Spark Knock While Trailer a trailer or operating the vehicle with a heavy
Towing or During Heavy Load load during high ambient temperatures and low
Operation humidity.
This condition may be corrected by using a

premium grade unleaded fuel and resetting the
initial ignition timing to the low side of the
allowable adjustment range.

79-90
I
[No.9 Junel9.19791
Subject Information
Antenna Splitter Box Relocation - The antenna splitter box is now located on the
1979 Cherokee, Wagoneer, and inner cowl top panel to the left of the right
Truck Models with C.B. Radio, side cowl panel and abqve the antenna cable
access hole. It is attached to the cowl panel
with double-coated tape.
Vi American Motors Sales Corporation

No. 9-07 April 25. 1979
Subject Information
New Latch and Striker Assembly - New door latch and lock striker assemblies are
1979 Cherokee-Wagoneer-Truck being used on 1979 Cherokee, Wagoneer, and Truck
Doors and 1979 Cherokee-Wagoneer models. The new striker assembly is adjusted by
Tailgates loosening the Torx-head screws in the striker
assembly and moving the assembly to the desired
position on the body pillar. Tighten the Ton-
bit screws to 18-30 ft. lbs. 24-40 N.m torque.
On 1979 Cherokee and Wagoneer model tailgates,

the same type of latch is used as is found on the
door. The striker is a stud-type with a Ton-
head and is adjusted by loosening the striker,
moving it to the desired position and then
tightening the striker to 18-30 ft. lbs.
24-40 N.m torque.
Service parts are available and are identified as

‘Type 2" in the latest Jeep Parts Catalog.
The Standard Servicing Operation and work times

are not affected by these changes.

_____

OF INTEREST TO: - File: Service General
J Dealer Principal XJ Service Writer
X Service Manager - Mechanic No. 9-06 March 30. 1979
Subject Information

liberal amount of WD-40 penetrating lubricant, or
drying, repeat the above procedure using AMC/Jeep
Golden Eagle window defogger is installed on a bronze tone
Out Spare Tire Carrier- 1976-79 mounted on the swing-out spare tire carriers. The
CJS and CJ7 Models carrier may be damaged if larger than specified
VI American Motors Sales Corporation

79.93
LI Dealer Principal Service Writer
X Service Manager Mechanic No. 9-05 March 3, 1979
Subject Information
Compression Pressure Specification The compression pressure specifications for

Update - 1977-79 Six- and Eight- 1977-79 six- and eight-cylinder engines have been
Cylinder Engines updated. The pressure specifications for both
six- and eight-cylinder engines are now 120 to
150 psi with a maximum allowable pressure

1977-79 Jeep Technical Service Manuals,
Roof Rack Moan - 1979 Wagoneer and A roof rack moan may be produced by the front end
Cherokee Models rail of the roof rack. The moaning noise can be
eliminated by positioning the front end rail over
the center stanchion with the large diameter of
the end rail toward the front of the vehicle.
NOTE: The roof rack moan is very similar to an

axle noise. Be sure not to misdiagnose the noise.

Additional copies of this letter are available through your zone oft ice.
79.94
OF INTERE ST TO: File: Service General
Q Dealer Principal X Service Writer
X Service Manager X Mechanic No. 944 January 25,1979
Subject Information
Forward Clutch Piston Center Seal - A new forward clutch piston center seal was phased
All Jeep Models With Hydramatic into production during the 1979 model year. The
Transmission new seal is a lip-type unit and replaces the
beveled edge-type seal previously used.
The new seal is interchangeable with the old seal

and can be used in current and prior model year
automatic transmissions.
Engine Operation Refinements have made emission control systems an

integral part of engine operation. If these
systems do not function properly1 they may cause
abnormal engine operation.
For example: if the EGR valve is not functioning

properly, the engine will ping or spark knock
severely. If this condition is allowed to
continue for a prolonged period of time, piston
burning or scuffing may result.
Dashpot Adjustment - Addition to A procedure has been developed for dashpot adjust
1979 Jeep Technical Service Manual ment on all 1979 Jeep vehicles equipped with a
manual transmission and a 258-2V or 304 CID
California engine.
The dashpot adjustment procedure should be noted

in the 1979 Jeep Technical Manual at the bottom of
page lA-20 and is as follows.
Dashpot Adjustment
With the throttle set at curb idle position, fully

depress the dashpot stem and measure the clearance
between the stem and the throttle lever. The
clearance should be 0.093 in. 2.362 mm ± 0.015
in. on. six-cylinder; ± 0.032 in 0.813 mm on
eight-cylinder. Adjust by loosening the locknut
and turning the dashpot.

Engineering Dept. * 14250 Plymouth Rd. * Detroit, Mich. 48232
Service
Additional copies of this letter are available through your zone offica
,n tic
X Service Manager X Mechanic No.943 November 16,1978
Subject Information
Automatic Transmission Clutch and The chart used in the 1976 through 1979 Jeep
Band Application Chart Technical Service Manuals is incomplete. The
chart should have shown that the Lo Clutch
Roller is also applied in 2-range first gear.
Correct the chart by inserting the necessary
indicator dot as shown in the illustration.
CLUTCH - BAND APPLICATION

FIi1N D 2 1
I I 23*2
ISIWAROCLUTCH * * * S S S
DIRECT CLUTCH S S
FROST SANS *
INTERMLDIATI CLUTCH S 13 5
ISTLIIMEWATE ROLLER S S
REAR SAID S S
LIcLUTCHIOLLER
- - -
S
-
S
£_ -
*
®ON SOT NO if FECT
‘Place dot here.
Service Technical Letter No. 9-02, Eliminate the subject and information in the
dated October 2, 1978 All 1979
- subject Service Technical Letter regarding blade-
Jeep Models - Starter Solenoid type starter solenoid terminals. Jeep vehicles
With Blade Terminals have stud-type starter solenoid terminals only.

7Q.QA
J Dealer Principal X Service Writer
X Service Manager IXI Mechanic No. 9-02 October 2, 1978
Subject information
Service Technical Letter Number The subject Service Technical Letter was
8-07, dated September 28, 1978 inadvertently numbered 8-07. The correct number
should be 9-01. Please make the necessary
correction and file this Service Technical Letter
in the Service General of your 1979 Diagnosis and
Repair Bulletin binder.
All 1979 Jeep Models Equipped With All Jeep Models equipped with Quadra-Trac built
Quadra-Trac-Transmission to after August 4, 1978 and VIM .J9A15NN009209 have
Quadra-Trac 0-Ring Seal an 0-ring seal between the automatic transmission
and Quadra-Trac mating surface.
The Quadra-Trac housing has been machined to

accept the 0-ring seal that replaces the gasket
previously used.
Part numbers for the 0-rjng seal and Quadra-Trac

assembly w/O-ring seal are as follows:
0-ring, Transfer 1 5359090 18.500

Case to Transmission
Transfer Case 1. 8128994 18.500

Assembly WQT
NOTE: If the front half of Quadra-Trac housing

needs replacing, you must order the old style
housing group 18.510-2, PN 8122386 and a
gasket group 18.500-3, PN 998315. The front
half of the Quadra-Trac housing that is machined
to accept the 0-ring seal is not available as
a replacement part at this time.
over
PU AmerIcan Motors Sales Corporation

79.97
Service Technical Lettercont’dI
Subject information
All 1979 Jeep Models Starter

- The starter solenoid on the subject vehicles has
Solenoid With Blade Terminals blade type terminals attached to the S and I stud
terminals. The addition of the blade terminals
allows either an early or late style harness to
be connected to the solenoid.
CAUTION: Do not remove the blade type terminals

on service applications that require the study
type push-on terminals. Loosening the stud
retaining nut may cause a loss of the internal
connection and render the solenoid inoperative.
1978 Jeep Owner’s Manual Supplement Under separate cover, we have sent to all dealers
several copies of a supplement to the Owner’s
Manual for 1978 Cherokees equipped with the Brush
Guard accessory. In the event that you need
additional copies, contact your local Zone Office.
1979 Jeep Technical Service Manual On pages 2E-6 and 2E-8 of the 1979 Jeep Technical
Correction Service Manual, tool number J-28488 appears twice
on DARS Chart step 7 and step 12. This tool
number should be J-24649. Please make the neces
sary correction.
79.95
X Service Manager Mechanic No. aw September 26, 1978
Subject Information
Early Built 1979 Cherokee and Some early production 1979 Cherokee and Wagoneer
Wagoneer Models Equipped With a models built with a black, russet, or desert
Bench-Style One-Piece Front Seat beige vinyl covered, bench-style front seat may
have incorrect listing material. The listing
material is the fabric sewn to the bottom edge of
the seat cover. When the seat cover is installed
the listing material is attached to the base of
the seat frame with hog rings. In the event a
vehicle is received with the seat cover pulled
away from the base of the seat frame and the list
ing material is white, replace the seat cover.
The following seat covers are available and can be
ordered as required.
Upholstery, Front Seat Cushion Cover
Quantity Color/Model/Part No. Group
1 Black Wag 5465153 29.152-1

Black Cke 5465197
29.152-1
1 Russet Wag 5465155
1 Russet Cke 5465217
I Desert Beige Wag 5465156 29.152-1

I Desert Beige Cke 5465199
The work time and operation number are available

in the current Standard Servicing Operations
Manual.
1979, 360 CID V-8 Engine Cold Some 1979, 360 CID V-S engines may have a spark
Engine Spark Knock knock condition during the engine warm-up period.
This condition is most noticeable during heavy or
wide open throttle acceleration.
Check the ignition timing to insure it is set to

specification but do not try to correct this con
dition by making other adjustments or replacing
parts. A service repair is being developed and
will be released as soon as possible.

fit’
Subject: Carbon Knock Application: 1980-81 Jeep Vehicles File: POWER PLANT
with Four-, Six-, or Eight-Cylinder Engines
Engine
- No.81-2 Feb. 19, 1981
The four-, six-, and eight-cylinder engines used in PROCE DURE

1980-81 Jeep vehicles may develop a knock caused by
carbon buildup on the pistons and combustion chambers.
Carbon knock is more likely to occur on high mileage 1 Remove air cleaner top.
engines but may also occur on low mileage engines
depending on the type of driving involved. Carbon knock is 2 Operate engine until it is at normal operating
not sensitive to engine loading and is most noticeable temperature
when the engine is not under load. Carbon knock may be
loudest when the engine is cold and may continue after the 3 Operate engine at fast idle speed and spray
engine warms up. cleaner directly into carburetor venturi until
- - - container is empty.
Service correction mvolves removing carbon buildup using
Jeep Carburetor and Combustion Area Cleaner, or 4 Stop engine when container is empty and allow
equivalent, if the knock is not sensitive to engine load, cleaner to penetrate carbon for five minutes.
The following part may be required. 5 open and close throttle rapidly
Description Quantity Part No. Group 6 Install air cleaner top.

CLEANER, Carburetor Case of 8993818 15.410
and Combustion Area 12
YEAR AND TIME

OPERATION DESCRIPTION MODEL LEVEL
80 81 82
COMBUSTION CHAMBERS, CYLINDER 1.059 1117 All 0.3 0.3 C

HEAD CLEAN
-
8i-039-O1A/J

S.rvic* Enginarlng D.portmsnt * 14250 Plymouth Road * D.trolt, Michigan 48232
Addötiona copies of this bulletin are available through your zone office.
Subject: Six-Cylinder Camshaft Application: 1977-80 Jeep Vehicles File: POW ER PLANT
No. 80-3 Feb. 4, 1980
valve timing, the cause may be a broken camshaft pin. any air conditioning system fittings.
It is no longer necessary to replace the camshaft be Move the condenser aside as a complete
Service correction involves replacing ing bolts and move condenser up and out
a broken of way.


ment.
3 Remove fan and shroud. drill bit.
3. Insert G448423 screw into drilled pin
4 Disconnect overflow hose, radiator hoses and and carefully pull pin from camshaft.
radiator. prevent metal chips from entering the pan.

S.rvic. Enginaring Dartnnnt * 14250 Plymouth Road * Dtrolt, Michigan 48232
80-2
CAUTION: If the camshaft moves rearward, repo light film of AMC Perfect Seal, or equivalent, on out
14 Install camshaft gear and timing chain. Tighten cover. Turn bolt until tool bottoms against cover.
camshaft gear bolt to 50 foot-pounds 68 N-m
108 N-m torque.
Install fuel pump. Tighten pump bolts to 16 foot. NOTE: If the crankshaft turns before the damper
pounds 22 N-m torque and connect fuel lines. bolt torque value is reached, the damper can be held
sides of timing case cover gasket with sealer. Apply
1/8-inch 3 mm bead of sealer to joint formed at 24 If equipped with air conditioning:
pulley.
18 Loosen front four oil pan bolts about 3 turns
c Install air conditioner condenser.
installation, 25 Install drive belts on pulleys.
19 Position timing case cover on engine. Place
26 Install radiator. Connect radiator hoses, trans
20 Install and tighten oil pan and front cover 27 Install fan and shroud,
screws.
pounds 9 N-rn torque and 5/16-18 oil pan screws
to 11 foot-pounds 15 N-rn torque.
24 Nm torque.
YEAR AND TIME

COOE NUMBER LEVEL
n 78 79
PIN, SPRING CAMSHAFt GEAR

DRIVE- REPLACE 1.040 1163 6-CyL 1.7 1.7 1.7 1.7 G
With Air Conditioning- Md 0.3 0.3 0.3 0.3
With Power Steering- Add. 0.4 0.4 0.4 0.4
SO-044-OIA/J
80-3
. L’s-sJ

Subject: Exhaust Manifold to Exhaust Application: 1980 Jeep Vehicles File: POWER PLANT
Pipe Studs and Nuts with Six-Cylinder Engines Engines
No 80-2 Nov. 2,1979
A new design exhaust manifold locking stud and 5 Install two new hexagon nuts and tighten them
hexagon nut has been introduced for 1980 six-cylin in equal amounts to 20 foot-pounds 27 N.m torque.
der engines.
STUD REMOVAL PROCEDURE
The stud incorporates a special thread design that
contains a locking feature the thread design can be 1 Clean foreign matter from stud.
recognized by its shallow thread depth. The stud
also has a triangular shaped surface as opposed to a 2 Turn two standard 3/8-inch xiS nuts down stud.
round surface that helps in the locking process.
The hexagon nut is coated with "Seez Pruf" coat 3 Using hand tools, turn nuts in opposite direc
ing and is an SAE grade 8 nut. These are the only tions to lock together.
stud and nut assemblies that should be used on 1980
six-cylinder engines. 4 Using hand tools, remove stud using locked nuts
as leverage point.
Because of the assembly design, special procedures
are needed for service. When servicing the joint only, 5 Start standard 3/8-inch x 16 nut onto new stud.
as in the case of a cylinder head removal, follow the Install nut onto end that contains approximately 1
Nut Removal Procedure. If studs are being replaced, inch of threads before band.
as in the case of stud damage or loss of the "shallow
thread" locking feature, the Stud Removal Procedure 6 Start stud into manifold.
must be followed to prevent possible damage to
the exhaust manifold. 7 Carefully tighten nut until about four threads
are exposed past nut.
NUT REMOVAL PROCEDURE
NOTE: Do not tighten nut down on stud any farther
1 Saturate stud and nut assemblies with AMC/Jeep than necessary as stud locking design may be
Heat Valve Lubricant part number 8993552 and disturbed.
allow to penetrate for approximately five minutes.
8 Start another standard 3/8-inch x 16 nut onto
CAUTION: Do not use impact tools as this can exposed threads. Using hand tools, tighten nuts in
damage the stud and/or manifold. opposite directions to lock together.
2 Remove existing nuts using hand tools. 9 Tighten stud into manifold to 20 foot-pounds
27 N-m torque.
3 Clean stud of foreign material.
10 Remove two nuts taking care not to back out
4 Position exhaust pipe flange over studs. stud.
YEAR AND TIME

CODE NUMBER LEVEL
80 81 82
STUD, EXHAUST PIPE FLANGE TO

MANIFOLD--REPLACE 4178 4192 6.CyL 0.7 G
Both 4.178 A 0.9 G
80-0 20.04 Al

ServIa Engineering Department . 14250 Plymouth loud * Detroit, Michigan 48232
80.4
Subject: Rear Crossmemher and Torque Application: 1980 CJ-7 Four- File: POWER PLANT
Reaction Bracket Reposition Cylinder Equipped Vehicles Built Engines
Between VIN J0M93XX009040
and J0M93XX014233
No. 80-1 Oct. 30,1979
Some 1980 CJ-7 four-cylinder equipped vehicles built 7 Align forward slot in rear crossmember over
between yIN J0M93XX009040 and J0M93XX014233 forward hole in frame see illustration. Install rear
were assembled with the torque reaction bracket engine mount nuts loosely to hold crossmember in
installed in the rear towards the rear of the vehicle place while crossmember bolts are installed. Tighten
set of holes in the transmission-to-transfer case crossmember bolts to 30 foot-pounds 41 N-m
adapter and the rear crossmember positioned incor torque.
rectly. This combination results in a noise being
caused by contact between the transfer case and the
rear crossmember reinforcement.
Service correction involves moving the torque reac

tion bracket to the front set of holes in the adapter
and correctly positioning the rear crossrnember.
PROCEDURE
1 Raise vehicle.
2 Support transfer case assembly.
Remove rear engine mount nuts and torque

3
reaction bracket stud nut. S CROSSMEMBER
90957
4 Remove rear crossmember bolts and rear cross- Rear Crossmember Location
member.
8 Tighten rear engine mount nuts to 40 foot-
5 Remove torque reaction bracket from trans pounds 54 N-rn torque. Install and tighten torque
mission-to-transfer case adapter. reaction bracket stud nut to 25 foot-pounds 34 N-rn
torque.
6 Install torque reaction bracket to adapter
using forward towards the front of vehicle set of 9 Remove support at transfer case.
holes in adapter. Tighten bolts to 30 foot-pounds
41 N-rn torque. 10 Lower vehicle.
CROSSMEMBER, REAR AND TORQUE

REACFION BRACKET REPOSITION-
80-021-BSA

Service Engineering Department e 14250 Plymouth Road e Detroit, Mlchigun 48232
80-5
Subject: Coolant Recovery Return Application: 1980 Cherokee, File: POWER PLANT
Hose Kinked Wagoneer and Truck Models With Cooling
Six-Cylinder Engine
No. 80-1 March 31, 1980

On some 1980 Cherokee, Wagoneer and Truck 2 Remove radiator cap.
models with a six-cylinder engine and coolant re
covery system, the coolant return hose may kink near 3 Inspect radiator upper hose for signs of pressure
the coolant recovery bottle. A kinked hose may not or fan belt rubbing. Replace radiator upper hose if
allow coolant to return from the recovery bottle to necessary.
the radiator and may cause the radiator upper hose to
collapse. NOTE: Do not waste reusable coolant.
Service correction involves replacing the existing cool- 4 Remove coolant recovery hose clamps at radia
ant recovery return hose with a molded-type hose. tor and coolant recovery bottle.
The following part is available and required. 5 Remove and discard existing coolant recovery
return hose.
Description Quantity Part No. Group Trim replacement coolant recovery hose as
follows: Cut 1.25 inches from short end of hose and
HOSE, Coolant cut 5.25 inches from long end of hose. Cut short hose
Recovery Bottle end at 450 angle and cut long end at 900 angle.
1 3237203 2.025
7 Install replacement coolant recovery hose. In
sert short end of hose into coolant recovery bottle
PROCEDURE and install long end on radiator filler neck. Be sure
hose end inserted in recovery bottle wifi always be
1 Place drain pan under radiator. submerged in coolant.
WARNING: Cooling system pressure must be re- 8 Install hose clamps. Refill radiator and install
lieved before removing the radiator cap. Place two or radiator cap.
three shop towels over the cap. Turn the cap counter
clockwise to its safety catch and allow pressure to re- NOTE: If the radiator fills prior to complete usage
lease. Do not press the cap down or attempt to re- of the expelled coolant, pour the remainder of the
move it until all pressure is released, coolant into the recovery bottle.
YEAR AND ‘TIME

OPERATION MODEL
50 81 82
HOSE, RADIATOR CORE OVERFLOW -
REPLACE 2.020 2026 6 Cyl. 0.2 M
HOSE, COOLING SYSTEM REPLACE - 2020 M

Includes hose clamps as required
2.038 6 Cyl. 0.3
Upper radiator
80-089-024

Service Engineering Deportment e 14250 Plymouth Road s Detroit, Michigan 48232
80-6
Subject: Spark Knock Repair Application: 1980 49-State File: POWER PLANT
Cherokee and J-10 Truck Engine Electrical
Models With Manual
Transmission, 360-Cifi
Engine, and Standard or
Heavy-Duty Cooling No. 80-2 April 10, 1980
Some early production 49-State Cherokee and J-10 INSPECTION PROCEDURE
Thick models with manual transmission, 360 Cli
eight-cylinder engine, and standard or heavy-duty Determine if vehicle has standard or heavy-duty
cooling may develop a persistent spark knock at a cooling as follows:
steady speed of about 40 mph.
e If vehicle has CTO switch in thermostat
Service correction involves adding a vacuum ported housing, vehicle has heavy-duty cooling
spark Cr0 switch, relocating the EGR Cr0 switch system. Refer to Correction Procedure -
on models with heavy-duty cooling, and replacing the With Heavy-Duty Cooling.
EGR valve restrictor plate,
The foilowing parts kit is required and will be availa e If vehicle does not have CTO switch in
thermostat housing, vehicle has standard
ble the week of May 5, 1980. Do not order parts cooling system. Refer to Correction Pro
before this date. cedure With Standard Cooling.
-

Correction Procedure -With Standard Cooling
KIT, Spark Knock
Eliminate 1 8130428 4.700 1 Remove air cleaner assembly,
2 Remove EGR valve. Discard EGR valve restric

This kit contains the following parts: tor plate and gaskets but retain EGR valve.
Description Quantity Part No. Group 3 Position gasket on each side of replacement
EGR restrictor plate and install restrictor plate and
TEE, Vacuum Ported EGR valve. Tighten valve attaching bolts to 14 foot-
Switch and Heater pounds 19 N-rn torque.
Hose Nipple-to-
Manifold 1 G444150 4.704 4 Drain approximately three quarts of engine
TEE, Vacuum 1 3210891 4.701 coolant from radiator into clean container.
GASKET, Exhaust Gas 2 8221283 4.700
TEE, Vacuum Hose 1 3233134 4.701 WARNING: Be very careful when draining the
PLATE, Exhaust coolant as it may be hot enough to cause poten
Gas Recirculating tially serious injury through scalding.
Valve Restrictor 1 3285342 4.700
SWITCH, Vacuum 5 Remove pipe plug from rear of thennostt
Ported Spark CTO 1 housing,
3229450 4.704
HOSE 0.01 56 ID
50 Inches Long NOTE: If the thermostat housing does not contain
1 8125812 4301 a pipe plug, replace the thermostat housing with
housing 3210852.
6 Install ported vacuum spark CTO switch in pipe
plug hole in thermostat housing. Tighten switch to
Description Quantity Part No. Group 20 foot-pounds 27 N.m torque.
GASKET, 7 Remove reverse delay valve and short length of
Thermostat AR 8187543 2i02 vacuum hose that connects valve to distributor
ROUSING, vacuum advance. Retain delay valve and short length
Thermostat AR 3210852 2.102 of hose.

Service Engineering Department * 14250 Piyniouth Road * Detroit, Michigan 48232
Additional copies of this bulletin si-a avallab.’e thmugh your zone office
80-7
8 Connect hose from vacuum line T-connector to 8 Install two-port EGR Cr0 switch removed
distributor vacuum advance unit. Then disconnect previously in nipple.to-manifold tee and tighten
opposite end of this hose and connect it to center switch to 20 foot-pounds 27 N’m torque. Po
port of spark CTO switch. sition CTO switch so switch ports are pointing up
ward. Tighten tee so that CTO switch faces front of
9 Connect 12-inch length of vacuum hose to vehicle.
vacuum line T-connector and to inner port of spark
CFO switch, 9 Connect heater hose to heater hose elbow.
10 Connect short length of vacuum hose and re 10 Remove and discard vacuum hose connected
verse delay valve to top port of spark CTO switch. Be to carburetor spark port. Replace this hose with
sure brown color coded side of delay valve is toward 24-inch length of vacuum hose and connect new hose
spark CTO switch. to carburetor spark port and to inner port of EGR
CTO switch.
11 Connect a two-inch length of vacuum hose to
reverse delay valve and install vacuum line T 11 Connect EGR thermal vacuum switch hose to
connector, supplied in kit, in opposite end of this remaining port on EGR CTO switch. Shorten hose as
hose. necessary to obtain satisfactory hose routing.
12 Using vacuum line T-connector as guide, cut 12 Install three-port vacuum ported spark Cr0
vacuum hose connected to diverter valve and mani switch in front of intake manifold at location form
fold vacuum port and connect cut ends of this hose erly occupied by EGR CTO switch. Tighten switch to
to T-connector. 20 foot-pounds 27 N-rn torque.
13 Fill cooling system and purge system of air. 13 Remove reverse delay valve and vacuum harness
that connects top port of Cli switch in thermostat
14 Verify vacuum hose routing. Refer to Figure 1. housing to carburetor spark port tee fitting. Retain
harness and delay valve.
15 Install air cleaner and close hood,
14 Connect nine-inch length of vacuum hose to
Correction Procedure - With Heavy Duty Cooling carburetor spark port tee fitting and to bottom port
of three-port vacuum ported spark CTO switch in
1 Remove air cleaner. manifold.
2 Remove EGR valve. Discard EGR valve restric 15 Locate vacuum, hose that connects manifold
tor plate and gaskets but retain EGR valve. vacuum tee fitting to bottom port of Cli switch
in thermostat housing and remove manifold vacuum
3 Position gasket on each side of replacement tee fitting tee and replace it with four-port hose tee
EGR valve restrictor plate and install restrictor plate supplied in kit.
and EGE valve. Tighten valve attaching bolts to 14
foot-pounds 19 N’m torque. 16 Connect vacuum hose from bottom port of CTO
switch in thermostat housing to a port on four-port
4 Drain approximately three quarts of engine hose tee.
coolant from radiator into clean container.
17 Install vacuum harness and reverse delay valve.
WARNING: & very careful when draining the Connect short vacuum hose to top port of three-port
coolant as it may be hot enough to cause po vacuum ported spark CTO switch and connect long
tentially serious injury through scalding. hose to remaining open port of four-port vacuum tee.
5 Remove EGR CTO switch from front of intake 18 Connect 9-inch length of vacuum hose to top
manifold. Retain switch. port of CTO switch in thermostat housing and to
center port of three-port vacuum ported spark CTO
NOTE: It may be necessary to remove the coil switch.
bracket to gain access to the EGE CTO switch.
19 Fill cooling system and purge system of air.
6 Disconnect heater hose from heater hose elbow
and remove elbow from intake manifold. 20 Install coil bracket if removed.
7 Install heater hose elbow in female end of 21 Verify correct hose routing. Refer to Figure 2.
vacuum ported switch and heater hose nipple-to-
manifold tee. 22 Install air cleaner and close hood.
80-8
-
- J PO*T!DVCUUM
Fig. 1 49-State 360 With Manual Transmission and STD Cooling
- PURGE VAW SIGNAL

CNIISTEE
.W41F0L0 VACUUM
EGS CTO - -
POIED VACUUM
Fig. 2 49-State 360 With Manual Transmission and HI Cooling
YEAR AND TIME

OPERATION DESCRIPTION COST OPERATION SKILL
MODEL
CODE NUMBER LEVEL
80 81
KIT, SPARK KNOCK ELIMINATE -
INSTALL 4.100 4297 0

With standard cooling Cke-Trk 0.5
With heavy-duty cooling Cke-Trk 0.7
80-075-04.1
80-9
Subject: Electric Choke and Idle Application: 1980 Jeep Models File: POWER PLANT
Solenoid Feed Wire Routing Equipped with Six-Cylinder Engine Electrical
Engme
No. 80-1 Oct. 26, 1979
On 1980 Jeep models with six-cylinder engines, the HARNESS

idle solenoid wire and the electric choke wire should
be routed with a clearance of at least 1/4 inch from
the air injection manifold. If these wires have less
than 1/4 inch clearance, they must be relocated.
NOTE: The electric choke and idle solenoid feed

wires are fused to protect the circuit if a short or
overload should occur.
Service correction involves routing the harness

containing both wires OVER the diverter valve hose
and between the carburetor and choke diaphragm.
PROCEDURE
1 Remove air cleaner.
MANUAL
2 Disconnect electric choke feed wire from TRANSMISSION
electric choke.
Electric Choke and Idle
3 Disconnect idle solenoid feed wire from idle Solenoid Feed Wire Routing
solenoid.
NOTE: The idle solenoid is not used on manual

transmission equipped vehicles and the feed wire 6 Connect electric choke feed wire to electric
must be tied back with a nylon strap, part number choke.
3223227 see illustration.
7 Install air cleaner,
4 Route harness containing both feed wires OVER
diverter valve hose and between carburetor and choke CAUTION: Route and secure wires and hoses so that
diaphragm see illustration. they are not pinched, kinked, pulled too tight or
interfering with moving parts such as the carburetor
5 Connect idle solenoid feed wire to idle solenoid linkage or edges of the hood,
if equipped.
YEAR AND TIME

CODE NUMBER I LEVEL
80 I 81 I 82
WIRES, IDLE SOLENOID AND ELECTRIC

CHOKE FEED REPOSITION
- 3165 3315 6-Cyl. 0.1
I °
80-007-031
P1 Amsdcai Motors Sales Corporation

S.rvlcø Enqln..rlng D.partin.nt * 14250 Plymouth Road * D.trolt, MichIgan 48232
Additional copies of This bulletin a,. available through your zone oFfice.
80-10
Subject: Altitude Performance Application: 1968-SO Jeep File: POWER PLANT -
No. 80-7 Nov. 10, 1981
formance adjustments for 1968-80 Jeep vehicles re control label, part number EF 8130457, to the engine
adjustments are intended to improve driveability perfor component that can be readily removed from the
certified.
These unique labels are available in a kit, part number engine compartment to identify these vehicles,
Distribution Services On 1968-80 Jeep vehicles originally sold for operation at
The adjustment procedures and unique labels must be ment or specified in the apropriate Jeep Thchnical Ser
made available at no cost to independent repair facilities vice Manual should be retarded 50* The engine idle
81-114..04AJ1

S*rvlcs Engineering Dpartm.nt * 14250 Plymouth Road * D#rolt, Michigan 48232
80-11
SCN 176

Subject: Exhaust Gas Recfrculation Application: 1980 49-State Cherokee File: POWER PLANT
EGR System Revision Wagoneer, and Truck Models With Fuel and Exhaust
360 CID Engine, Automatic Trans Systems
mission, 2.73 or 3.31 Ratio Axles
and Standard or Heavy-Duty Cooling
System No. 80-6 Oct. 27, 1980
The EGR system on 1980 Cherokee, Wagoneer, and * If vehicle has EGR/CTO switch in right rear
Truck models with 360 CID engine, automatic trans corner of intake manifold, vehicle has heavy-
mission, 2.73 or 3.31 ratio axles, and standard or duty cooling system. Refer to Revision Pro
heavy-duty cooling system may be revised to improve cedure With Heavy-Duty Cooling System.
-
acceleration. This revision is an EPA approved change

and applies to all similiarly equipped 1980 Cherokee,
Wagoneer, and Truck models. Revision Procedure - With Standard Cooling
Service revision involves replacing the EGR valve 1 Remove air cleaner assembly.
restrictor plate and forward delay valve, and adding
a non-linear valve to the EGR system. 2 Remove EGR valve and remove valve gaskets 2
and restrictor plate. Retain valve but discard gaskets
The following parts kit is required and available: and plate.
4
Description Quantity Part No. Group 3 Install replacement gaskets and restrictor plate
code T on EGR valve and install valve on manifoldil
4
KIT, EGR System Tighten valve attaching bolts to 14 foot-pounds
4.700 19 N.m torque.
Revision 1 8130437
Kit Contents: Remove and discard forward delay valve from
4
GASKET, EGR vacuum hose that connects EGR/CTO switch to
Valve 2 3221283 4.700 EGR/TVS switch.
FITTING, Vacuum
Hose Connector 1 3233134 4.701 5 Tnstall replacement forward delay valve in hose
VALVE, Non-Linear 1 3233991 3.051 with black side of valve toward EGR/CTO switch
Valve, Forward Delay 1 3235261 4.700 Fig. 1.
RESTRICTOR
PLATE, EGR Valve 6 Remove and discard tee fitting in manifold
Code T 1 3235343 4.700 vacuum-to -diverter valve vacuum hose and install
HOSE, Vacuum vacuum hose connector fitting in place of tee fitting.
Eight Inches Long 1 3228064 4.700
FITTING, Vacuum 7 Connect 4-inch length of vacuum hose to center
Hose Tee H.D. port of non-linear valve and to open port on vacuum
Cooling 1 3210891 3.050 hose connector fitting installed in previous step Fig.
1.
PROCEDURE
Inspection Procedure 8 Disconnect vacuum hose attached to tee fitting
in canister purge valve signal-to-carburetor hose and
Determine if vehicle has standard or heavy-duty connect hose to bottom port of non-linear valve
cooling as follows: Fig. 1.
* If vehicle has EGR/CTO switch in right 9 Connect 4-inch length of vacuum hose to upper
front corner of intake manifold, vehicle has port of non-linear valve and to open port of tee
standard cooling. Refer to Revision Pro fitting in canister purge valve signal-to.carburetor
cedure With Standard Cooling. hose Fig. 1.

80-12
PURGED VAPORS - CANISTER PURGE
FROM FUEL VALVE SIGNAL
EVAPORATIVE SYSTEM
DIVERTER VALVE
AIR PUMP
NON-LINEAR VALVE
SPARKICTO SWITCH
EGR VALVE
DISTRIBUTOR
ORIFICE PLATE
EGR/TVS
REVERSE DELAY
VALVE Oil. FILLER CAP
EGR/CTO SWITCH
1._ fl- FRONT -

FORWARD
DELAY VALVE REVISED VACUUM
EMISSION CONTROL
SYSTEM SCHEMATIC MANIFOLD VACUUM J I
PORTED VACUUM = =
Fig. 1 Standard Cooling System
Revision Procedure-With Heavy-DutyCooling System 6 Connect 4-inch length of vacuum hose to center
port of non-linear valve.
1 Remove air cleaner assembly.
7 Locate vacuum hose that connects bottom port
2 Remove EGR valve and remove valve gaskets 2 of spark/CTO switch to vacuum tee fitting and cut
and restrictor plate. Retain valve but discard gaskets hose midway between switch and tee fitting. Connect
and plate. hose from spark/CTO switch to bottom port of non
linear valve and connect hose from the fitting to top
3 Install replacement gaskets and restrictor plate port of non-linear valve Fig. 2.
code T on EGR valve and install valve on manifold.
Tighten valve attaching bolts to 14 foot-pounds 8 Locate vacuum hose that connects reverse delay
19 N.m torque. valve to manifold vacuum fitting and cut hose
midway between valve and fitting; then connect cut
4 Remove and discard forward delay valve from ends of hose to vacuum hose tee fitting supplied in
vacuum hose that connects EGR/CTO switch to kit.
carburetor Fig. 2.
9 Connect 4-inch length of vacuum hose attached
5 Install replacement forward delay valve in hose to center port of non-linear valve to vacuum hose tee
with black side of valve toward carburetor Fig. 2. fitting installed in previous step.
80-13
______ _______
PURGED VAPORS
FROM FUEL CANISTER PURGE
EVAPORATIVE VALVE SIGNAL
SYSTEM
DIVERTER VALVE
AIR PUMP
HEAVY DUTY COOLING

PLATE CTO SWITCH
VALVE DISTRIBUTOR
EGR/ IVS
FILLER CAP
SPARK/CTO SWITCH
fl- FRONT -
REVISEDVACUUM
-- MANIFOLD VACUUM f I
EMISSION CONTROL PORTED VACUUM
SYSTEM SCHEMATIC
Fig. 2 Heavy-Duty Cooling System
YEAR AND TIME

CODE NUMBER LEVEL
80 81 82
EGR SYSTEM-REVISE 4.700 4289 Cke-Wag-Trk 0.4 G

Includes replacement of EGR valve restrictor
plate, forward delay valve, and installation
of non-linear valve
80458-04J
Subject: Running Change to Four-Cylinder Application: 1980 CM Models With File: POWER PLANT
Engine Choke System Four-Cylinder Engine Fuel and Exhaust
Systems
No, 80-5 July 18,1980
The choke operating time has been extended on 1980 CAUTION: The holding fixture must be used to
CJ models with four-cylinder engines. This revision avoid damaging the carburetor throttle plates.
entered production as an EPA approved running
change in April of this year and can also be applied to 6 Cut heads from rivets that attach choke cover to
1980 four-cylinder CJ models built before April. carburetor choke housing using hammer and small
chisel Fig. 1. Take care to avoid damaging choke
housing or choke cover retainers when removing
Service revision of 1980 four-cylinder CJ models built rivet heads.
before April of this year involves installing a revised
choke cover and adjusting primary side vacuum break, 7 Remove remainder of each rivet from choke
fast idle cam position, and fast idle speed. housing using hammer and small pin punch. Do not
damage choke housing when removing rivets.
The following parts are required and are available. 8 Remove retainers and choke cover. Discard
choke cover but keep retainers.
9 Rotate fast idle cam until fast idle adjusting
COVER AND COIL, screw is on highest step of cain.
Choke 1 8133347 4.001
10 Position replacement choke cover on choke
RIVET, Drive 3 8133348 4.001 housing and align notch on cover with projection on
choke housing to index cover.
PROCEDURE
1 Raise hood and inspect number on sticker

attached to choke cover,
a If number on sticker is 70172, revised

choke cover has been installed. Return auto
mobile to owner.
b If number on sticker is other than number

indicated in step a, proceed to step 2.
2 Remove carburetor air cleaner.
3 Disconnect fuel line, vapor vent line, vacuum

hoses, electrical connectors, and throttle linkage from
carburetor.
4 Remove bolts and nuts attaching carburetor to

manifold and remove carburetor.
5 Mount carburetor on holding fixture J-9789-

118. Fig. 1 Removing Choke Cover Rivets

AdditIonal copies of this bulletin am available through your zone office.
NOTE: Be sure the tang on the choke cover coil is 16 Perform Fast Idle Speed Adjustment to obtain
engaged with the choke coil lever in the choke setting of 2500 RPM. Refer to page 84 in 1980 Jeep
housing. Technical Service Manual Supplement for procedure.
11 Install choke cover retainers and secure cover to
choke housing using drive rivets. Tap rivets into place 17 Install carburetor air cleaner.
using hammer and punch to expand and seat rivets in
housing Fig. 2.
12 Perform Primary Side Vacuum Break Adjust

ment to obtain setting of 19°. Refer to page 83 in
1980 Jeep Technical Service Manual Supplement for
procedure.
NOTE: The vacuum break adjustment setting of 19°

is a revised specification. Please note this change in
your 1980 Jeep Technical Service Manual Supplement.
13 Perform Fast Idle Cam Position Adjustment to

obtain setting of 18°. Refer to page 82 in 1980 Jeep
Technical Service Manual Supplement for procedure,
14 Install carburetor on manifold. Tighten car

buretor attaching bolts and nuts to 13 foot-pounds
17 N.m torque.
15 Connect fuel line, vapor vent line, vacuum hoses,

electrical connectors, and throttle linkage to car
buretor. Fig. 2 Seating Drive Rivets
YEA R AND TIME

COST OPERATION
COVER, CARBURETOR CHOKE - .
INSPEC’F 4.021 4131 4cyl.

Model 2SE 0,1 G
Cover, carburetor choke Replace
- 4.021 A
Model 2SE 0.7 G
Primary side vacuum break Adjust
- 4.906 B
Model 2SE 0.1 G
Fast idle cam position Adjust
- 4.908 C
Model 2SE 0.1 0
Idle speed, fast Adjust
- 4.908 D
Model 25E 0.1 6
8O-103-OSJ
80-16
Subject: Fuel Tank Sending Unit Application: 1980 Cherokee and File: POWER PLANT
Service Wagoneer Models Built After Fuel and Exhaust
December 17, 1979 Systems
No. 80.4 April 2, 1980
It is not necessary to lower the fuel tank to service 6 Disconnect sending unit wire and ground wire.
the fuel gauge sending unit on Cherokee and
Wagoneer models built after December 17, 1979. 7 Disconnect fuel lines from sending unit.
Vehicles built after this date will have an access hole
in the rear floorpan that allows the sending unit to 8 Remove locknut that retains sending unit in fuel
be serviced from within the vehicle. tank and remove sending unit.
When servicing the fuel tank sending unit on subject 9 Inspect condition and fit of sending unit 0-ring
models use the procedure provided in this bulletin. in groove around tank opening. Replace 0-ring if it
is damaged or does not fit properly.
The following parts are required:
10 Install sending unit and locknut. Tighten lock
Description Quantity Part No. Group nut to 14-18 foot-pounds 19-24 N.m torque.
RIVETS NOTE: Socket Wrench J-23 726 may be used to

125 x 275 inch 4 4005899 20.035 tighten the locknut.
GASKET-IN-A-TUBE AR 8993317 15.260 11 Connect fuel lines to sending unit.

PROCEDURE 12 Connect sending unit wire and ground wire.
1 Fold rear seat forward and secure seat by
13 Apply 1/8-inch bead of RTV silicone sealer
attaching holding strap to B-post.
around outer edge of access cover.
2 Remove rear mat retainer, if equipped, and 14 Install and secure access cover using 0.125 x
remove skid strips as necessary. 0.275 rivets. Remove any excess sealer after in
stalling rivets.
3 Remove heads from rivets that attach access
cover to floorpan using a 5/32 drill. CAUTION: Do not use screws to attach the access
cover to the floorpan.
CAUTION: Do not drill through the floorpan.
4 Remove access cover using a chisel or large flat 15 Position mat or carpet and install retainer, if
blade screwdriver. equipped.
5 Remove remaining rivets and clean rivet holes. 16 Place seat in upright position and latch seat
Remove all rivet material from top of fuel tank. securely.
YEAR AND TIME

MODEL -
CODE NUMBER LEVEL
80 81 82
SENDING UNIT, FUEL TANK - REPLACE -. 3.614 4154 G

Includes R & R fuel tank 8393 0.8
Wag-Cke-Ttk 1.0
With floor access cover Wag-Cke-’Thk 0.3
Fuel tank - Drain and refifi as required A Oi G
P1 American Máiàrs Sales Corporatian 80-072-04.1

S.rvlc. Engineering Deportment * 14250 Plymouth Road * Detroit, Michigan 45232
80-17
Subject: Microprocessor ECM Shield Application: 1980 California CJ File: POWER PLANT
Models With Four-Cylinder Engine Fuel & Exhaust Systems
Built Prior to yIN J0M93AB058103
No. 80-3 June 16, 1980
1980 California CJ Models with a four-cylinder 4 Disconnect harness connectors from micro
engine built after yIN J0M93AB058103 are equipped processor and remove microprocessor.
with a protective shield for the microprocessor
ECM - 5 Insert two shield retainers into slots in micro
processor.
This shield may also be installed on 1980 California
CJ models with four-cylinder engine that were built 6 Install shield on retainers using two holes in
prior to VIN J0M93AB058103. Service installation shield as guide. Position shield on microprocessor
involves affixing a decal to the shield, then installing studs and install shield retainer nuts finger-tight.
the shield over the microprocessor ECM.
7 Install microprocessor on left inner cowl panel
and install nylon spacers on mounting studs with
The following parts are available for service installa small shoulder of spacers facing microprocessor see
tion. ifiustration.
Description Quantity Part No. Group 8 Connect plug connectors to microprocessor.
KIT, Shield 1 8130433 3.053 9 Install and tighten microprocessor attaching nuts
Kit Contents: to 3 foot-pounds 4 N.m torque.
SHIELD,
Microprocessor NOTE: If the protective felt on the cowl seam near
ECM 1 5752624 the microprocessor interferes with microprocessor
DECAL 1 5752657 installation, trim the felt as necessary.
RETAINER,
Shield 2 4200319
NUT, Shield
Retainer 2 4200408
PROCEDURE
1 Clean smooth, recessed area on face of shield

with isopropyl alcohol and allow area to dry.
2 Remove backing from decal and affix decal to

cleaned area on shield.
NOTE: Do not touch the adhesive surface of the

decal after it is exposed. MICROPROCESSOR
ECM
3 Remove nuts attaching microprocessor to left SHIELD 81041

inner cowl panel and move microprocessor away from
panel. Remove nylon spacers from microprocessor
Microprocessor Shield Installation
studs and set spacers aside.

Deportment e 14250 Plymouth Road * Detroit, Michigan 48232
Service Engineering
80-18
YEAR AND TIME

CODE NUMBER LEVEL
so Si 82
SHIELD, MICROPROCESSOR ECM -
INSTALL California 4.750 4051 4-Cyl. 0.3 0
8O-O81.04.J
80-19
Subject: Vacuum Diagram Correction Application: 1980 49-State File: POWER PLANT
to 1980 Jeep Technical Service Cherokee and J-l0 Truck Models Fuel and Exhaust
Manual with 360 CID Eight-Cylinder En- Systems
gine, Manual Transmission, and
Heavy Duty Cooling
No. 80-2 March 12, 1980
The vacuum diagram on page V-23 of the 1980 Jeep Please correct your manual by moistening and
Technical Service Manual is incorrect. The diagram is affixing the attached correction diagram over the
for 49-State Cherokee and J-1O Truck Models existing diagram on page V-23.
equipped with 360 CID eight-cylinder engine, manual
transmission, and heavy duty cooling.
8O-063-04J

Service Engineering Department e 14250 Piymouth Road e Detroit, Michigan 48232
Additional copies of this bul?etin are available through your zone office.
80-20
PURGE VALVE SIGNAL
CAN ISTER
DIVERTER VALVE
AIR PUMP
COOLING
DISTRIBUTOR
OIL FILLER CAP
SPARK CTO SWITCH
FRONT -E’
EGR CTO
3 MANIFOLD VACUUM -S
PORTED VACUUM
801378
49 STATE 360 WITH MANUAL TRANSMISSION AND HD COOLING

Subject Exhaust Pipe to Exhaust Application: 1980 Six-Cylinder File: POWER PLANT
Manifold Leak Equipped Jeep Models Fuel and Exhaust
Systems
No. 80-1 Oct.31,1979
Some early built six-cylinder engine equipped Jeep PROCEDURE

vehicles may develop an exhaust leak between the
exhaust pipe and exhaust manifold. This may be due 1 Raise vehicle.
to the loss of the design interference locking feature
of the locking stud and hexagon nut. 2 Tighten existing nuts to 20 foot-pounds 27 N-m
torque.
If a leak should occur, service correction involves
tightening the existing nut to 20 foot-pounds 3 Turn second nut onto each stud.
27 N-rn torque and installing a second nut to lock
it in place. 4 While holding first nut, tighten second nut on
The following parts are available and will be required. each stud to 20 foot-pounds 27 N-rn torque.
Description Quantity Part No. Group 5 Lower vehicle.
NUT, Hexagon 2 400667 4.178 6 Start engine and check for exhaust leaks.
YEAR AND TIME

CODE NUMBER LEVEL
80 81 82
NUTS, EXHAUST PIPE FLANGE TO MANI

FOLD TIGHTEN AND INSTALL
- 4J78 4219 6-Cyl. 03 M
50-01 7-04J

Service Engineering Deportment e 14250 Plymouth Rood e Detroit. Michigan 41232
Additional copies c/this bulletin are available through your zone office.
80-22
Subject: T-176 Four-Speed Manual Application: 1980 Four-Cylinder File: CHASSIS
Transmission Used in 1980 Four-Cylinder CJ Models Built Between YIN Clutch Manual
-
CI Models J0M93AB725578 and YIN Transmission

J0M93EB727300
No. 80-4 June 16, 1980
Due to a supplier shortage of SR-4 four-speed manual Description Quantity Part No. Group
transmissions, 1980 four-cylinder CJ models built
between YIN J0M93AB725578 March 24, 1980
SHAFT ASSEMBLY,
and YIN J0M93EB727300 April 22, 1980 were
Rear 83 1 5362813 9.100
equipped with a T-176 four-speed rnanual trans-
mission and 4.09:1 ratio axles. SHAFT ASSEMBLY
Rear 93 1 5362814 9.100
The following parts list outlines the components that KNOB, Gear Shift
Lever 83-93 1 5361405 7.030
are unique to these models.
LEVER, Floor Gear
Shift 83-93 1 5359835 7.001
Description Quantity Part No. Group WIRE, Backup Lamp
83-93 1 5751748 3.318
TRANSMISSION, BRACKET,
T-176 83-93 1 5359390 6.001 Transmission Exhaust
HOUSING, CLUTCH Pipe Support 83-93 1 5362829 18.200
83-93 1 3251256 5.054
PIPE, Exhaust 83 1 5362826 4178
PIPE, Exhaust 93 1 5362827 4.178
SHAFT ASSEMBLY, The standard servicing operations and work times as
Front Propeller published in the current 580 Manual are not affected
83-93 1 5362815 9100 by this bulletin.
SO-121-06J

Service Engineering Department e 14250 Plymouth Rood e Detroit. Michigan 48232
Additional copies c/this bulletin are available through your zone office.
80-23
Subject: Clutch Pedal Return Adjustment Application: 1980 CJ Models With File: CHASSIS
Manual Transmission and Six- or Clutch Manual
-
Eight-Cylinder Engine Transmission
No. 80-3 May 28, 1980
If the clutch pedal on 1980 CJ models with manual 4 Check clutch pedal operation.
transmission and six- or eight-cylinder engine does
not return completely after the pedal is released, the a If pedal returns completely, return vehicle
pedal may be adjusted using the procedure provided to owner.
in this bulletin.
b If pedal does not return completely, pro-
Service correction involves adjusting clutch pedal ceed to next step.
freeplay and installing an additional return spring on
5 Modify hooked-end of spring 3197208 by re
the clutch pedal if necessary,
shaping it to configuration shown in illustration.
The following part is available and may be required. MODIFIED
SHAPE
Description Quantity Part No. Group ORIGINAL

-C-
=
SHAPE % %
SPRING 1 3197208 8.180
PROCEDURE
Modifying Spring 3197208

1 Raise vehicle.
6 Install modified spring as follows: Install modi
2 Check clutch linkage operation. Repair binding fied end of spring on clutch pedal stop and install
or bent linkage components if necessary. opposite curved end in unused hole in overcenter
spring bracket.
3 Adjust clutch pedal freeplay to 1/2- to 3/4-inch
maximum freeplay. 7 Lower vehicle.
AND TIME
YEAR_____
CODE NUMBER LEVEL
80 81 82
SPRING, CLUTCH PEDAL RETURN -
INSTALL 5.135 5007 83-93 0.3 G

Includes adjust clutch pedal free play
80403-053

Additional copies of this bulletin are available through your zone of/ice.
80-24
Subject: T-176 4.Speed Manual Application: 1980 Jeep CJ, File: CHASSIS
Transmission Shift Problems Cherokee and J.10 Truck Clutch-Manual
Models With T-176 4-Speed Transmission
Manual Transmission
No. 80-2 March 20, 1980
Some early production T-176 4-speed manual trans 7 Position transmission case cover in vise so shift
missions used in the subject models may develop forks are facing upward. Use wood blocks to pro
shifting problems such as high shift effort, loose tect cover from vise jaws and do not overtighten vise.
shifting, or the transmission locks In two gears at
once preventing vehicle movement with the clutch 8 Place all shift forks in neutral position.
engaged. These conditions may be the result of loose
transmission case cover shift lever fulcrum pins, a 9 Remove shift rail support plate attaching bolts
damaged reverse rocker arm assembly, missing poppet and tabbed washers and remove support plates Fig.
balls, springs, or interlock rings or burrs on the edges 1.
of the shift lever pivot ball.
10 Remove first-second shift rail.
Service correction involves replacing the transmission
case cover and any missing poppet balls, springs and
11 Remove third-fourth shift rail, shift lug, and in-
interlocks, and chamfering rough edges on the shift
terlock pin.
lever pivot ball if necessary.
The following parts are required and will be available 12 Remove reverse shift rail.
the week of April 7, 1980. Do not order parts before
this date. 13 Remove poppet balls.
Description Quantity Part No. Group 14 Remove shifter interlock rings.
KIT, Transmission 15 Remove poppet springs.

Case Cover Repair 1 8130431 6.009
Kit contents: 16 Remove cover from vise.
Cover Assembly 1 8130429
Parts Package 1 8130430 17 Clean all components in solvent and dry using
compressed air.
PROCEDURE 18 Inspect all components. Replace any compo
nents that are nicked, cracked, broken or excessively
1 Remove transfer case and transmission shift worn.
lever knobs, trim rings and boots.
19 Clamp replacement transmission case cover and
2 Remove floor covering and transmission access reverse rocker arm assembly in vise using protective
cover from floorpan. wood blocks and install replacement fulcrum pins in
cover.
3 Shift transmission into third gear.
CAUTION: To avoid damaging the cover do not
4 Remove transmission control housing cap Fig. overtighten the vise jaws.
1. Push cap down and turn counterclockwise to re
move. 20 Lubricate shift rails and shift rail grooves in
cover with petroleum jelly.
5 Remove transmission case cover attaching bolts,
21 Install replacement poppet springs in trans
6 Remove transmission case cover. mission case cover bores.

Additional copies vi this bulletin are available through your zone office
80-25
BACKUP
FULCRUM PIN 2 LAW SWITCH
SHIFT LEVER
KNOB
NUT
-I
SHIFT LEVER TRANSMISSION
CASE COVER
TRANSMISSION CONTROL
HOUSING CAP
FIRST-SECOND
SPRING
SHIFT FORK
INTERLOCK
PIN
SHIFT
THIRD-
FOURTH
SHIFT
LUG
INTERLOCK PIN
THIRD.FOLJRTH
SHIFT FORK
REVERSE FORK
SHIFT RAIL REVERSE SHIFT

SUPPORT PLATE RAIL
810358
Fig. 1 Transmission Case Cover Assembly - Model T-176
22 Install poppet balls one on each spring. contact all three shift to rails to press rails down
ward evenly.
23 Position reverse gear shift rail and fork on re
verse rocker arm in transmission case cover. 28 While holding shift rails downward, position
shift rail retaining plates on housing and install plate
NOTE: Be sure the notch on the shift rail is po attaching bolts and tabbed washers finger-tight.
sitioned over the reverse poppet ball and that re 29 Remove wood block and tighten shift rail re
verse rocker arm is engaged in the reverse fork slot. taining bolts to 12-15 foot-pounds 16-19 N-m
torque. Be sure tabbed washers are in correct po
24 Install third4ourth shift rail and shift fork sition before bending washer tabs.
assembly in transmission case cover.
30 Check shift rail operation. Each rail must slide
NOTE: Be sure the interlock pin is in position in the smoothly in cover groove. Be sure it is not possible
shift rail before further assembly. to over shift into another gear position. After check.
ing shift operation, place forks in third gear position.
25 Install first-second shift rail and fork assembly.
Be sure shift rail notch is over poppet ball in trans 31 Install replacement gasket on transmission case
mission case cover. cover.
26 Install shifter interlock rings in cover and be
tween poppet balls, 32 Install transmission case cover and gasket on
transmission. Be sure all shift forks are seated in cor
27 Press downward on shift rails to compress pop responding gear sleeves, and be certain that reverse
pet balls and springs. Use wood block long enough to fork is seated in reverse sliding gear groove.
80-26
33 Apply sealant to threads of transmission case
cover attaching bolts.
34 Install two transmission case cover shoulder

bolts only to hold cover in position. Tighten bolts
to 12-15 foot-pounds 16-19 N-m torque.
35 Grind and file edges of shift lever pivot ball slot

to approximate chamfer of 1/32-inch Fig. 2. This
will ensure smooth contact surface with fulcrum pins
in transmission case cover.
36 Install shift lever, spring, spring retainer, and

control housing cap Fig. 1. Push cap downward
and turn clockwise to install and seat. Be sure trans
mission is still in third gear before installing shift CHAMFER THESE EDGES
ON BOTH SIDES
lever.
37 Check shift operation in all gear positions. If
operation is OK, install and tighten remaining case
cover attaching bolts to 12-15 foot-pounds 16-19
N-rn torque. If shift problem persists, loosen cover
attaching bolts and align cover on transmission case. 81035A
38 Install access cover, floor covering, boots, trim

rings, and shift lever knobs. Fig. 2 Shift Lever Chamfer Areas
The following standard servicing operation and work times will apply:
YEAR AND TIME

MODEL
CODE NUMBER LEVEL
80 81 82
COVER, TRANSMISSION CASE R & R - - . -. 6.009 6006 83-93 0.7 G

Includes replace gasket Cke-Trk 0.9
Transmission case cover -Overhaul 6.009 A 0.5 G
With carpet Add
- 0.1
80-065-06J
80-27
Subject: Inspection of Clutch Housing Application: 1980 Cherokee, File: CHASSIS
and Clutc h Lever Clearance Wagoneer and Truck Models Clutch-Manual
with Manual Transmission Transmission
Built Prior to VIN
J0D25NN008776
No. 80-1 Jan.11,1980
If one of the specified vehicles requires clutch service, 3 Loosen clutch lever release lever boot and read
the clutch housing and clutch lever clearance must be casting numbers see illustration.
inspected. a. On six-cylinder engines:
* Casting number must be 3238422.
On the specified vehicles, service correction requires If not, replace housing.
an initial inspection to determine which clutch hous
ing has been installed and modification and/or
replacement of the clutch housing as necessary. CLUTCH
HOUSING
The following parts may be required and will be
available after Jan. 7, 1980. Do not order parts before
this date.
Description
HOUSING, Clutch
15-16-17.18-25-45
6-Cyl.
Quantity
1
Part No.
3238423
Group
5.054
CORE
C
HOUSING, Clutch
15-16-17-18-25.45
V.8 1 3235827 5.054
HOUSING, Clutch
46 V.8 1 3235826 5.054
STUD, CASTING
NUMBER
Adapter-to-Clutch
Housing 1 5356352 5.054
NUT, Hex
9/16 inch
1 G9419144 6,005
WASHER, Lock
9/16 inch 1 G120898 17.820
Clutch Housing Inspection
b. On eight-cylinder engines:
1 Raise vehicle. * Casting numbers must be 3235887 or
3238422.
2 Inspect clutch housing release lever opening. * On J.20 Trucks left lower transmission
If opening is 3-1/2 inch x 2-1/8 inch, replace housing bolt next to lever opening must be
as described in Clutch Housing Replacement and removed and shortened to 1.25 inch
Modification Procedure. 32 mm.

S.rvla Enghtnrlng D.partm.nt * 14250 Plymouth Rood * D.troit MichIgan 48232
80-28
NOTE: If transmission bolt threads are damaged In 8 Disconnect transfer case shift rod at transfer
clutch housing on J-20 Trucks refer to Clutch Hous- case.
Mg Replacement and/or Modification Procedure.
9 Disconnect front propeller shaft at transfer case.
4 Inspect core injection boss see illustration for
interference with clutch throwout lever. If throwout 10 Remove lower bolts from adapter plate to trans
lever is contactmg ejection boss, refer to Core mission. Loosen exhaust pipe bracket and remove ex
Ejection Boss Removal Procedure. haust support.
CORE EJECTION BOSS REMOVAL PROCEDURE 11 Disconnect transfer case vent hose and lockout
switch connectors.
1 Remove front propeller shaft at front axle
U-joint yoke. , 12 Support transfer case. Remove upper bolts
from adapter to transmission and remove trans
2 Using long punch, centerpunch starter hole in fer case.
boss.
13 Disconnect backup light switch connector from
3 Using 3/8 inch drill bit, drill hole through boss. transmission.
4 Using sharp chisel, chip away remainder of boss. 14 Support engine. Remove transmission bolts
at clutch housing and remove transmission.
5 Remove clutch housing inspection plate. Use
compressed air to remove all loose metal. 15 Remove starter motor bolts and cable and
remove starter motor.
6 Install clutch housing inspection plate,
16 Remove clutch release idler pivot bolts and
7 Install boot and connect clutch linkage and disconnect adjuster and lever spring.
wljustpedal free play.
17 Remove inspection plate.
8 Install front U-joint straps and bolts and tighten
to 15 foot-pounds 23 N-m torque. 18 Remove clutch housing bolts and housing.
9 Lower vehicle. 19 Remove clutch throwout lever spring, lever,

throwout bearing, and pivot ball from housing.
CLUTCH HOUSING REPLACEMENT AND/OR
MODIFICATION PROCEDURE CAUTION: Do not allow the hole to be machined
larger than 0.6250 inch.
2 Remove shift and transfer case lever boot. 20 On J.20 Truck, drill out lower left next to lever
opening transmission hole to 5/8 inch. Coat lower
CAUTION: Be sure shift lever pin does not fall into half of stud opposite-threaded end with Loctite
transmIssion. 271 or equivalent. Press stud into housing.
3 Unscrew shift lever cap, remove pin and shift 21 Completely remove core ejection boss, if pre
levers, sent, following steps 2 through 4 of Core Ejection
Boss Removal Procedure.
4 Mark front and rear propeller shafts and yokes
for assembly reference. Disconnect rear propeller
NOTE: This step applies to an original or a new
a er case.
clutch housing if the core ejection boss is found.
5 Disconnect speedometer cable at transfer case.
22 Coat pivot ball with grease and install in clutch
6 Disconnect parking brake cable at crossmember housing.
and at C-clips.
23 Install clutch housing, tighten top retaining
7 Support transmission, disconnect rear cross- bolts to 30 foot-pounds 41 N-m torque. Tighten
member bolts and remove crossmember. dowel bolts to 45 foot-pounds 61 N-m torque.
80-29
24 Install starter motor. Tighten bolts to
20 foot- 38 Connect vent line and retaining clip. Connect
pounds 27 N-m torque, Tighten starter terminal
nut to 55 inch-pounds 6 N-rn torque. lockout switch connector,
25 Install inspection cover, inner support 34 Connect transfer case shift rod, wave washer,
bracket flat washer and cotter pin.
with bellcrank, and tighten bolts to 14 foot-pounds
19 N-rn torque.
35 Install speedometer cable.
26 Install transmission aligning clutch shaft
clutch driven plate splines and tighten bolts and 36 Install front propeller shaft using reference
55 foot-pounds 75 Nrn torque. to
marks made during removal. Tighten shaft-to-yoke
bolts to 15 foot-pounds 20 N-rn torque.
27 Install clutch throwout lever boot. Loosen
jamnut and adjuster to obtain freeplay. 37 Install crossmember, Tighten bolts to 35
Align foot.
linkage to throwout lever and remove freeplay. pounds 48 Wm torque. Remove support stand.
28 Connect backup lamp switch wires.
38 Connect parking brake cable and adjust.
29 Clean mating surface of transmission and trans
fer case, apply Pennatex No. 3 or equivalent sealer 39 Install rear propeller shaft using reference marks
to both sides of replacement transfer case-to-trans. made during removal. Tighten bolts to 15 foot-
mission gasket and position gasket on transmission. pounds 20 N-rn torque.
30 Align and install transfer case assernbly. Be 40 Check and refill transmission and transfer case
sure transfer case input gear splines are aligned with if necessary.
transmission output shaft.
41 Install gear shift lever, locating pin and tighten
shift lever cap.
NOTE: Do not install any transfer case attaching 42 Install shift lever and transfer case lever boot.
bolts until transfer case is completely sea ted against
transmission. 43 Connect battery negative cable.
44 Reset clock.
31 Attach exhaust pipe support bracket. Install
45 Check and adjust clutch pedal freeplay if neces
transfer case retaining bolts and tighten to 40 foot.
sary.
pounds 54 N-rn torque.
46 Check transrnission and transfer case for proper
32 Tighten exhaust pipe clarnp. shifting.
YEAR AND TIME

cosi OPERATION SKILL
OPERATION DESCRIPTION MODEL ‘ LEVEL
CODE NUMBER
80 01 82
HOUSING, CLUTCH- INSPECT 5.054 5031 Wag- 0.1 G

Cke
Trk
5.054 A J-20 0.1 G
Bolt, Transmission- Shorten
5.054 B 0.5 G
Boss, Core Ejection-Remove
Housing, Clutch- Replace 0
5.054 C 2.4
and/or Modify
I I I I
so.022-05J
60-30
Subject; Moan or Buzzing Noise From Application: 1980 Jeep CJ Models File: CHASSIS
Automatic Transmission When Shifting With Model 999 Automatic Automatic
Into Reverse Transmission Built Prior To Transmission
Build Date Code 6863
No. 80-1 Mar. 17, 1981
On some 1980 CJ models with a model 999 automatic

transmission built prior to build date code 6863, the
transmission may occasionally produce a moan or buzz
ing noise when shifted into reverse or when the gear-
shift selector lever is between the Park and Reverse
detents. This condition may he caused by the nonnal
PREVIOUS SWITCH VALVE DESIGN
rapid flow of transmission fluid over the finely machined
center land of the switch valve in the transmission valve
CENTER
body. On transmissions built after date code 6363, a new
switch valve with an undercut center land was phased
into production and is now available for service see
illustration. The new valve design eliminates the
possibility of any occasional noise caused by normal fluid
flow over the center land,
Service correction involves verifying the condition using

the diagnosis procedure provided in this bulletin and in NEW SWITCH VALVE DESIGN
stalling the new switch valve if diagnosis indicates this is
necessary. Switch Valve Comparison
The following part is available and may be required.

6 Apply service brakes and shift transmission into
Description Quantity Part No. Group Reverse.
VALVE, Switch 1 8180452 7 Increase engine speed until moan or buzzing noise
l&495
occurs. Maintain engine speed at point where noise
is loudest for approximately one minute then return
DIAGNOSIS PROCEDURE engine to idle speed.
1 Check transmission build date code. If
transmission
was built prior to date code 6868,
2, If transmission was built after proceed to step
date code 6863,
CAUTION; If the noise is loudest at an engine
speed that
refer to automatic transmission diagnosis is at or near torque converter stall speed,
Chapter 2C of Technical Set-vice Manual section in tain engine wpee4 for more than S seconds. do izot main
tional diagnosis, for addi
2 Apply parking brake firmly, 8 Shift transmission into Park,

remove dipstick im
mediately, and inspect oil on dipstick for evidence of
3 Start engine and apply service brakes. foaming aeration.
4 Shift transmission into all gear a If oil does not display evidence
transmission into Neutral. ranges; then shift of foaming aera.
tion, proceed to Switch
Valve Replacement
procedure,
5 Check transmjssIo fluid level b If oil does display evidence
lined in Technical Service and condition as out of foaming, refer to
automatic transmission diagnosis
level if necessary. Manual, Correct fluid section in
Chapter 2C of Technical Service
Manual for ad
ditional diagnosis.
P1 Amer ican Motors Sales Corpo.

Seivic. Engln,pg Dportm.nt
* 14250 Plymouth Rood * D,troft MichIgan 48232
Additional copies ot this bulletin
a’s available through your zone
off/ce.
80-31
Switch Valve Replacement 8 Install line pressure adjusting screw assembly and
spring retainer and bracket, Tighten bracket
1 Raise vehicle on hoist. attaching screws to 35 inch-pounds 4 Nm torque.
2 Remove transmission oil pan and valve body as out 9 Install replacement oil filter on valve body. Tighten
filter attaching screws to 35 inch-pounds 4 N-m
lined in Chapter 22 of Technical Service Manual.
torque,
3 Remove oil filter from valve body.
10 Install valve body and oil pan as outlined in Chapter
4 Remove screws that attach throttle pressure ad. 2C of Technical Service Manual,
justing screw spring retainer and bracket and re
move retainer and bracket. Hold retainer and 11 Lower Vehicle.
bracket firmly against spring force while removing
last attaching screw. 12 Fill transmission to correct level with AMC,
Dexron, or equivalent automatic transmission
fluid.
5 Release pressure applied to spring retainer arid
bracket and remove bracket, line pressure adjust
13 Verify noise correction by performing steps 2
ing screw assembly, line presure regulator spring,
through 7 of Diagnosis Procedure again.
switch valve spring, and switch valve. Do not dis
turb line and throttle pressure adjusting screw
settings during removal. a If noise is eliminated, return vehicle to owner.
6 Install replacement switch valve in valve body bore.
Be sure valve is new-type with undercut on center b If some noise is still present, check for restric
land see illustration. tion in transmission oil cooler and cooler lines
and correct as necessary. Refer to oil cooler and
7 Install switch valve and line pressure regulator cooler line flushing procedure in Technical Ser
springs. vice Manual.
YEAR AND TIME

OPERATION DESCRIPTION CODE NUMBER MODEL - LEVEL
19 50 51
NOISE AUTOMATIC
TRANSMISSION - DIAGNOSE 16221 904-998 0.1 0.1 G
Switch valve Replace
- 36.495 A 0.8 0.8 G
Includes oil pan and valve body R & R
81-o68-LSA/,J
80-32
____
FILE: Axles-Suspension-
P1 Jeep Brakes-Steering CHASSIS -
Transfer Case/Quadra-Tree
No. 3-04-82 Mar. 8, 1982
TECHNICAL BULLETIN
PROBLEM AND Transfer case shift lever rattles or makes a buzzing noise in some
APPLICATION: 1980-82 CJ and Scrambler models.
CORRECTION: Install a flat washer and rubber bumper on the transfer case shift
lever ball-end see illustration.
PARTS: Description Quantity Part Number Group
WASHER, Flat 1 G13l016 17.814
BUMPER, Rubber 1 637936 35. 300
WARRANTY Reimbursable within the provisions of the applicable warranty.

ELIGIBILITY:
SSO INFORNATION
Cost Operation Year and Time Skill

Operation Description Code Number Model -80- -81- -82- Level
LEVER, TRANSFER CASE

SHIFT MODIFY
- 18.135 18019 CJ 0.2 0.2 0.2 G
PROCEDURE:
1. Raise the vehicle.
2. Remove the shifter shaft nut and slide the shifter shaft out of the
shift lever.
3. Lift the shift lever upward and out of the shift control link.
4. Install the flat washer and rubber bumper on the ball-end of the shift
lever see illustration. Be sure the flat washer is seated against
the shoulder at the ball-end of the shift lever.
continued

Service Engineering Department *
Addit,onaI copies of this bulletin are available through your zone office.
80-33
-2-
5. Seat the shift lever firmly in the shift control link. Reinsert the
shifter shaft into the shift lever and front output bearing cap and
install the shifter shaft nut.
6. Lower the vehicle.
FLAT
WASHER
RUBBER
BUMPER
SHIFT LEVER
BALL-END
Installing Washer and Bumper

On Shift Lever Ball-End
82-057-J
80-34
Subject: Transfer Case Drive Sprocket Application: 1980 Jeep Cherokee, File: CHASSIS -
Thrust Washer Noise Wagoneer, and Truck Models with Transfer Case/
Model 208 Transfer Case Quadra-Trac
No. 80-3 Oct. 2, 1981
On some 1980 Cherokee, Wagoneer, and Truck models 8 Remove transfer case rear yoke using tools
with a model 208 transfer case, the transfer case drive J-8614-O1, -02, -03 if necessary.
sprocket thrust washer inside diameter may have a
rough surface finish that could cause a squeal noise to 9 Inspect output seal in rear retainer if seal exhibits
occur occasionally. The noise is most noticeable in the signs of oil leakage, remove and discard seal.
30-55 mph range and only when the transfer case is in
two wheel drive high 2H position, the front hubs 10 Remove speedometer driven gear and sleeve from
unlocked, and when the transfer case is at normal rear retainer.
operating temperature.
11 Mark rear retainer for assembly alignment refer
Service correction involves road testing to verify the ence and remove retainer attaching bolts. Tap re
noise condition and replacing the transfer case drive tainer with rubber mallet to loosen it and remove
sprocket thrust washer if necessary. retainer.
The following parts may be required and will be 12 Remove pump housing.
available after October 19, 1981. Do not order parts
before this date. 13 Remove speedometer gear.
14 Remove oil pump.
WASHER, Thrust 1 8134130 18.820
18.870 15 Remove drive sprocket retaining ring.
SEAL, Output 1 8133432
PROCEDURE 16 Remove and discard drive sprocket thrust washer
see illustration.
1 Road test vehicle in 30-55 mph range with hubs
unlocked and with transfer case in two-high posi
tion and at normal operating temperature.
a If squeal noise occurs, proceed to step 2.
b If squeal noise does not occur, thrust washer
is not problem. Refer to 1980 Jeep Technical
Service Manual for additional diagnosis,
2 Raise vehicle on hoist.

3 Position drain pan under transfer case. Remove fill
plug and drain plug and drain lubricant from
transfer case.
4 Mark rear propeller shaft and transfer case yoke
for assembly alignment reference.
5 Disconnect rear propeller shaft from transfer case

yoke and secure shaft to underside of vehicle.
- -
6 Remove speedometer adapter and cable. -
7 Remove and discard transfer case rear yoke re -ccr

taining nut and seal. Use tool J-8614-O1 to hold Drive Sprocket Thrust Washer
yoke while removing nut. Removal/Installation
80-35
17 Clean rear case and rear retainer mating surfaces 28 Install transfer case rear yoke and install replace
thoroughly. ment yoke seal and retaining nut. Tighten retain
18 Check pump housing seal for nick, cuts, or signs of ing nut to 120 foot-pounds 163 N.m torque.
abrasion. Replace seal if damaged.
29 Install replacement 0-ring on speedometer adapter
19 Lubricate replacement drive sprocket thrust and install adapter and cable. Tighten adapter re
washer with 10W-30 motor oil and install thrust tainer bolt to 100 inch-pounds 11 N.m torque.
washer.
20 Install drive sprocket retaining ring. 30 Install and tighten drain plug to 18 foot-pounds
21 Install oil pump. 24 N.m torque.
22 Install speedometer gear. 31 Fill transfer case to edge of fill plug hole with lOW-
30 motor oil.
23 Install output seal in retainer if necessary.
24 Lubricate lip of rear seal and pump housing seal 32 Install and tighten fill plug to 18 foot-pounds
and tabs of pump housing with petroleum jelly. 24 N.m torque.
25 Install pump housing in rear retainer. 33 Connect rear propeller shaft to transfer case yoke.
26 Apply Loctite 515, or equivalent sealer, to mating Align shaft and yoke using reference marks made
surfaces of rear case and rear retainer. at disassembly. Tighten shaft clamp strap bolts to
27 Align rear retainer and rear case index marks and 14 foot-pounds 19 N.m torque.
install rear retainer on case. Install and tighten
rear retainer attaching bolts to 23 foot-pounds 34 Lower vehicle and verify proper transfer case
31 N’m torque. operation.
YEAR AND TIME

OPERATION DESCRIPTION MODEL LEVEL
CODE NUMBER
ec Cl 82
ROAD TEST c 0717 0.3 G

DRIVE SPROCKET THRUST WASHER -
REPLACE 18.350 18.011 Cke.Wag-Trk 0.8 G
81-109-lU
80-36
Subject Transfer Case Output Shaft Seal Application: 1980-81 Jeep Vehicles File: CHASSIS
Leak Diagnoeis Equipped with Model 219 Transfer Case/Quadra
Quadra-Trac Transfer Case Trac
No. 81-1 Feb. 23, 1981
On some 1980-81 Jeep vehicles with a model 219 5 Remove and discard transfer case rear yoke nut
Quadra-Trac transfer case built prior to 10-28-80, the and seal washer. Use tool 3-8614-01 to hold yoke
adhesive tape strip on the vent chamber seal may while removing nut.
separate from the seal and block the rear retainer vent
passage. If the vent passage becomes blocked, pressure 6 Remove rear yoke using tools 3-8614-01, 02, 03,
buildup within the transfer case could cause lubricant to if necessary.
leak from one or both output shaft seals and be incor
rectly diagnosed as a seal problem. Model 219 transfer 7 Remove speedometer cable and adapter from rear
cases built on or after 10-28-80 have a new self adhering retainer. Discard adapter seal, it is not reusable.
vent chamber seal that does not require an adhesive tape
strip. 8 Mark rear retainer and rear case half for assembly
alignment reference and remove rear retainer
Service diagnosis and correction of a leak condition in bolts and retainer. Tap retainer with rawhide or
volves first checking the transfer case build date, replac plastic mallet to loosen and pry retainer from case
big the vent chamber seal if necessary, and replacing using slots in retainer only.
one or both output shaft seals if diagnosis indicates this
is necessary. 9 Remove vent chamber seal from retainer interior
and clean seal mating surface in retainer
thoroughly. Clean mating surfaces of retainer and
The following parts are available and required: rear case and dry both surfaces thoroughly.
10 If diagnosis indicated that rear output seal in
Description Quantity Part No. Group retainer was leaking, remove seal and clean seal
bore in rear retainer thoroughly.
SEAL, Vent Chamber 1 8133743 1&000
SEAL, Front and Rear AR 8130808 18.000 11 Coat outer edge of replacement output seal with
Output silicone sealer and install seal in retainer using
tool J-29162.
12 Install replacement vent chamber seal. Remove

PROCEDURE seal adhesive protector strip and position seal over
vent hole inside retainer. Be sure hole in seal is
aligned with hole in retainer and that length of
vent seal is parallel with front face of retainer.
Vent Chamber and Rear Output Shaft Seal
Replacement 13 Coat retainer mating surface of rear case with
silicone sealer.
14 Align rear retainer and rear case reference marks
2 Remove transfer case fill and drain plugs and and install retainer on case.
drain lubricant from transfer case.
15 Install and tighten retainer attaching bolts to 23
3 Mark rear propeller shaft and transfer case yoke foot-pounds 31 N.m torque.
for assembly alignment reference.
16 Install rear yoke, replacement yoke seal washer,
4 Disconnect rear propeller shaft at transfer case and replacement nut. Tighten nut to 120 foot-
yoke and secure shaft to underside of vehicle. pounds 163 N.m torque.
$.rvlc. Enghinrlng D.partmsnt . 14250 Plymouth Road * Dtrolt. MIchigan 4*232

Additional copies of this bulletin are available Through your zone office.
80-37
CAUTION: Do not attempt to reuse the original yoke 2 Disconnect front propeller shaft from yoke and
nut. This nut isasef locA’ing design and should not be secureshafttoundersideofvehicle.
reused.
3 Remove and discard transfer case front yoke nut
17 Install replacement speedometer adapter seal and and seal washer. Use tool J8614-01 to hold yoke
install speedometer driven gear assembly in trans- while removing nut.
fer case. -
4 Remove transfer case front yoke using tools

NOTE: Do not reuse the adapter 0-ring seal, it is desiqn- 3-8614-01, 02, 03, if necessary.
ed to sweU in. service to provide improved sealing
qualities and could be cut or toni. if reuse is attempted. 5 Remove front output shaft seal. Clean seal bore
thoroughly,
foot-pounds 24 N.m torque. 6 Coat replacement front output seal outer surface
with silicone sealer.
19 Align and connect rear propeller shaft to yoke
using assembly alignment reference marks. 7 Install replacement output seal in front case bore
Tighten clamp strap bolts to 15 foot-pounds using tool 3-29162.
20 N.m torque.
8 Install front yoke, replacement yoke seal washer,
NOTE: If diagnosis indicated that thefront output shaft and replacement yoke nut. Tighten yoke nut to 120
seal was leaking, proceed to Front Output Shaft Seal. foot-pounds 163 Nn torque.
Replacement.
CAUTION: Do not attempt to reuse the original yoke
20 Fill transfer case to edge of fill plug opening with nut. It is a self-locking design and should not be reused.
1OWSO motor oil, API grade SF or SE.
9 Align and connect front propeller shaft to yoke
21 Install and tighten transfer case fill plug to 18 using assembly reference marks. Tighten clamp
foot-pounds 24 N.m. strap bolts to 15 foot-pounds 20 N.m torque.
22 Lower Vehicle. 10 Fill transfer case to edge of fill plug hole with
10W30 motor oil, API grade SE or SF.
Front Output Shaft Seal Replacement 11 Install and tighten fill plug to 18 foot-pounds
24 N.m torque.
1 Mark front propeller shaft and transfer case yoke
for assembly alignment reference. 12 Lower vehicle.
. YEAR AND TIME

OPERATION DESCRIPTION NUMBER MODEL LEVEl.
CODE
so ii $2
SEAL, VENT CHAMBER REPLACE

- - .. l&436 18009 Cke-Wag -Trk OS 0.8 G
Includes rear bearing retainer R & R
and rear output shaft replacement if
necessary
SEAL, FRONT OUTPUT SHAFT - 18.218 18007 Cke-Wag -Trk 0.6 0.6 6
REPLACE
81O4$-18MJ
80-38
Subject: Transfer Case Shift Lever Rattle Application: 1980 Cherokee, File: CHASSIS
Wagoneer, and Truck Models Transfer Case
With Automatic Transmission
No. 80-2 July 29, 1980
Some 1980 Cherokee, Wagoneer, and Truck models 4 Install shift lever on shift rod.
with automatic transmission may develop a transfer
case shift lever rattle. The rattle occurs at the point 5 Install spring washer and remaining flat washer
where the transfer case shift lever is connected to the on shift rod see illustration.
upper shift rod see illustration -
6 Install cotter pin.

Service correction involves installing a spring washer
and flat washers on the upper shift rod to decrease 7 Lower vehicle and check transfer case shift
clearance between the shift rod and shift lever. lever operation.
The following parts are required.

WASHER
WASHER, Spring 1 815535 7.125
SHIFT FLAT WASHER
WASHER, Flat 2 943961 7125 ROD
PIN
PIN, Cotter 1 4004295 2&406
PROCEDURE

CASE
2 Remove shift lever-to-shift rod retainer and SHIFT
disconnect lever from rod. LEVER
3 Install one flat washer on shift rod see illustra

tion. Correcting Transfer Case Shift Lever
The following standard servicing operation and work time will apply
YEAR AND TIME

CODE NUMBER LEVEL
80 81 82
LEVER, TRANSFER CASE SHIFT - Cke

Correct 18.450 18049 Wag-Trk 0.2 6
80-133-09J

Servic. Engin.ei-ing D.portm.nt * 14250 Plymouth Road * Dtroit, Michigan 48232
80-39
Subject: Transfer Case Shift Lever and Application: 1980 Cl Models File: CHASSIS
Shaft Renlacement Transfer Case/
Quadra -Trac
No. 80-1 Jan. 9, 1980
Some 1980 CJ models may have a transfer case that is PROCEDURE

difficult to shift. This may be tiie result of the trans
fer case shift lever shaft being bent at the threaded 1 Remove transfer case as outlined in Chapter 2D
end. of 1980 Technical Service Manual and remove broken
shift lever shaft from transfer case.
Service correction involves replacement of the shift
lever shaft and lever, if necessary.
2 Inspect shift lever and replace if bent, distorted
The following parts are required and wl be available or fractured. If fractured, be sure to remove threaded
the week of Jan. 28, 1980. Do not order parts before portion of shift lever shaft from shift lever.
this date.
Description Quantity !att_No. Group
3 Install replacement shift lever shaft on transfer
SHAFT, Transfer Case case.
Shift 1 5360045 18.180
4 Install transfer case as outlined in Chapter 2D of
LEVER, Transfer Case 1980 Technical Service Manual.
83-93w/4-cyl. and SR4
93w/6 or 8-cyl. and
T176 1 5360044 18.125
LEVER, Transfer Case

93w/SR4 and 6-cyl. 1 5360129 18.125
YEAR AND TIME

CODE NUMBER I I LEVEL
80 I 81 82
CASE ASSEMBLY, TRANSFER-R & It

Shaft, Shift Lever-Replace
18.135
18.135
18000
F
83-93 1.0
0.1
I &
6
80-041-DIM

S.rvic. Enginoring Dpartmnt * 14250 Plymouth Road * D.troit, MIchigan 48232
80-40
P’I Jeep
Date: June 19, 1980
Application: 1979-80 Jeep
Cherokee, Wagoneer and J-10
frucks
File: CHASSIS.Prop.
Shaft-Axles
This isa Type "5" Product Recall Campaign subject to all limited, replacement rear wheel bearing kits are not to
campaign procedures and involving safety-related be ordered for dealer stock!
elements.
Some 1979 and 1980 Jeep Cherokee, Wagoneer and J-10
‘lI’uck models equipped with the AMC/Jeep rear axle 1 Raise and support vehicle
built between 1979 VIN numbers J9A1SNN069283
and J9F45NC154704 and 1980 VIN numbers 2 Inspect rear axle housing cover to determine what
JQE18NN00004S and J0D45NN024993 may have rear type of axle is in vehicle.
wheel bearing retainers and seals on some of the subject
models which may have been assembled improperly a If axle has round, dome shaped cover Fig. 1,
during production. This condition could result in wheel vehicle has AMC/Jeep axle and will require repair if
bearing damage and possible disengagement of the campaign identification mark is not present. Place
wheel and axle shaft from the axle while the vehicle is in campaign-inspection identification paint mark on
motion. cover Fig. 1 and proceed to repair procedure.
Service correction involves an inspection to determine b If axle has oval, irregular shaped cover Fig. 1,
what type of axle Dana or AMC/Jeep is in the vehicle
and replacement of BOTH right and left rear wheel
vehicle has Dana axle nd does not require any
repairs. I
bearings, seals, retainer rings, and retainer plates on
AMCIJeep axles. 3 Lower vehicle,
The following parts kit is required:
NOTE: Each vehicle will require TWO kits.
Part
Description Qt No. Group Price
KIT, Rear Wheel

Bearing 2 8130510 8.300 $13.40
KIT Contents: inner oil seal, retaining ring,

wheel bearing, outer seal, retainer plate AMC/JEEP AXLE DANA AXLE
HOUSING HOUSING
COVER COVER
The Zone will provide a VIN list and an initial supply of
parts equal to 40% of the vehicles on your VIN list for Fig. 1 Axle Housing Cover IdentificatIon
each dealer with any vehicles involved. However, the
campaign procedures apply to all dealers. On all JEEPAXLE REPAIR PROCEDURE
undelivered, campaign-involved vehicles, the
correction must be made before the vehicle is sold or Axle Shaft and Bearing Removal
otherwise put in service.
1 Raise and support vehicle and remove rear wheels.
July 7, 1980. Because campaign parts supplies are 2 Remove rear brake drums.

Service Englnwing Department * 14250 Plymouth Read * Detroit, Michigan 48232
80-41
NOTE: Make sure that the brake linings are kept frre of !t I
grease and oil.
3 Remove nuts attaching brake support plates and

retainers to axle tube flanges. Nuts are accessible
through holes in axle shaft flanges.
4 Remove axle shafts using Adapter Ibol .1-21579 and
Slide Hammer .1-2619-01 See Fig. 2.
TOOL TOOL
J-21519 J-2619-O1
FIg. 3 Notching Bearing Retaining Ring -
Ctierokee-Wagoneer-J-10 Truck Axle

70543
8 Pack wheel bearing lubricant in cavity of

Fig. 2 Axle Shaft Removal -
replacement oil seal and between seal lips and install
Cherokee-Wagoneer-J-1 0 ituck seal on axle shaft seat. Outer face of seal must face axle
shaft flange.
5 If cup portion of wheel bearing assembly remains in
the axle housing after the axle shafts are removed, NOTE: In order to prevent damaging the seal, it is
remove the bearing cups using tools J-2619-01 and important that the seal lips be lubricated before
.1-26941. installation and that the seal lips contact the machined
portion of the shaft only.
6 Remove axle shaft inner oil seals from axle housing
tubes. 9 Pack replacement wheel bearing with wheel bearing
lubricant. Force lubricant through cup rib ring end
Axle Shaft Bearing Replacement until it comes out at other end, around bearing.
CAUTION: Under no circumstance should the axle 10 Install wheel bearing on axle shaft. Be sure cup rib
shaft retaining ring or bearing be removed using a ring is facing axle shaft flange.
torch. Heat will transfer into the axle shaft bearing
journal and weaken it. 11 Install bearing retainer ring on axle shaft.
1 Mount axle shaft in vise. Use protective jaws on vise 12 Press bearing and retainer ring on axle shaft
to avoid scratching or damaging shaft. simultaneously using tool .1-22192-01 or .1-23674 and
2 Drill 14-in. 6mm diameter hole in retaining ring.
Hole depth should be approximately three-fourths of
ring thickness.
CAUTION: Do not allow drill to contact the axle shaft.
3 Position a chisel over the drilled hole in the

retaining ring and cut a deep groove in the retaining
ring with the chisel. This will enlarge or split the ring
allowing the ring to b? removed from the axle shaft See
Fig. 3.
4 Slide retaining plate and oil seal toward axle shaft

flange to provide room for bearing removal tool between
seal and bearing.
5 Remove axle shaft bearing using arbor pressand tool

.1-22912-01 or .1-23674 See Fig. 4.
6 Inspect axle shaft bearing and seal surfaces for

scratches. Remove scratches using crocus cloth.
Fig. 4 Axle Shaft Bearing Removal -
7 Install retainer plate on axle shaft. Cherokee-Wagoneer-J-1O ituck Axle
80-42
arbor press. Be sure bearing and retainer ring are CAUTON: This procedure is necessary to ensure that
properly seated squarely against axle shaft shoulder. the seal and bearing cup rib ring are seated squarely in
the axle tube. The seal can be damaged if this procedure
NOTE: When the seal and bearing seat against each is not followed.
other some lubricant should be forced out of the other
side of the bearing.
Axle Shaft and Bearing Installation
1 Clean inner oil seal and bearing bores in axle

housing tube and install replacement inner seal using
tool J-25135-01, then apply wheel bearing lubricant to
seal and to bottom one-third of cavity between eal and
bearing bore shoulder.
2 Apply thin coating of wheel bearing lubricant to

outside diameter ofwheel bearing cup and outer oil seal.
CAUTION: Take care to avoid damaging the oil seal

when installing the shaft.
3 Insert splined end of shaft into differential side gears

and start cup rib rings and seals into axle tube. FIg. 5 Axle lUbe Flange Boft and Nut
Tightening Sequence
4 Align retainer plate and bolts and push axle shaft
into housing as far as possible. Install nuts on bolts
finger tight only 6 Tighten nuts to final torque of 50 foot-pounds 68
N.m torque in a cross pattern Fig. 5.
NOTE: The outer oil seal must be squarely seated
against the bearing. 7 Install rear brake drum, locknuts and wheels.
Tighten rear wheel nuts to 72 foot-pounds 98 N.m.
5 ‘lighten all nuts alternately and evenly in a cross torque.
pattern Fig. 5 to approximately 15 foot-pounds 20
N.m. torque to seal and cup rib ring evenly in axle tube. 8 Remove supports and lower vehicle.
ALPHA
REAR AXLE - Inspect & Identify

includes Drive-In/Drive out A Wag-Che Truck 0.1 0.1 G
BEARINGS, REAR AXLE SHAFT - Replace both sides
Includes Inspection and Drive-in/DrIve-out B 1.4 1.4 0
CLAIM HANDLING & CAMPAIGN REPORTING Cover Sheet: contains instructions for the owner and
shows the dealer where to imprint his dealer plate.
Owners of record will be mailed the AMC and Jeep CCI Copy: to be submitted to CCD for campaign
combined Product Recall Campaign Notice and Claim reporting and crediting.
Form Fig. 6. This form is to be used in place of a
warranty claim and a campaign reporting card. Factory Copy: to be used as a packing copy for
returnable parts when required.
This Product Recall Campaign Notice and Claim Form
is a six-page form that is pre-printed with the Dealer Accounting/Dealer Service/Owner File
customer’s name and address and the campaign name Copy: this copy is for the dealer file.
of record along with a cover letter outlining the defect Customer Copy: to be given to the customer as a record
and instructions to present the complete form to the of the campaign service performed.
Reply Card: to be used by the owner if ownership or
The six copies are: address has changed.
80-43
_____________ ________________
Upon presentation of this form by an owner, the dealer total campaign VIN range contained in the Campaign
should: DRB to ensure the vehicle is eligible to receive
* Imprint the combined notice and claim form in the campaign services.
upper right hand corner with his dealer plate and
remove the cover sheet. When using a blank form, be sure to enter the owner’s
* Complete the header information boxes. name and address, yIN, Zone PDC and Dealer Code,
* Have the owner sign the form on the owner signature campaign name or number, date of compliance and
line. dealer’s signature in the areas provided and X the
* Perform the required campaign service as outlined in appropriate service box as outlined in the Diagnosis and
the DRB. Repair Bulletin.
* Complete the form by entering the R.O. date, mileage
and placing an X in the appropriate alpha code box Based on the alpha box checked, the dealer will
indicating the campaign service which was automatically be credited on the mid or end-of-month
performed. The alpha code, which takes the place of memorandum of warranty transactions code 40
the cost code and operation number, can be found on referencing the claim number on the form. The single
page 3 of this DRB. credit shown will include Drive-in/Drive-out,
* Sign the form in the area provided and mail the CCD corresponding labor, parts cost and applicable parts
copy to CCD in Milwaukee. mark-up.
NOTE: Do not make out a separate warranty claim. Although it will no longer be necessary for the dealer to
The new form is the warranty claim. enter the parts and labor costs for processing of the
recall claim, the dealer may wish to complete the
In the event the owner misplaces or neglects to bring in internal records box in the lower left hand corner of the
the campaign notice and claim form, the dealer should claim. The figure shown in this box should he entered on
use a blank Campaign Notice and Claim Form. A small the dealer’s claim register along with the claim number.
supply is included with this DRB. Should you need more
forms, they are available from your Zone Service Starting with this JEEPAXLE Campaign, it will no
Department. longer be necessary to complete a warranty claim form
and a campaign reporting card after servicing an AMC
Before providing campaign services for a vehicle where or Jeep vehicle involved in a product recall campaign.
the owner fails to present the campaign notice and claim
form, the dealer must check the Vehicle Identification PLEASE NOTE: All prior campaign claims will
Number VIN against his Campaign YIN List or the continue to be handled as in the past.
n San
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FIg. 6 Sample Completed Combined Product Recall Campaign Notice and Claim Form
NOTE: This sample claim represents inspection and replacement of the rear axle shaft bearings. An inspection
only would be alpha code A.
Fl Jeep
Date: May 27, 1980
I Application: 1979 and 1980
Jeep CJs
File: CHASSIS - Axle and
Prop Shaft
This is a 1jpe S" campaign subject to all campaign INSPECTION PROCEDURE

procedures and involving safety-related elements.
1 Place transmission gear selector in neutral and raise
Some 1979 Jeep CJ models built between VIN vehicle.
J9M83AC849545 and J9M83AC851591 and 1980 Jeep
CJ models built between YIN J0M93AH700384 and 2 Rotate propeller shafts and inspect the following
J0M83AC701781 may have been assembled with other U-joint to yoke attaching clamp bolts with Thrx heads.
than specified universal joint to yoke attaching clamps
and bolts. As a result, these bolts may not hold torque 1979 CJ Models - Inspect bolts and clamps at both
due to interference between the bolthead flange and the front axle yoke and rear axle yoke.
clamp. This could result in the loosening of the bolts,
uncoupling of the propeller shaft U-joints and yokes and 1980 CJ Models - Inspect bolts and clamps at all
loss of drive to the front and/or rear wheels. yokes.
Service correction involves inspecting the subject ve If all bolt heads have small flange Fig. 1 and there isno
hicles for the proper universal joint to yoke clamps and interference with clamp, clean yoke using wire brush
bolts and replacing the substandard components. Refer and shop cloth with solvent. Color every yoke with dab
to the Inspection Procedure. of light colored paint where screws and clamps were
correct to note campaign completion, and return vehicle
The Zone will provide a VIN list to each dealer with to owner.
vehicles involved. However, the campaign procedures
apply to all dealers. On all undelivered campaign
involved vehicles, the inspection/correction must be
made before the vehicle is sold or otherwise put in
service.
The parts required for this campaign have already been

shipped to all dealers on a no-charge basis. Each dealer
has received bolts and clamps for every vehicle on his
VIN list. Additional parts may be ordered as needed
from your Zone Parts Distribution Center.
Part
Description Qt No. Group FIg. 1
BOLT, Propeller
Shaft to Yoke A/R 4006363 9.100
If any bolt heads have large flange Fig. 2, then clamp
CLAMP, Propeller and bolts must be replaced. Refer to the Replacement
Shaft to Yoke A/R 3235473 9.100 Procedure.
PU American Motor! Sales Corporation

INSPECT
1 Remove and discard propeller shaft yoke bolts and THIS POINT CLAMP
clamps identified as faulty during inspection. FOR INTERFERENCE
BOLT
NOTE: These torx head bolts require a thin wall, ES

Thrx-drjve socket as found in the J-25359-02 Thrx bit
and socket set.
2 Install new bolts and clamps and tighten replace
ment bolts to 15 ft. lbs. 19N.m torque.
3 Clean yoke using wire brush and shop cloth with

solvent.
Is
0.418 . 0.438
inch
Incorrect
Fig. 2
4 Color every yoke with dab of light colored paint
where screws and clamps were replaced to nbte cam
paign completion.
5 Lower vehicle.
ALPHA
DPERATION DESCRIPTION FOR CLAIM MODEL -79 -80- LEVEL
BOLTS/CLAMPS. Propeller Shaft to Yoke - Inspect

includes Drive-in/Drive-out A 83-93 0.2 M .
Replace includes Drlve-in/Dfive-out and

Inspection Time Allowance
One B 0.4
Iwo C 0.5
three D 0.6
Ill E 0.7
CLAIM HANDLING AND CAMPAIGN REPORTING Factory Copy: to be used as a packing copy for return
able parts when required.
Beginning with this campaign, owners ofrecord will be
Dealer Accounting/Dealer Service/Owner File
mailed a new AMC and Jeep combined Product Recall
Copy: this copy is for the dealer file.
Campaign Notice and Claim Form Fig. 3. This new
form is to be used in place of a warranty claim and a Customer Copy: to be given to the customer as a record
campaign reporting card. of the campaign service performed.
Reply Card: to be used by the owner if he or she no
This new Product Recall Campaign Notice and Claim longer owns the vehicle or has moved.
Form is a six-page form that is pre-printed with the
customer’s name and address and the campaign name Upon presentation of this form by an owner, the dealer
should:
of record along with a cover letter outlining the defect
and instructions to present the complete form to the * Imprint the combined notice and claim form in the
dealer at the time the vehicle is serviced. upper right hand corner with his dealer plate and re
move the cover sheet.
The six copies are: * Complete the header information boxes.
Cover Sheet: contains instructions for the owner and * Have the owner sign the form on the owner signature
shows the dealer where to imprint his dealer plate. line,
CCD Copy: to be submitted to CCD for campaign * Perform the required campaign service as outlined in
reporting and crediting. the DRB.
80-46
* Complete the form by entering the tO. date, mileage provided and "X" the appropriate service box as outlined
and placing an X in the appropriate alpha code box in the Diagnosis and Repair Bulletin.
indicating the campaign service which was performed.
The alpha code, which takes the place of the cost code Based on the alpha box checked, the dealer will auto
and operation number, can be found in the SSO Block of matically be credited on the mid or end-of-month
this DRB. memorandum of warranty transactions code 40 re
ferencing the claim number on the form. The single
* Sign the form in the area provided and mail the CCD claim credit will include Drive-in/Drive-out, corre
copy to CCD in Milwaukee. sponding labor, parts cost at dealer net and applicable
parts mark-up.
In the event the owner misplaces or neglects to bring in
the campaign notice and claim form, the dealer should Although it will no longer be necessary for the dealer to
use a blank Campaign Notice and Claim Form. A small enter the parts and labor costs for processing of the
supply is included with this DRB. Should you need more recall claim, the dealer may wish to complete the inter
forms, they are available from your Zone Service De
nal records box in the lower left hand corner of the
pai-tment. claim. The figure shown in this box should be entered on
the dealer’s claim register along with the claim number.
If an owner fails to present the campaign notice and
claim form, the dealer must check the Vehicle Identifi
Starting with this UJOINT Campaign, it will no longer
cation Number VIN against his Campaign VIN List or
be necessary to complete a warranty claim form and a
the total campaign VIN range contained in the Cam campaign reporting card after servicing an AMC or
paign DRB to ensure the vehicle is eligible to receive Jeep vehicle involved in a product recall.
campaign services.
PLEASE NOTE: All prior campaign service claims
When it is necessary to use a blank campaign form, be
must be handled as in the past, using a warranty claim
sure to enter the owner’s name and address, VIN, Zone form properly completed for the campaign repair.
PDC and Dealer Code, campaign name or number, date
of campaign service and dealer’s signature in the areas
Ameflean Motors
VU Sales Corporation r;:.-snti rs. 1-’-
SERVICING DEALER IOENTICtCATION
SERVICING DEALER:
PRODUCT RECALL Alter the required campaign service has been perlormed.
CAMPAIGN NOTICE AND please imprint your plate to the right and sign the claim end Shiv"
CLAIM FORM complete the applicable intormalion below. Follow the in
slnjctions in the Diagnosis and Repair Bulletin IDROI for this
aulho,,00 has the repair work be campaign Please heaccurate and legible since this intorma
perrormed on Ihe described rmator lion will be used br campaign reporting and crediting. Marl VI1MIIL&I 115
vehicle The vehicle may be opeeaiea by this claim to CCD in Mitwaiaee. If returnable paris are
you Or your personnel 0’ test and involved. lollow the applicable bulletin instructions. ‘‘il IllivA MIlSeill
inspection purposes
Owl’e’ S
a. S.oniaiuie
leooure ikie, IoN Campus.. Sc Jr Cop suiaesoule cuccr.iu U iv

X!ieerd..uV
I lheoaeiios,s ordRhea,ieci!ni,ii
.t sol w.o .j00000ls hllD_ IA B C 0 E r G
rae oar ira. I INS lereisl Cfl p-- i .<j -
Authorized OWNER INFORIAATtON

.
Dealer Signature X - - - - .._Qaa, . -- - -- NAME
ANN leAd II
This it to certity hat the required cantetaign Service has bee, AODMESS l?31 OIILFAits 1111511
performed tree of charge to the earle! ot the above vehicle.
CITY, STATE, ZIP ANY-rohN i USA I 21-i S
VEhICLE IDENTIFICATION NO JulJSNNoOllU4a

Upon completIon this lorm should be submitted with your
Warranty Claims to COD.
Casçaiga Nare end No. II.JOINI ShoAl
FOR SERVICING DEALER FOR CCD USE

INTERNAl. RECORDS USE ONLY
COST I SALE
Lauor Value $
Mel Pails Value
r Atonance S
Total Claim VaLue
Fig. 3 - Completed Combined Product Recall Campaign Notice and Claim Form
The above is a sample claim illustrating Drive-In/Drive-Out and inspection plus replacement of 3 bolts/clamps.
60-47
Subject; Revised Procedure for Measuring Application: 1980 CJ Models File: CHASSIS
and Conecting Steering Knuckle Ball Stud Axles Propeller Shaft
-
Preload
No.80-i Aug. 12,1980
A revised procedure for measuring and correcting 5 Disconnect steering connecting rod at right-
steering knuckle ball stud preload on 1980 II models side steering knuckle.
has been developed. The procedure for 1980 Cherokee,
Wagoneer and Truck models remains the same as out 6 Remove cotter pin and retaining nut that attach
lined in the 1980 Jeep Technical Service Manual. tie rod to right-side steering knuckle. Retain nut but
discard cotter pin.
The revised procedures involve measuring ball stud 7 Rotate both steering knuckles through complete
preload, adjusting torque on the upper ball stud split arc several times. Work from right side of vehicle to
ring seat or replacing the upper and lower ball studs, rotate knuckles.
road testing to evaluate steering, and adjusting front
axle caster if necessary. 8 Assemble socket and 0-50 foot-pound 0-68
N.m capacity torque wrench and install wrench on
tie rod retaining nut.
The following parts may be required and will be
NOTE: The torque wrench must be positioned at a
available the week of August 4, 1980. Do not order
90° angle to the steering knuckle arm to obtain an
parts before this date.
accurate reading.
9 Rotate knuckles slowly and steadily through a

Description Quantity Part No. Group complete arc and measure torque required to rotate
knuckles.
RING, Split 2 8121365 10.004
STUD, Steering a If reading is less than 25 foot-pounds
Knuckle Ball Upper 2 8122495 10.006 34 N.m, turning effort is within specifications,
STUD, Steering check steering gear, pump, or column.
Knuckle Ball Lower 2 8122496 10.006
SHIM, Front Spring
to Axle 30 2 8129807 11.100 b If reading is more than 25 foot-pounds
34 N.m, turning effort is excessive. Proceed
to next step.
PROCEDURE 10 Disconnect tie rod from both steering knuckles.
11 Install 1/2 x 1 inch bolt, flat washer, and nut in

Ball Stud Preload Measurement tie rod stud mounting hole in one steering knuckle.
Tighten bolt and nut securely.
1 Raise vehicle.
12 Install socket and 0-50 foot-pound 68 N.m
Remove front wheels. capacity torque wrench on bolt previously installed
2
in steering knuckle.
3 If vehicle has steering damper, disconnect
damper at tie rod and move damper aside. NOTE: The torque wrench must be positioned at a
90° angle to the steering knuckle arm to obtain an
4 Unlock steering column. accurate reading.

Servlc. Englnnrlng Department * 14250 Plymouth Road * DetroIt, MIchigan 48232
80-48
13 Rotate steering knuckle slowly and steadily 8 Position steering knuckle on axle and install
through complete arc and measure torque required replacement lower ball stud jamnut finger tight -
to turn knuckle. only.
14 Install bolt, flat washer, nut, torque wrench and 9 Install and tighten upper ball stud slotted nut
socket on opposite steering knuckle and measure to 10-20 foot-pounds 13-27 N.m torque to draw
torque required to rotate knuckle, lower ball stud into tapered hole in axle yoke. Do not
install upper ball stud split ring seat at this time.
a if reading is less than 10 foot-pounds 14
N-rn, steering effort is within specifications, 10 Tighten replacement lower ball stud jamnut to
check for tight or damaged tie rod ends, lubricate 80 foot-pounds 108 N.m torque.
or replace as necessary, and proceed to next step. 11 Remove upper ball stud slotted nut and install
replacement split ring seat using Tool J-23447.
b If torque reading is more than 10 foot- Tighten seat to 65 foot-pounds 88 N-rn torque.
pounds 14 Nm, turning effort is ecesswe. 12 Install slotted nut on upper ball stud. Tighten
Proceed to Ball Stud Preload Correction proce- nut to 100 foot-pounds 136 N-rn torque. Align and
dure. install cotter pin without loosening slotted nut.
15 Install tie rod. Tighten tie rod retaining nuts to NOTE: If the cotter pin holes In the nut and stud are
40 foot-pounds 54 N.m minimum torque and mstall not aligned, tighten the nut only to align the holes.
replacement cotter pins. Never loosen the nut to align the holes.
16 Install connecting rod. Tighten connecting rod 13 Install front axle shafts and steering spindles
retaining nuts to 40 foot-pounds 54 N.m minimum loo and measure turning effort of each steering
torque and install replacement cotter pns. knuckle as described in Ball Stud Preload Measure
17 Install front wheels. ment.
a U turning effort is less than 10 foot-pounds
18 Lower vehicle.
14 N.m torque, proceed to step 14.
Ball Stud Preload Correction
b If turning effort is more than 10 foot-
1 Remove front axle shafts as outlined in cha$er pounds 14 N.m torque, replace upper and
lower ball studs with replacement parts de
U of the 1980 Jeep Technical Service Manual.
*bed in this bulletin and repeat Ball Stud
2 Loosen lower bali stud jamnut. Preload Correction procedure, but, tighten split
ring seat to 50-foot pounds 68 N-rn torque
3 Remove cotter pin and slotted nut from upper instead of torque value indicated in step 11.
ball stud. Then tighten upper ball stud slotted nut to
80 foot-pounds 108 Nm torque instead of
4 Unseat upper and lower ball studs by striking torque value indicated in step 12.
studs with lead hammer. 14 Install front axle shafts.
5 Remove upper bail stud split ring seat using Tool 15 Connect tie rod to steering knuckle arms.
J-23447. Discard seat after removal. Tighten tie rod end retaining nuts to 40 foot-pounds
54 N-m minimum torque and install replacement
6 Remove lower ball stud jainnut and remove cotter pins.
steering knuckle. Discard jamnut after removal.
16 Attach connecting rod to steering knuckle arms.
7 Clean following surfaces thoroughly: Upper ball Tighten connecting rod end retaining nut to 40 foot-
stud split ring seat threads, lower ball stud taper in pounds 54 N’m minimum torque.
steering knuckle, threads and tapered surfaces of ball
studs, and upper ball stud retaining nut thread. 17 Connect steering damper to tie rod, if equipped.
80-49
18 Install front wheels. Tighten wheel retainingnuts b if steering wheel requires assistance to re
to 75 foot-pounds 102 N-rn torque, turn toward center after making turns, proceed
to next step.
19 Lower vehicle.
21 Install +30 shim between each front spring and
20 Road test vehicle to verify steering effort axle spring pad to increase caster to desired maximum
correction and also check steering wheel returnability angle of +6°.
after making turns.
NOTE: To maintain proper seating of the spring
a If steering wheel returns toward center center bolts in the spring pads, caster should not be
unassisted after turns, return vehicle to owner. increased by more than +30.
The Standard Servicing Operations and work times as published in the current 550 Manual are not affected
by this bulletin.
80-095-lw
80-50
Subject: Disc Brake Noise Application: 1978-79-80 Cherokee, File: CHASSIS
Wagoneer, and Truck Models Brakes-Wheels-Tires
No. 80-1 Sept. 29, 1980
Some 1978-80 Cherokee, Wagoneer, and Truck models 2 Inspect braking surfaces of each disc brake rotor.
may develop a low frequency disc brake noise that is
imilsr to a squeal-type noise. This noise is caused by
the disc brakeshoes. a If surfaces are only lightly rusted or scored,
remove rotors as outhned in appropriate Techni
Service correction involves replacing the inboard and cal Service Manual, mount rotors in disc brake
outboard disc brakeshoes on both front wheels with a lathe, and clean rotor surfaces using flat sanding
shoe set that has a steel noise insulator on the out discs while turning rotors in lathe.
board brakeshoe.
b If rotor surfaces are severely scored,
The following new brakeshoe set is required and will cracked, chipped, excessively worn, or have
be available the week of October 6, 1980. hard spots a series of shiny or dark-colored
spots, replace rotor as outlined in appropriate
Desaiption Quantity Part No. Group Technical Service Manual.
SHOE SET, Front

Wheel Disc Brake 3 Install replacement brakeshoes and disc brake
Both Front Wheels 1 8130435 8.000 calipers on each front wheel as outlined in appropriate
PROCEDURE
1 Remove disc brake calipers and brakeshoes. The standard servicing operations and work times as
Refer to Chapter 2G in 1978-79-80 Jeep Technical published in the 1978-79-80 SSO Manuals are not
Service Manuals for procedure. affected by this bulletin.
80.loo-08J

Servics EngIns.rlng Dspartmsnt . 14250 Plymouth Rood . D.troiL Michigan 48232
n.ci
____________
FILE: Windshield-Windows
VU Jeep
-Body hardware BODY -
Body General
No. 5-01-82 Feb. 15, 1982
TECHNICAL BULLETiN
PROBLEM AND Power windows on some 1980-82 Wagoneer, Cherokee, and Truck models
APPLICATION: may make a scraping, clicking sound when operated or may not open
completely. This may be due to the door glass bottom channel
becoming cocked on the glass and catching on the regulator arm.
CORRECrION: Install a polypropylene wedge at each end of the door glass bottom
channel to prevent cocking.
PARTS:
Part Description Quantity Part Number Group
WEDGE, Door AR 5762644 25.030

Glass Bottom
Channel
WARMNTY Reimbursable within the provisions of the applicable warranty.

ELIGIBILITY:
SSO INFORMATION:
Operation Description Code Number Model 80 -81- 82 Level
CHANNEL, FRONT OR REAR

DOOR GLASS BOflOM
INSTALL WEDGES.... 25045 Wag-Cke-Trk C
One door 0.8 0.8 0.8
Each additional
door Add
- 0.7 0.7 0.7
Replace bottom
channel Add....
- 0.2 0.2 0.2
Front 25.030
Rear 25.032
PROCEDURE:
1. Remove the door glass and bottom channel as outlined in chapter 3J of

the 1980-82 Jeep Technical Service Manuals.
2. Inspect the bottom channel. Replace the channel if bent, distorted,

or otherwise damaged.
3. Position the sides of the bottom channel parallel to the door glass
and install a polypropylene wedge at each end of the channel. Posi
tion the wedges between the side of the channel and the seal and press
the wedges to the bottom of the channel as shown in the illustration.
continued
‘1 American Motors Sales Corporation

Service Engineering Department * 14250 Plymouth Road * Detroit, Michig.n 48232
80-62
-2-
4. Install the door glass and bottom channel as outlined in chapter 33 of

Caution: Be sure that the division and glass side channels are
securely attached to the door. The bottom channel can contact the
regulator if either of these channels are loose.
5. Verify proper power window operation.
DOOR GLASS
BOTTOM CHANNEL
SEAL
POLYPROPYLENE
WEDGE
Installing Wedges in Bottom Channel
82-031-3
80-53
Application: 1980 Cherokee and File: BODY
Subject: Underbody Spare Wheel Mounting
Wagoneer Models Built Prior to Body General
Bar
YIN J0M17NC065724 June 19,
1980
No. 80-2 July 18,1980
On some 1980 Cherokee and Wagoneer models built 6 Clamp mounting bar in vise and straighten bar
mounting leg until it is at 900 angle to bar frame
prior to VIN J0M17NC065724 and equipped with an
underbody mounted spare wheel, an intermittent see illustration.
underbody noise may occur when the vehicle travels
over bumps. This condition may be the result of 7 Position mounting bar in mounting plates and
contact between the spare wheel mounting bar and install hinge pin, spring, washer, and cotter pin.
rear axle housing cover.
8 Install spare wheel and tire assembly.
Service correction involves inspecting the rear axle
9 Remove supports and lower vehicle.
housing cover for scratch marks, which indicate that
contact has occurred, and modification of the spare MOUNTING
SPRINGS
wheel mounting bar if necessary. WASHERS
COTTER PINS
PROCEDURE
1 Raise and support vehicle.
2 Inspect rear axle housing cover for scratch marks.
a If scratch marks are evident, proceed to

step 3.
b If scratch marks are not evident, inspect
all other underbody components for source of WHEEL
MOUNTING
noise and repair as necessary. BAR
3 Remove spare wheel and tire assembly. ORIGINAL

ANGLE
4 Remove cotter pin, washer, and spring from
hinge pin that attaches mounting bar to mounting
plates see illustration.
80251
5 Remove hinge pin and remove spare wheel
mounting bar. Spare Wheel Mounting Bar Modiflcation
YEAR AND TIME

CODE NUMBER LEVEL
80 BI 82
BAR, SPARE WHEEL MOUNTING

UNDERBODY - INSPECT 14.150 20141 Wag-Cke 0.1 G
Modify A 0.2
80-129-BSJ

Service Engineering Department * 14250 Plymouth Road * Detroit Michigan 48232
Add itlonal copies of this bulletin are available through your zone office.
80-54
Subject: Soft Top With Metal Application: 1980 CJ Models BODY
Door Fit With Soft Top and Metal Doors Body General
No. 80-1 Feb. 6, 1980
On some 1980 Cd mpdels with a soft top and metal 5 Insert horizontal support rod into socket.
doors, the inside top snap on the vertical support
blades may be difficult to fasten. This condition may 6 Engage vertical support rod tab in horizontal
be caused by a misaligned hole in the horizontal support rod.
support rod.
7 Reposition soft top roof bow and strap on
Service correction involves checking hole position in soft top.
each support rod and replacing the support rods if
the holes are misaligned. 8 Loosen vertical support blade.
The following parts are available and may be re 9 Adjust blade position as necessary to align it
quired: with supports.
10 Snap soft top to body panels and vertical sup

Description Quantity Part No. Group port blade.
ROD, Horizontal 2 8132799 40.014

Support
F
PROCEDURE N
SOCKET
1 Unsnap soft top from vertical support blade and

body side panel.
2 Unsnap soft top from roof bow and reposition ROD

roof bow.
3 Remove horizontal support rod from vertical

support rod and remove horizontal support rod from
socket see illustration. BLADE
4 Check hole position, in horizontal support rod.

Hole should be located 28 inches from end of rod
see illustration. Replace rod if hole is misaligned. Soft Top Supports for Metal Door
RODS, HORIZONTAL SUPPORT -
REPLACE BOTH
80-06 2-B sJ
Service Engineering Departm.nt * 14250 Plymouth Road * Detroit, MichIgan 48232
80-55
FILE: Body/Chassis
VU Jeep Electrical BODY

Electrical
Nn. 8-03-82
Body
Sant.
-
10. 1Q82
TECHNICAL BULLETIN
PROBLEM AN Oil pressure gauge needle flutters during engine operation on some
ginning with code B20l 2-1-82.
PARtS: Description Quantity Part Number Group
GAUGE, Oil 1 5750279 3 * 605

Pressure
S.R.T. INFORMATION
Operation
Operation Description T.I.C. Number S.R.T.
‘CO. GAUGE, OIL PRESSURE

REPLACE 8-352 8999 0-3

REIMBURSEMENT:
PROCEDURE:
1. Remove the original oil pressure gauge as outlined in Chapter 1L of the appro
2- Obtain a replacement oil pressure gauge and check the gauge date code before in
stallation to be sure it is one of the improved gauges. The code must be B201
2-01-82 or later.
NOTE: Code letter B indicates the month, such as B for February, C for March, or
D fo April. The first number indicates the year, which in this case is
code C2l7 would represent March 17, 1982 and code D208 would represent
3. Install the replacement oil pressure gauge as outlined in Chapter lL of the appro
82-064-J

Service Engineering Department * 14250 Plymouth Road * Detroit, MIchigan 48232
80-56
Subject: Power Sun Roof Option Application: 1980 Wagoneer File: BODY
Limited Models Body Electrical
No. 80-8 Aug. 11, 1980
A power sun roof is now available as an option on

1980 Wagoneer Limited models. The sun roof features
a sliding glass panel operated by an electric motor arid
a manually operated sun screen A nylon knit, one-
-
piece headliner with bonded foam backing and a

padded vinyl roof are standard on every Wagoneer
model equipped with the optional sun roof.
The electric motor that operates the sliding glass panel

is activated by a two-position switch mounted in the
windshield header. The electric motor itself is mounted
in the forward portion of the sun roof housing
assembly. Electrical feed to the motor is through the
A/C terminal of the fuse panel. Circuit protection is
provided by the A/C terminal fuse and by a 20 amp,
in-line fuse in a harness wire located just below the
left A-pillar.
An additional feature of the sun roof is the ability to

close the sliding glass panel manually if an electrical
power failure should occur. A cranking tool is provided
with the sun roof for this purpose, Refer to Manual 81106 A
Operation of Glass Panel procedure. Fig. 1 Removing/Installing Halo Assembly Attaching

Screws
A rubber drain hose is used at each corner of the sun
roof housing. These hoses remove any water that may
bypass the weatherstrip seal surrounding the roof
opening. The forward hoses are routed downward
through the A-pfflars. The rearward hoses are routed
downward through the D-pillars.
Whenever it is necessary to service the power sun roof,

refer to the procedures provided in this bulletin.
POWER SUN ROOF SERVICE AND ADJUSTMENTS
Halo Assembly Removal
1 Open glass pane! partially and remove halo

assembly attaching screws Fig. 1.
2 Grasp center of halo assembly and pull assembly

downward to disengage front tabs from track. Fig. 2 Removing/Installing Halo Assembly

Service Engineering Department e 14250 Plymouth toed e D.troit, Michigan 48232
Rnc7
3 Close glass panel fully, slide nab assembly Sunscreen Removal
forward, and remove assembly from vehicle Fig. 2,
1 Remove halo assembly and glass panel. Refer to
Halo Assembly Installation Halo Assembly Removal and Glass Panel Removal
1 Close glass panel and position rear portion of procedures.
halo assembly on glass panel.
2 Open sunscreen fully,
2 Open glass panel partially.
3 Working from outside of vehicle, push sunscreen
3 Install halo assembly attaching screws. upward at center of screen and slide screen forward
and upward to remove it Fig. 4.
Glass Panel Removal
Sunscreen Installation
1 Remove halo assembly. Refer to Halo Assembly
Removal. 1 Working from outside of vehicle, curve sunscreen
upward at center of screen and slide screen rearward
2 Close glass panel and remove outboard screws and downward into sun roof opening Fig. 4.
from front guide shoe assemblies Fig. 3. Then
loosen inboard screws and rotate guide shoes to 2 Install glass panel and halo assembly. Refer to
disengage slide portion from track. Glass Panel Installation and Halo Assembly Installation
procedure.
3 Release rear slide tension springs by rotating
them to inboard position Fig 3.
4 Remove screws attaching rear guide shoes and

retainers to tabs in glass panel and remove retainers
CURVE SUNSCREEN
Fig. 3. UPWARD AT CENTER
TO EASE REMOVAL
5 Working from outside of vehicle, raise front of OR INSTALLATION
glass panel and slide panel forward and out of vehicle.
Glass Panel Installation

1 Position glass panel in vehicle.
2 Install rear guide shoes and retainer brackets on

glass panel and install guide shoe and retainer bracket
attaching screws.
3 Install rear slide tension springs Fig. 3. 511060
NOTE: Be sure the spring is positioned under the Fig. 4 Sunscreen Removal/Installation
spring lock roller.
Cable and Side Track Removal
4 Engage slide portion of front guide shoe assem
blies in track and install guide shoe attaching screws. 1 Remove halo assembly, glass panel and sunscreen.
Refer to removal procedures outlined in this bulletin,
5 Install halo assembly. Refer to Halo Assembly
Installation. 2 Remove screws that attach cable front cover and
REAR SLIDE remove cover Fig. 6.
TENSION SPRING
3 Remove drive gear plate Fig. 5.
4 Remove side track cover screws and remove side

track cover Fig. 5.
5 Disengage cable from front track and motor gear
and remove cable by pulling it upward and outward.
NOTE: It may be necessary to reposition the front

cable guide before the cable can be removed from the
track.
0110CC
Fig. 3 Front Guide Shoe and Rear Tension Spring 6 Lift side track upward and remove side track.
80-58
FRONT
GUIDE SHOE
ft
KNURLED
ADJUSTING
NUT
GLASS
PANEL
SEAL
REAR
GUIDE
REAR SLIDE
TENSION SPRING
UN
81 IQ6F
CABLE TRACK
FRONT RETAINER
COVER
BRACKET
DRAIN SIDE
HOSE TRACK
RETAINER
HOUSING
FRONT CABLE AND ASSEMBLY
TRACK SIDE TRACK
BRACKET
SPACER
ELECTRIC
MOTOR
sc SUN ROOF
CONTROL
SWITCH
AUXILIARY
CRANK TOOL
81 106E
Fig. 5 Power Sun Roof Assembly
80.59
Cable and Side Track Installation 2 Raise and support housing on reinforcement ring.
1 Position side track in sun roof housing. Be sure 3 Install shims if equipped, and tighten housing
track retainer is seated in hole at rear of housing attaching hardware.
Fig. 5.
4 Connect drain tubes to housing assembly Fig. 5.
2 Slide cable assembly into side track and install
cover on side track. 5 Connect sun roof switch to motor harness.
3 Pull cable until rear guide shoe contacts side 6 Position ground wire on housing assembly and
track cover, connect wire to right A-pillar.
NOTE: If both cables have been disengaged from the 7 Install headlining. Refer to Headlining Installa
motor gear, be sure both rear guide shoes are in tion.
contact with the side track covers before proceeding.
This is very important 8 Install sunscreen, glass panel, and halo assembly.
Refer to Installation Procedures outlined in this
4 Position cables in front track and engage cables bulletin.
with teeth of drive gear.
5 Install drive gear plate. Vinyl Roof Removal

CAUTION: Do not operate the motor at this time as 1 Remove moulding clips and remove mouldings
the cables could be damaged. around vinyl roof.
6 Install cable front cover. 2 Remove all sealing material around openings to
expose vinyl top edges.
7 Install sunscreen, glass panel, and halo assembly.
Refer to installation procedures outlined in this 3 Mask cowl top, sides and rear of vehicle, and
bulletin, windows with paper. Insert paper in windows, then
close windows to hold paper in place.
Power Sun Roof Housing Removal
4 Remove luggage rack. Refer to Chapter 3L in
1 Remove halo assembly, glass panel, and sun- 1980 Technical Service Manual for procedure.
screen. Refer to removal procedures outlined in this
bulletin. 5 Loosen vinyl material at front pillars and along
windshield header.
2 Remove headlining, Refer to Headlining Re
moval. NOTE: It may be easier to remove the vinyl material
and padding simultaneously.
3 Disconnect ground wire at right A-pillar and
move wire away from housing assembly. 6 Remove material and sealer from drip rail. Pry
sealer loose using screwdriver or other suitable tool
4 Disconnect sun roof switch from motor harness. if necessary.
5 Disconnect drain tubes from sun roof housing 7 If vinyl material and padding is difficult to re
Fig. 5. move, soak adhesive next to fabric using rag dampened
with 3M General Purpose Adhesive Cleaner or equiva
6 Remove housing attaching nuts. lent.
7 Remove shims, if equipped. NOTE: It is not necessary to remove the old vinyl top
adhesive. However, it is important that the roof
8 Support housing and remove housing attaching surface be smooth and free of irregularities to prevent
hardware from brackets. hhligh:htg’ after a new cover is installed.
9 Lower housing assembly away from reinforce- 8 Remove vinyl material from foam padding using
ment ring and remove housing from vehicle. 3M General Purpose Adhesive Cleaner, or equivalent.
Power Sun Roof Housing Installation WARNING: Always use rubber gloves when working
with solvents and be sure the work area is well
1 Position housing assembly in vehicle, ventilated.
80.60
Vinyl Roof Installation 13 Brush adhesive onto cover, ledge of windshield,
and rear window opening. Allow adhesive to dry until
1 Remove all dust and foreign material from roof tacky before bonding.
panel.
14 Work vinyl cover into crease line areas around
2 Position padding on roof panel and cut away roof using smooth fiber stick.
foam padding at sun roof opening and luggage rack
attaching screw holes. 15 Trim excess cover material from around drip
rails, windshield, and rear window.
3 Remove paper backing from foam padding to
expose padding adhesive and bond padding to roof 16 Trim vinyl material around sun roof opening and
panel. Use roller or soft cloth to ensure positive bond. luggage rack attaching screw holes.
NOTE: Be sure the foam padding is smooth and free 11 Brush adhesive onto cover arid ledge of sun roof
from any irregularities to prevent highlighting after a opening. Allow adhesive to dry until tacky before
new cover is installed, bonding,
4 Mark centerline of roof panel above windshield 18 Position and work vinyl cover into sun roof
and rear window openings. opening using smooth fiber stick.
5 Align center of vinyl cover with centerline mark 19 Install luggage rack. Refer to Chapter 3L of
above windshield and rear window. 1980 Technical Service Manual.
6 Secure cover to pinch weld flange at centerline 20 Apply bead of 3M Super Silicone Sealer black
locations with ta. preferred or equivalent along top of windshield
rubber weather strip and vinyl cover.
7 Check cover for alignment at both sides and at
roof extension panels. NOTE: It may be necessary to apply sealer to the
drip rails also.
8 Fold cover in half at centerline,
21 Remove excess sealer using 3M General Purpose
9 Apply smooth, even coat of 3M Vinyl Trim Adhesive Cleaner or equivalent and remove all masking
Adhesive or equivalent to 15-inch wide strip of one tape and paper.
side of foam padding and to vinyl cover. Start at
center when applying adhesive and work from front 22 Install mouldings and clips.
to rear.
Headlining Removal
NOTE: Allow the adhesive applied to the vinyl
material and foam padding to dry until it is tacky to 1 Remove sun visors, escutcheons, and center
the touch. support.
2 Remove windshield moulding and end caps.

10 Bond cover to foam padding using a roller or
soft cloth to ensure positive bond and to eliminate
air pockets. Bond cover by starting at centerline and 3 Remove sun roof switch and disconnect switch
working toward side, wires.
4 Remove sun roof opening trim welt and remove

NOTE: To remove wrinkles caused by folding, keep motor cap.
the cover fabric taut while installing it.
5 Spray 3M Release Agent or equivalent, across
11 Apply adhesive to remainder of cover and foam headlining at windshield and around sunroof opening.
padding and in drip moulding at side of cover being Allow several minutes for release agent penetration.
installed. Allow adhesive to dry until tacky.
12 Apply smooth, even coat of adhesive to 15-inch CAUTION: When removing the headlining, use care
wide strip of foam padding and to vinyl cover on to avoid separating the foam backing from the fabric.
opposite side of vehicle. Start at center and work If the fabric begins to separate from the backing,
from front to rear when applying adhesive. Allow make a second application of the release agent.
adhesive to dry until tacky.
6 Remove headlining from roof panel and sun
NOTE: When applying the cover to the foam padding, roof opening.
always work from the center to the outside to elimi
nate air pockets to ensure positive bonding. 7 Remove headlining from side retainer
RU-Al
8 Remove lens from dome lamp. Remove screws 13 Spray 3M General Trim Adhesive or equivalent,
attaching lamp to sun roof housing and remove lamp. on roof panel along top of windshield.
9 Remove coat hooks. 14 Using sun visor holes as guides, pull headlining
forward and attach it along windshIeld.
10 Remove lens from cargo lamp, then remove
screws attaching cargo lamp to roof bow and remove 15 Install headlining along both sides using Installer
lamp and switch. Tool .1-2772-C.
11 Remove tailgate opening moulding and end caps. 16 Connect and install sun roof switch.
12 Spray 3M Release Agent, or equivalent across 17 Install windshield moulding and end caps, and
headlining at tailgate opening moulding. Allow motor cap.
several minutes for release agent penetration.
18 Install sun visors, escutcheons, and center
CAUTION: When removing the headlining, use care support.
to avoid separating the fcam backing from the fabric.
If the fabric begins to separate from the backing, 19 Remove masking tape.
make a second application of release agent.
Power Sun Roof Switch Removal/Installation
13 Remove headlining from tailgate opening.
1 Pull switch downward and disconnect switch
14 Remove headlining from side retainers and slide wires.
headliner rearward and out of headlining brackets.
2 Connect switch wires and install switch in switch
15 Remove headlining from vehicle through tailgate opening.
opening.
Power Sun Roof Motor Removal
Headlining Installation
1 Open sun roof glass panel; then disconnect
Install headlining in vehicle through tailgate battery negative cable.
1
opening. Insert headlining in headlining brackets and
slide headlining forward. 2 Remove sun visors, escutcheons, center support,
and windshield moulding and end caps.
2 Spray 3M General Trim Adhesive, or equivalent
across at roof panel at tailgate opening. 3 Remove sun roof switch and motor cap.
3 Attach headlining to roof panel at tailgate 4 Spray 3M Release Agent or equivalent across
opening and install tailgate opening moulding and end headlining at windshield. Allow several minutes for
caps. release agent penetration.
CAUTION: When removing the headlining, use care
4 Pull headlining forward. Install headlining up to to avoid separating the foam backing from the fabric.
coat hook locations along both sides using Installer If the fabric begins to separate from the backing,
Tool .1-2772-C. make a second application of the release agent.
5 Pull front edge of headlining downward.
5 Connect and install cargo lamp and I
6 Remove motor mounting screws and remove
6 Connect and install cargo lamp switch. motor.
7 Spray 3M General Trim Adhesive or equivalent, Power Sun Roof Motor Installation
on sun roof opening flange.
Install coat hooks. 1 Position motor in horsing and install motor

8 mounting screws.
9 Pull headlining forward and attach it to sun roof 2 Place strip of masking tape across top of wind-
opening flange. shield at roof panel.
10 Install sun roof opening trim welt. 3 Spray 3M General Trim Adhesive or equivalent
on roof panel along top of windshield.
11 Connect and install dome lamp and lens.
4 Pull headlining forward and attach it along
12 Place strip of masking tape across top of wind- windshield. Use sun visor holes as guides when
shield at roof panel. attaching headlining.
80-62
5 Connect wires to sun roof switch and install Glass Panel Height Adjustment
switch and motor cap.
Adjusting Front of Panel
6 Install sun visors, escutcheons, windshield trim
moulding and end caps, and center support.
7 Connect battery negative cable, and check sun Removal.
roof operation.
2 Loosen front guide shoe attaching screws Fig.
NOTE: If the motor slips and does not open and close 7.
the glass panel, the motor clutch located in the gear
portion of the motor may have to be adjusted. Refer 3 Turn knurled nut on each front guide shoe
to Motor Clutch Adjustment in Power Sun Roof dockwise to lower glass panel or counterclockwise
Service and Adjustments section. to raise panel and obtain desired height adjustment
Fig. 7.
Motor Clutch Adjustment

4 Tighten front guide shoe attaching screws to
1 Remove motor cap to gain access to adjusting 20 inch-pounds 2.3 N-rn torque after adjusting
screw. Cap is located in headlining just above, and at panel height.
center of windshield.
2 Loosen clutch plate adjusting screw jamnut CAUTION: Do not adjust the glass panel too high as
using deep socket. it could be damaged when the panel is opened or
closed.
3 Tighten adjusting screw to 50 inch-pounds
5.6 N-m torque.
4 Tighten jamnut and install motor cap,

Glass Panel Parallel Alignment
CAUTION: Do not operate the electric motor while

the glass panel or cables are removed from the track
as cable damage could occur.
1 Open glass panel approximately 1/4-to-1/2 inch.
2 Determine how much forward edge of glass panel

is out of parallel with forward edge of opening in
roof panel and note variation.
3 Open panel approximately eight inches to gain
access to cable and drive gear mechanism.
4 Remove cable front cover and drive gear plate.
5 Remove one cable from track.
6 Move one side of glass panel slightly fore or aft

as required to obtain parallel alignment with forward
edge of roof panel opening Fig. 6.
7 Install cable in front track and insert cable in

drive gear teeth.
8 Install drive gear plate and cable front cover.
9 Position glass panel approximately 1/4-inch

from fully closed position.
SIIOGG
10 Check parallel alignment. Repeat steps 2
through 9 to obtain proper alignment if necessary. Fig. 6 Glass Panel Parallel Alignment
80-83
5 Check glass panel alignment and operation in
ADJUSTING
NUT open and closed positions. Repeat steps 2 through
4 to obtain proper height if necessary.

Installation.
Adjusting Rear of Panel

Removal.
2 Release rear slide tension spring and rotate spring

to inboard position Fig. 3.
3 Loosen rear slide adjuster nut Fig. 8 and raise

or lower panel as required to obtain desired adjust
ment.
4 Tighten rear slide adjuster nut to 30 inch-pounds

FRONT GUIDE SHOE 3.3 N.m torque after completing adjustment.
ATTACHING SCREWS
511061
Installation.
Fig. 7 Glass Panel Front Height Adjustment
Manual Operation of Glass Panel
If an electrical malfunction should ever occur, the

glass panel can be opened or closed manually as
follows:
1 Remove small round motor cap located in center

of windshield header near front edge of sun roof
opening. Cap removal will provide access to motor
driveshaft.
ATTACHING SCREW
2 Remove screw in driveshaft using flat bladed
screwdriver a cranking tool blade end located in
glovebox.
3 Rotate motor driveshaft using cranking tool.

Rotate driveshaft clockwise to close glass panel, or
counterclockwise to open panel.
ADJUSTING SCREW 4 Install screw in driveshaft and install access plug

in windshield header after opening/closing glass panel.
Vinyl Top Repair
Bulges or Blisters
Bulges or blisters in the vinyl top indicate poor

bonding or trapped air. They can be eliminated by
piercing the bulge or blister to expel the air. Heat
the area for 10 to 15 seconds with Heat Gun J-25070,
Fig. 8 Glass Panel Rear Height Adjustment held 10 to 15 inches from the material.
80-64
Immediately press and hold vinyl material fIrmly 3 Dampen a dean cloth with clean water and apply
against foam padding and metal with a felt pad or it over wrinkled area.
roller until vinyl cover cools. Do not nib vinyl.
Rubbing will result in a polished area.
4 With iron at proper operating temperature, move
iron continuously over dampened cloth until wrinkle
Wrinkles is removed.
Minor wrinkles in the vinyl top material may be Maintain pressure on vinyl top material until material
removed with the application of moist heat as follows: cools.
Wash vinyl top surface thoroughly using AMC CAUTION: Apply pressure to the vinyl top material
1
Vinyl Cleaner or equivalent, only. Do not rub the uinyl top repair area as this could
impair the finish of the vinyL
2 Set heat control or household-type flat iron to
warm.
R AND TIME
MODEL
CODE NUMBER LEVEL
PANEL, GLASS SLIDING, SUN ROOF -
R& R 25.405 25218 Wag. 0.3 G

Panel-Replace 25.405 A 0.1 0
CABLE, SUN ROOF REPLACE - 28.452 25222 Wag. U

Includes cable adjustment
One 0.3
Both 0.4
HEADLINING - ft & R 29.011 29125 Wag. 1.3 G

HEADLINING - LOWER FRONT HALF.... 29.011 29114 Wag. 0.9 G
HEADLINING - LOWER REAR HALF 29.011 29116 Wag. 0.5 G
HOUSING, SUN ROOF R & R - 28.454 25220 Wag. 1.8 G
Includes lower front half of headlining
HALO ASSEMBLY, SUN ROOF - R& R . . -. 28.468 25216 Wag. 0.1 G

Halo assembly - Replace 28.468 A 0.1 G
Sliding Glass Panel - Adjust Height 25.405 B Wag. 0.2 G
CLUTCH, SUN ROOF MOTOR - ADJUST... 28.450 25224 Wag. 0.1 0
MOTOR, SUN ROOF - REPLACE 28.450 25226 Wag. 0.8 G
SWITCH, SUN ROOF - REPLACE 3.810 25228 Wag. 0.2 G
80-123-BSJ
80-65
Subject: Instrument Cluster Lens Application: 1980 Jeep Cl-S and File: BODY
CJ-7 Models Body Electrical
No. 80-7 June 30, 1980
On some 1980 CJ-5 and CJ-7 models, a slight mist CAUTION: Take care to avoid damaging the fuel and
may form on the instrument cluster lens during high temperature gauges when drilling the vent holes in the
humidity conditions. Although the gauges are still instrument cluster case.
quite visible, a customer may be dissatisfied with this
condition. 12 Clean all metal chips from instrument cluster
case.
Service correction involves drilling vent holes in the
instrument cluster case as outlined in the following 13 Install speedometer head in instrument cluster.
procedure.
14 Install lens, retainer, and bezel on instrument
cluster. Secure parts on cluster by crimping bezel at
four locations shown in illustration,
PROCEDURE
VENT HOLES VENT HOLES
1 Disconnect battery negative cable. 3/4.INCH APART 3/4-INcH APART
2 Disconnect speedometer cable at speedometer

head.
3 Remove windshield holddown knobs and fold

windshield forward onto hood.
4 Remove dash pad from dash panel.
5 Remove steering column bezel.
6 Remove screws that attach instrument panel to

dash panel and move instrument panel outward to
gain access to instrument cluster attaching nuts.
7 Remove instrument cluster attaching nuts and

move cluster away from instrument panel. 1/2"
POSITION VENT
HOLES 1/2-INCH
8 Tag all bulbs and wires connected to instrument INWARD FROM
cluster for assembly reference. Then disconnect REAR OF CASE
wires, remove bulbs, and remove instrument cluster.
9 Remove bezel, retainer, and lens from instrument

cluster.
10 Remove speedometer head from instrument

CRIMP
cluster case. BEZEL
AT THIS
POINT
11 Drill six 1/8-inch diameter holes in instrument 4 LOCATIONS
cluster case in locations shown in illustration. Position
each pair of holes in upper portion of case approxi
mately 3/4-inch apart. Position two holes in lower
part of case 1.1/4 inches apart to avoid contacting
bulb in this portion of case. Vent Hole Locations
fl American Motors Sates Corporation
Service Engineering Department * 14250 Plymouth Road * DetroIt, Michigan 48232
80-66
-- - - - - - ------ - -- - .- -, --- - ----. 1 -
15 Connect bulbs and wires to instrument cluster. 19 Install dash pad on dash p
Refer to assembly reference tags for correct wire
locations. 20 Raise windshield and install windshield hoiddown
knobs.
16 Install instrument cluster in instrument panel
and install cluster attaching nuts. 21 Connect speedometer cable to speedometer head.
17 Position Stniment peJ on d and 22 Connect battery negative cable.

install instrument panel attaching screws.
18 Install steering column bezel.
The following operation and standard work times will apply
YEAR AND TIME

COST OPERATION
NU
so si n
CLUSTER ASSEMBLY, INSTRUMENT -
MODIFY 3.505 3299 C.J 0.8 C

With Air Conditioning Add
- 0.1
With Fabric Top Add
- 0.1
With Molded Top Add
- 03
8O-117-BSJ
80-67
VIJeep4

Subject: Power Window Operation and Application: 1980 Cherokee, File: BODY
Diagnosis Wagoneer, and Truck Models Body Electrical
Equipped With Power Windows
and Built Prior to VIN
J0D15NC053176
No. 80-6 June 6, 1980
The electrically operated power windows in some PROCEDURE

1980 Cherokee, Wagoneer and Truck models built
prior to VIN JOD15NCOSS1I6 may bind, become 1 Disconnect battery negative Cable.
inoperative, operate slowly, or become inoperative
during cold weather conditions. 2 Remove door trim panel and water dam paper.
Service correction requires an accurate diagnosis of WARNING: The window regulator assembly is spring
the power window system. Slow operation or a loaded. The window glass must be supported in the
binding condition may be caused by improperly UP position and the regulator arm connected to the
adjusted window glass slide or division channels. An lower slide channel to prevent the regulator spring
inoperative window condition will require the circuit from unloading.
tests outlined in Section 3.1 of the 1980 Technical
Service Manual Supplement to determine if the 3 Support window glass in UP position by inser
condition is related to the window switch, motor, or ting wood block through door inner panel to support
wiring. If diagnosis indicates motor replacement is lower slide channel.
necessary, use the service replacement motor de
scribed in this bulletin. 4 Disconnect feed wires to motor at connector.
The following parts may be 5 Remove motor attaching nuts and bolts and
remove motor assembly.
Description Quantity Part No. Group 6 Install replacement motor assembly.
MOTOR ASSEMBLY, 7 Connect feed wires to motor.
Electric Window Drive
Left Side 1 8132691 2&300 8 Remove wood block used to support window.
MOTOR ASSEMBLY, 9 Install water dam paper and trim panel.
Electric Window Drive
Right Side 1 8132692 23300 10 Connect battery negative cable.
COST YEAR AND TIME

OPERATION DESCRIPTION OPERATION SKILL
CODE MODEL
NUMBER LEVEL
80 81 82
MOTOR, ELECTRICALLY OPERATED
FRONT DOOR WINDOW REPLACE 23.103 23158 Wag-Cke
-
0.6
Trk
MOTOR, ELECTRICALLY OPERATED
REAR DOOR WINDOW REPLACE 23.173 23168 Wag-Cke
-
0.5 Q
Trk
80-109-BSJ
U Amedcan Motors Sales Corporation

80-68
Subject: AM/FM Stereo Radio Option Application: 1980 CJ-5 and CJ-7 File: BODY - Body
Models Electrical
No. 80-5 April 30, 1980
An AM/FM stereo radio is now available as an option 5 Disconnect radio mounting bracket and remove
on 1980 CJ-5 and Cl-? models. This radio option radio.
includes dual speakers that are mounted in the instru
ment panel. 6 Remove nuts that attach speakers to instrument
panel and remove speakers.
If it is ever necessary to remove the AM/FM radio
and/or speakers on 1980 CJ models equipped with Installation
this option, refer to the following removal and in
stallation procedure. 1 Position speakers on instrument panel and install
speaker retaining nuts.
PROCEDURE 2 Install radio in instrument panel, connect radio

mounting bracket, and install radio nuts and control
1 Disconnect battery negative cable. knobs.
2 On models equipped with air conditioning, 3 Connect radio wires, speaker wires, and antenna
remove evaporator housing attaching screws and wire.
move housing away from instrument panel.
4 On models with air conditioning, position
3 Remove radio control knobs and nuts, evaporator housing on instrument panel and install
housing attaching screws.
4 Disconnect speaker wires, radio wires, and
antenna wire. 5 Connect battery negative cable.
OPERATION DEScRIPTION g ERA

o!MUMN MODEL
YEAR AND TIME
i a
SKILL
LEVEL
RADIO, AM/FM STEREO - a &R 15.327 3580 83-93 0.3 G
SPEAKERS, AM/FM STEREO RADIO -
R& K 15.321 3582 83-93 0.3 G
RAdio Speaker - Replace 15.821 A 83-93 0.4 G
SO-102.BSJ
P1 Amedcan Motors Sales Corporation

80-69
Subject: Stereo Radio Rear Speakers Application: 1980 Cherokee File: BODY
Missing Laredo Models Built Prior to Body Electrical
VIN J0E17NN027333
No. 80-4 Feb. 14, 1980
Some 1980 Cherokee Laredo models ordered with 5 Install speakers in left and right mounting
the four speaker stereo radio option may have been brackets.
built without the rear speakers.
6 Position and attach left and right speaker and
Service correction mvolves installation of the t& bracket assemblies to body panels according to
speakers and speaker wrrng harness if necessary. template supplied in speaker kit.
The following parts are available and required. 7 Connect speaker wires to cross-body harness
connections.
8 Operate radio to check and ensure that all four
JUMPER, Harness 1 5751957 15.320 speakers are functional.
SPEAKER KIT, 1 8997198 15.320 9 Install rear quarter trim panels and inside spare
.
Rear tire if equipped.
PROCEDURE Vehicles Without Power Tailgate
Vehicles With Power Tailgate 1 Remove inside spare tire if equipped.
1 Remove inside spare tire if equipped. 2 Remove both rear quarter trim panels.
2 Remove both rear quarter trim panels. 3 Remove knockouts from trim panels and cut out
trim material. Paint bezels and grilles with match-
3 Remove knockouts from trim panels and cut ing trim colors outlined below. Then install bezels
out trim material. Paint bezels and grilles with match- and grilles.
ing trim colors outlined below. Then install bezels
and grilles.
Black Blue Russet Dark Desert Tan
NA 8993597 8993596 8993499

Black Blue Russet Dark Desert Tan
NA 8993597 8993596 8993499 4 Install gaskets around speaker openings on

back of trim panels.
4 Install gaskets around speaker openings on back 5 Install speakers in left and right mounting
of trim panels. brackets.

Snvics Engineering Department * 14250 Plymouth Road e Detroit, Michigan 48232
80.70
6 Position and attach left and right speaker and 9 Remove seat belt lower mount.
bracket assemblies to body panel according to tern-
plate supplied in speaker kit. 10 Remove rear floor noulding at tailgate opening.
NOTE: The rear speaker harness may have been 11 Position and route harness under carpeting.
omitted in pmduction. If the harness cannot be start at jumper harness at radio and route back to
located in the rear quarter panel area, proceed to left speaker and across to right rear speaker.
step 7. However, if the harness is located in the
quarter panel area, proceed to step 14. 12 Operate radio to check and ensure that all
four speakers are functional.
7 Remove glove box from dash panel and inspect
wire harness running from radio to speakers. Wire 13 Install glove box, seat belt lower mount, scuff
harness part number should be 5751957. If not, plate and rear floor moulding.
replace harness as described in following steps.
14 Install both rear quarter trim panels and inside
8 Remove left scuff plate and loosen carpeting. spare tire if required.
YEAR AND TIME

MODEL
CODE NUMBER LEVEL
so at 82
SPEAKERS, RADIO REAR INSTALL.

- .. 15.321 3603 17 0.7 C
Includes brackets and color coat
Harness-Install 15.321 A 0.5 C
Material allowance for paint is_$0.70
80-05045,1
80-71
Vl Jeep
Date: January 28, 1980
This is a Trpe "5" campaign subject to all campaign The PDC’s already have their supply of campaign
procedures and involving safety-related elements. A parts. Parts can now be ordered, only as needed, from
copy of the combined owner notification and correc your local PDC.
tion reporting card for this campaign is shown in
Figure 1. INSPECTION PROCEDURE
Some 1980 Jeep Cherokee, Wagoneer and ‘fluck mod 1 Inspect headlamps. If cat.head shaped logo appears
els built between VIN numbers JOE17NN000065 on glass and a bulb is seen in unit, headlamps are
and J0E15NN005299 may have been assembled with incorrect and must be replaced. Refer to replacement
incorrect headlamps for the U.S. market. procedure below. If both headlamps are sealed beam
units, then vehicle should be returned to the owner.
Service correction involves inspecting both the right
and left headlamps and if necessar3ç replacing the REPLACEMENT PROCEDURE
headlamps found to be incorrect with the correct
parts. 1 Remove headlamp retaining ring screws and re
move retaining ring.
The following part may be required for correction:
2 Disconnect wiring and remove lamp assembly and
Group dispose of it.
Description Qty Part No. No.
Bulb, Headlamp A/R 8128683 3.280 3 Connect wires on replacement sealed beam head
Sealed Beam lamp and position lamp in place.
4 Position retaining ring and install retaining ring

The Zone will provide a yIN list for each dealer with screws.
any vehicles involved. However, the campaign proce
dures apply to all dealers. On all undelivered, 5 Aim headlamps according to local standards.
campaign-involved vehicles, the inspection!
correction must be made before the vehicle is sold or The following operations and standard work time
otherwise put in service. will apply:
WARRANTY
REPORTING OPERATION YEAR AND TIME SKILL
OPERATION DESCRIPTION CODE NUMBER MODEL 80 LEVEL
Bulb-Headlamp-inspect 3.280 3315 WAG, .1 M

CKE,
iRK
Replace Both-lncI. Aiming A .3 M
Applicable Condition Code: 56 Product Recall Campaign
-

Service Engineering Department * 14250 Plymouth Road * DetroIt, MichIgan 48232
80-7 2
________________________ ________________________________________________
CLAIM HANDLING card Fig. 1 for each vehicle as soon as the campaign
Several vehicles may be listed on a single Warranty
Claim form, reference the Warranty Administration CAUTION: On multiple-vehicle claims, do not delay
Manual, Section 7, Product Recall Campaign. Com any claim so that CCD will receive it beyond the time
plete and mail the reporting half of the notification outlined in the Warranty Administration Manual.

- InstructIons: OWNER Instructions: DEALER
a
II you do not now own this vehicle. please just fill in

This section is for the dealer to use when your vehicle
below either a. b. or ci and MAIL DIRECTLY TO
AMERICAN MOTORS SALES CORPORATION goes info, the reQuired attention
a Sold or Traded to: o Correction made

Nane Picas. Print:
o Correction not reQuired
0,
Zone and Dealer Code
Address
H I H
city Stale
b Present owner name and address not known 0

Dealer Signature
c Removed from service because of collision
damage or otherwise 0 Dais Vehicle Serv,ced
Campaign Data Reporting Section

YiN Vehicie identilicsiion Number
I ii Notice of Product Recall Campaign involving Your Vehicle

This notice is sent to you in accordance with the requirements of the National 1’affic and Motor Vehicle
Safety Act.
Jeep Corporation has determined that some 1980 Jeep Wagoneers, Cherokees, and ‘frucks may have head-
lamps that do not conform to Federal Motor Vehicle Safety Standard No. 108, Lamps. Reflective Devices,
and Associated Equipment. Your vehicle may have a headlamp that is not a sealed beam type as required
by the Federal Standard, in the interest of your safety and complete satisfactioa with our product. Jeep
Corporation wants to Inspect your vehicle to assure that proper headiamps have been installed. If neces*
sary, we will replace the present headlamp with a sealed beam type. This service may elimiaate an incon
venience to you should a replacement unit of your present headlamp become necessary and not be readily
available.
Jeep Corporation urges that you contact your Jeep dealer immediately to arrange an appointment for the
dealer to inspect the right and left headlamps, and if necessary, replace one or both with a sealed beam
type. This service will be performed at no charge to you. The time necessary to inspect and service your
vehicle will be approximately 45 minutes. Although the time required to service your vehicle is less than
one hour, we do suggest that you contact your dealer to arrange an appointment before tendering your
vehicle for service.
If your dealer does not perform this service on your mutually arranged appointment date or within five
days thereafter and without charge, please contact the Local American Motors Sales Corporation Zone
Office listed in your Owner’s Manual or American Motors Corporation, Owner Relations, 14250 Plymouth
Road. Detroit, Ml 48232 ‘Iblephone 313 493-234i, If your dealer fails or is unable to provide this service
within a reasonable time or without charge, you may wish to notify the Administrator, National Highway
‘fraflic Safety Administration. Washington, D.C. 20590.
When your vehicle goes in for the required attention: Please be sun this complete notification card goes with it
because the card is to be used by the dealer for repo*iag purpose.. in case you do not now own this vehicle please
send us the "Change of Ownership" infonnation. using side 2 of this card.
FIg. 1- Owner Notification aid Cormction

RepertIn Card
80-73
Subject: Moisture Entering Parking and Application: 1976-SO CJ Models File: BODY
Front Directional Signal Lamp Assembly Body Electrical
No. 80-2 Dec. 7, 1979
Some 1976-80 Cd models may have moisture entering MOUNTING

GASKET
the parking and front directional signal lamp assem-

Description Quantity Part No. Group F
LAMP, Assembly
Parking and Front
Directional Signal AR 5461340 3.292
GASKET, Directional LENS

and Parking AR 991400 3292
PROCEDURE
from grille panel and inspect mounting gasket for any and gasket. Rotate housing and gaskets 1800 so
2 Inspect internal bulb sockets for corrosion, lens to housing see ifiustration.
procedure on existing assemblies, required to grille panel being careful not to strip
8127445, to bulb socket to prevent corrosion, screws if required,

OPERATION DESCRIPTION MODEL 16-SO LEVEL
CODE NUMBER

AND/OR REPOSITION 3.292 3403 C.] 0.1 G
Replace One or both 3.292 A CJ 0.1 G
80-032-BSA

S*rvic. Enginoring D.portm.nt . 14250 Plymouth Road * D.troit, Michigan 48232
Additional copies ci this bulletin are available through your zono office.
80-74
Subject: Front Door Wire Router Application 1980 Wagoneer, File: BODY
Plates Cherokee and Truck Models with Body Electrical
Door Speakers
No. 80-1 Nov. 8, 1979
Some early built 1980 Wagoneer, Cherokee and PROCEDURE

Truck Models have 1980 design front doors with a 1 Using DuPont Galvanized Iron and Zinc Refin.
large opening at the front for wire harness routing ishing System Step 2 227 5, or equivalent, follow
and previous design front door hinges which allows manufacturers directions and prepare galvanized
the door to open farther than 1980 design hinges, plates for painting.
This combination of door and hinges causes both an
appearance problem due to the large opening and 2 Prime wire router plates.
an unusual stress on front door speaker wires. 3 Remove speaker wire retainer caps and remove
speaker wire from retainers. Remove retainers from
doors.
Service correction involves repairing broken speaker
4 inspect speaker wires for signs of damage.
wires, replacing speaker wire retainers if necessary Repair areas of insulation damage with electrical
and installing a wire router plate in each front door.
tape, or if wire is broken, repair by soldering wire
ends together using rosin core solder or equivalent
The following parts are required and will be available and wrap with electrical tape.
after November 26, 1979. Do not order parts before
this date. NOTE: Do not use excessive wrappings of tape as
Description Quantity Part No. Group wire may not fit into the retainer.
5 Insert speaker wire into plate slot and align

PLATE, Wire
plate over opening in front door inner panel. Using
Router 2 8130421 15.320 two screws, fasten plate to door panel. Make sure
SCREW, No. 10-16 tang of plate is engaged into door inner panel.
x .50 4 8120054 17.671 6 Color coat plates taking care not to spray
front door trim panel.
RETAINER, Door
Speaker Wire AR 5454901 15.320 7 Slide speaker wires into speaker wire retainers.
Install retainer cap. Snap speaker wire retainers into
RETAINER CAP, plate and secure retainers with screws. Tape both
Door Speaker Wire AR 5454902 15.320 ends of retainers for added speaker wire retention.
YEAR AND TIME

CODE NUMBER LEVEL
o 81
PLATES, FRONT DOOR WIRE ROUTER -
INSTALL 15.322 15327 Cke-Wag-Trk 0.4 6

Speaker Wires, Repair 15.322 A 0.1 6
8O-016-BSJ

krvlc* Engin..rlng Dportm.nt * 14250 Plymouth Rood * D.trolt. MIchigan 41232
80-75
_________

Subject: Air Control Cable Operation Application: 1978-81 CJ-5 and CJ-7 File: BODY
Models Heater - Air
Conditioning
No. 81-1 April 13, 1981
cable and intake duct vent operation and can also be 11 Disconnect heater control cables.
used on all 1978-81 CJ-5 and CJ-7 models.
Installation
1 Install defroster duet and tube assembly.

Fresh Air intake 1 5758809 22.020
PROCEDURE
Removal


bracket.
14 Refill radiator.
81-060-133

S.rvic. Englnarlag D.partm.nt * 14250 Plymouth Road * Dstroit. MIchigan 48232
Subject: Sun Roof Glass Frame Seal Application: 1980-81 Cherokee, File: BODY
Wagoneer and Truck Models With Headlining Hardtop -
Manual Sun Roof Enclosure Exterior -
Decals and Overlays
No. 81.2 March2, 1981
A new sun roof glass frame seal for the pop-up sun roof 2 Apply 3M Release Agent, or equivalent, to seal and
used on 1980-81 Cherokee, Wagoneer, and Truck allow several minutes for penetration.
models has been released for production and service use. 3 Apply second application of release agent to seal and
The new seal has an improved configuration for increas-
allow several minutes for adhesive bond to soften.
ed compression and sealing ability and entered produc-
tion on January 5, of this year. 4 Remove seal from frame.
If it becomes necessary to replace the sun roof glass 5 Remove all adhesive residue from frame using 3M
frame seal on a 1980-81 Cherokee, Wagoneer, or Truck
model pop-up sun roof, the new seal should be used. General Purpose Adhesive Remover, or equivalent.

Installation
1 Apply thin bead of 3M Super Weatherstrip Ad-
SEAL, Sun Roof Glass 1 8133809 28.811 hesive, or equivalent, in frame channel.
Frame
2 Position and install replacement seal in channel.
PROCE DURE
3 Apply thin film of petroleum jelly to seal and glass
Removal contact surfaces.
1 Remove glass assembly. 4 Install glass assembly.
The following standard service operation and work times will apply:
COST OPERATION YEAR AND TIME

OPERATION DESCRIPTION MODEL SKILL
CODE NUMBER I LEVEL
80
SEAL, SUN ROOF GLASS TO

FRAME-REPLACE
28.417 15.375 Cke, Wag.,
Trk.
0.4 I 0.4 I G
I
8 1-065-BSi

S.rvlc. Enginaring D.portmsnt * 14250 Plymouth Rood * Dotroit, Michigan 48232
Subject: Sun Roof Arm Operator Application: 1979-80 CJ-7 File: BODY
Hardtop Models With Type-i Headlining-Hardtop
Sun Roof Enclosure-Exterior
Decals and Overlays
No. 80-2 Jan. 14, 1981

A new metal ann operator for the Type-i sun roof used
on 1979 and some 1980 CJ-7 hardtop models has been
released. The new ann operator provides increased
sealing ability by applying additional compression force
on the sun roof weatherstrip improving sealing against
water leaks.
If it becomes necessary to replace the arm operator on a
Type-i sun roof, the following new part should be used.
OPERATOR, Sun Roof

Arm Metal 1 8129249 28.806
PROCEDURE
1 Close sun roof.
Type-i Sun Roof Assembly

2 Remove ann operator attaching screws and nuts
see illustration.
4 Insert replacement arm operator into channel
opening and position arm operator on sun roof.
3 Move arm operator into channel opening and
remove arm operator. 5 Install arm operator attaching screws and nuts.
OPERATOR, SUN ROOF ARM

REPLACE
80-164-BSJ
S.rvIc. Enginnrlng D.partmsit * 14250 Plymouth Road * Detroit, Michigan 48232

80-78
Subject: New Sun Roof Vinyl Trim Ring Application: 1980 Cherokee and File: BODY
Wagoneer Models Headlining-Hardtop
Enclosure-Exterior
Decals and Overlays
No. 80-1 Sept. 18, 1980
On some 1980 Cherokee and Wagoneer models PROCEDURE

equipped with the manual sun roof option, the sun
roof trim ring may hang down due to pressure applied 1 Remove sun roof trim ring.
to the trim ring by the headlining. A new sun roof
trim ring has been developed to prevent this condition. 2 If headlining extends below trim ring surface of
sun roof frame, measure distance between trim ring
Service correction involves measuring the distance surface of sun roof frame and headlining.
between the sun roof frame and headlining, installing
a new sun roof trim ring, and replacing the front a If distance is less than one inch, proceed to
headlining if necessary. step 3.
b If distance is more than one inch, replace

The following part is available and may be required: front headlining as outlined in 1980 Jeep
Technical Service Manual. Use original headlining
as template, cut sun roof opening in replacement
Description Quantity Part No. Group headlining before installation, and proceed to
step 3.
RING, Sun Roof
Vinyl Trim 1 8133577 28.810 3 Install new sun roof trim ring.
YEAR AND TIME

CODE NUMBER LEVEL
80 81 82
RING, SUN ROOF VINYL TRIM -
REPLACE 28.415 25201 Cke-Wag. 0.2 G

Headlining, front Replace
- 29.015 A 0.4 G
SO-150-BSJ
‘I Amerlcwi Motors Sales Corporation

S.rvlc. Enginesring Deportment * 14250 Plymouth Road * Detroit, Michigan 48232
80-79
Subject: Water Leak or Wind Noise Application: All 1980-81 Jeep File: BODY
Recommended Sealing Products. Vehicles Metal Repair -
Painting Water
-
Leaks/Wind Noise
No. 81-2 Jan. 21, 1981

Some 1981 vehicles may exhibit some water leak and The following chart describes some of these typical
wind noise problems. Locating the leak can be water leak and wind noise areas and recommended pro-
accomplished by following the test procedures described ducts which can be used to seal these areas.
in chapter 3A of the Technical Service Manual.
Water Leak or Wind Noise Recommended Sealing Products

Interior Sody SoIWVI
Weld Nut * seen
floor ,,
Spol Weld
Btn Holes
Heater
Plenum
Cflanter
JOmIS
and
Sew,,,
Plug Holes ai-id ow trucl’s IT
r -
Weath&SblP
and
Sody Psiel
3M_Products
Brushable Seam Sealer C S S e
Joint and Seam Sealer . . -jr

All-Around Auto Body Sealant S * C
Drip Check Sealer e 5
SbpCalk e S C S
Auto Bedding and Glazing Compound C
Windshield Sealer e
Windo-Weld Resealant . S
Kent_Industries_Products
QuikLeakCheck * e e *
Seal-a-Seam S .
Silver Seal e
WetlDry Resealant C C
Leak Seal e
Glass Mastic e I
Uquid Rubber S
Bedding and Glazing Compound 5
81-036-BSAJJ

80-80
Subject: Interior Wind Noises Application: 1980-81 Cherokee, File: BODY
Wagoner and Thick Models Metal Repair-
Paint-Water
Leaks/Wind Noise
No. 80-3 Oct. 9, 1980
Some 1980.81 Cherokee, Wagoneer, and Truck models 5 Repeat sealant application on opposite front
may develop an interior wind noise or air leak that door division channel.
may be the result of air entering the vehicle in the
following areas:
* Front Door Division Channel

* Intersection of Cowl-A-Pillar-Instrument Panel
* Holes in Inner Cowl Panels
Service correction involves performing the repair

procedures outlined in this bulletin at each of these
areas.
Description Quantity Part No. Group DIVISION

CHANNEL
BUTTON, Plug 3 4001716 27.038
TOUCH-N-FOAM AR 8130438 80.051
GASKET-IN-A-TUBE AR 8993317 15.260 51161
Fig.1
PROCEDURE
Front Door Division Channel

Intersection of Cowl-A-Pillar-Instrument Panel
Noise from this area can be isolated by using a
stethoscope placed along the rolled edge of the An air leak at this area can be detected from Side
division channel inside the vehicle during road testing. the vehicle using a stethoscope placed at the lower
corner of the windshield at both A-pillars during
1 Insert small flat blade screwdriver in gap between a road test. In severe cases, an air leak can be detected
rolled section and flat section of front door division by placing a hand in the windshield lower corner area
channel. Insert blade at top and bottom Fig. 1, and to feel the air flow.
open gap slightly to allow application of sealer.
1 Raise hood.
2 Apply black silicone sealer, Gasket-In-A-Tube,
or equivalent, along gap in division channel. 2 Using grease pencil, place mark on both outer
cowl panels 1-inch below horizontal flange and 5/8-
3 Remove screwdriver. inch outboard of vertical flange Fig. 2.
4 Wipe off excess sealer. S Centerpunch and drill 1/2-inch diameter hole in
each panel at marked locations.
NOTE: Steps 1 through 4 are to be performed on
both the inside and outside surfaces of the division 4 Shake Touch-N-Foam container and install
channel. nozzle and tubing on container.

Ssrvlc Engineering Department 5 14250 Plymouth Road * D.troit, Michigan 48232
80-81
_______
DASH PANEL Holes in Inner Cowl Panels

HORIZONTAL The inner cowl panel holes may produce a draft on
the driver and passenger’s legs rather than an actual
wind noise, This condition can be detected by a visual
inspection.
1 Open driver’s side door and view inner cowl

panel through upper hinge pocket in area where in
strument panel lower attaching bolt is located Fig. 3.
2 Locate weld nut hole in cowl panel that is
approximately 3-inches above and 1/2-inch to rear
of instrument panel lower attaching bolt Fig. 3.
3 Plug weld nut hole using 3M Strip-Caulk or
OUTER COWL PANEL equivalent.
4 Plug 1/2-inch hole in inner cowl panel located
FLANGE above parking brake assembly. Plug hole using button
plug Fig. 3.
COWL PANEL 5 Repeat steps 1 through 3 on passenger side
inner cowl panel.
Fig. 2
NOTE: The passenger side inner cowl panel has only
one hole in it
5 Turn Touch-N-Foam container upside down and
make trial application of foam on section of cardboard
or newspaper. INSTALL STRIP CAULK HERE DR IVE R’S S IDE
,.INNER COWL
6 Insert container tube into holes drilled in cowl PANEL
panels until container tube contacts A-Pillar.
INSTALL BUTTON
PLUG HERE
‘7 Pull tubing out approximately 1-inch, aim for
A-Pillar, and press and hold nozzle for 8 to 10
seconds. /
8 Release container nozzle. Allow few seconds for
foam to stop flowing from container tube before
removing tube.
9 Repeat steps 6 through 8 on opposite outer

V
cowl panel.
NOTE: Uncured foam may be removed from painted
surfaces by carefully wiping the area with lacquer
thinner or an equivalent solvent.
10 Install button plugs in holes drilled in outer
cowl panels.
11 Close hood.
12 Allow foam to cure for 1-1/2 hours; then road

test vehicle to verify noise correction.
13 Remove excess sealer that may appear in lower
corner of windshield weatherstrip after foam has
cured. Use razor blade or similar tool to remove
excess sealer. Fig. 3
80-82
YEAR AND TIME

CODE NUMBER LEVEL
80 81 82
CHANNEL, FRONT DOOR DWISION -
SEAL 23J18 25011 10-20 G

Both 0.2
Material allowance is $0.70
PANELS, COWL SIDE SEAL - 20.155 20121 10-20 0.2 G
COWL-A-PILLAR-INSTRUMENT PANEL
INTERSECTION SEAL - 20.195 20135 10-20 0.2 G
80-149-881
80-83
Subject: 1980 Phase-Out/1981 Phase-In Application: 1980 Jeep Vehicles File: BODY
Program Paint Information Metal Repair-Painting-
Water Leaks/Wind
No1se
No. 80-2 July 31, 1980
As part of the 1980 Phase-Out/1981 Phase-In Program, ten new 1981 colors may be used on 1980 models.
They are:
1981 Paint Code Color Replaces
1A Montana Blue 01-I
18 Moonlight Blue OJ
1C Sherwood Green Metallic OE
1D Autumn Gold OR
1E Copper Brown Metallic New Color
1H Chestnut Brown Metallic 9A
11 Vintage Red Metallic 9C
1K Deep Maroon Metallic 9P
1L Steel Gray Metallic OB
1M Oriental Red OP
NOTE: Some intermix formulas are marked N/A because they were not available at time of publication.
Contact your local paint jobber for information not contained herein.
MONTANA BLUE MONTANA BLUE MONTANA BLUE MONTANA BLUE

DAR3366 35-31503 DDL3366 34-31503
DMR49O 60 F5R-100 108.0 DMA3S9 14 L4R-320 114.0
DMR411 122 F5L-70 222.0 DMA375 24 L4L-309 230.0
DMR474 185 F5B-81 450M DMA321 444 L4M-321 358.0
DMR400 297 V6V-175 495.0 DMA358 554 L4W-301 922.0
DMR414 452 F5W-80 953.0 DMA311 884
DXR495 472 DMA31O 1044
DMR499 1052

S.rvlc. Engineering Department . 14250 Plymouth Road * Detroit, Michigan 48232
80-84
____________________ ____________________
_____________________
MOONLIGHT BLUE MOONLIGHT BLUE MOONLIGHT BLUE MOONLIGHT BLUE

DITZLER SHERWIN-WILLIAMS DLTZLER SHERWIN-WILLIAMS
DAR3367 35-31504 DDL3367 34-31504
Code Setting Code Setting Code Setting Code Setttng
DMR486 7 F5P-92 14.1 DMA311 4 L4W-301 20.7

DMR400 17 FSW-80 35.3 DMA317 132 L4Y-334 51.1
DMR49O 61 FSY-72 56.5 DMA32O 192 L4B-320 83.7
DXR495 81 F5B-81 162.0 DMA3O4 672 L4L-313 890.0
DMR413 1081 V6V-175 207.0 DMA31O 992
FSL-94 913.0
SHERWOOD GREEN SHERWOOD GREEN SHERWOOD GREEN SHERWOOD GREEN

IMTZLER
DAR3368
I SHERWIN-WILLIAMS
35-31505
DITZLER SHERWIN-WILLIAMS
34-31505
Mixing 1 Quart J Mixing 1 Quart Mixing 1 Quart Mixing 1 Quart
DMR43S 10 F5N-76 56.0 L4S-345 6.5
DMR476 18 F5N-85 112.0 L4S-335 23.4
DMR49O 94 P58-101 180AJ N/A L4B-320 43.0
DMR44O 248 F5B-81 264.0 T1C-324 69.0
DXR495 268 FSG-79 384.0 L4N-342 226.0
DMR482 1038 V6V-175 429.0 L4G-337 434.0
F5Y-72 913.0 L4Y-334 890.0
AUTUMN GOLD AUTUMN GOLD AUTUMN GOLD AUTUMN GOLD

DITZLER SHERWIN-WILLIAMS IMTZLER SHERWIN-WILLIAMS
DAR3369 35-31506 DDL3369 34-31506
DMR491 136 F5R-100 6.7 DMA356 6 L4M-338 4.8
DMR400 326 P58-81 35.5 DMA313 90 L4B-320 19.1
DMR487 476 FSY-93 449.0 DMA333 110 L4W-301 448.0
DMR4S6 836 V6V-175 494.0 DMA311 540 L4Y-303 924.0
DXR495 856 F5W-80 984.0 DMA329 1060
DMR499 1106
COPPER BROWN COPPER BROWN COPPER BROWN COPPER BROWN

35-31507 34-31507
F5M-71 42.1 L4B-302 8.5
F5N-76 447.0 L4W-301 22.2
V6V-175 492.0 L4M-341 56.4
N/A F5S-74 913.0 N/A L4Y-334 158.0
L4S-343 308.0
T1C-324 522.0
L4N-342 890.0
80-85
CHESTNUT BROWN CHESTNUT BROWN CHESTNUT BROWN CHESTNUT BROWN
METALLIC METALUC METALLIC METALLIC
DAR3371 35-31508 DDL3371 34-31508
Mixing 1 Quart Mixing 1 Quart Mixing 1 Quart Mixing .1 Quart
DM11435 32 F5S-69 88.0 DMA32O 26 L4S-345 14.4
DMR453 358 P5B-81 194.0 DMA3O9 34 L4S-343 575
DMR49O 434 FSM-78 469.0 DMA312 62 T1C-324 11&0
DXR495 454 V6V-175 504.0 DMA360 122 L4B-320 201.3
DM11476 1034 FSN-85 902.0 DMA3O7 982 L4M-338 49&0
L4N-342 8840
VINTAGE RED VINTAGE RED VINTAGE RED VINTAGE RED

DAR3372 35-31509 34-31509
DMR41O 10 F5B-81 25.8 L4B-320 13.8
DM11451 290 F5M-96 103.0 L4S-345 124.0
DMR435 336 FSS-101 348.0 N/A L4M-318 256,0
DM11452 856 V6V-175 393.0 T1C-324 532M
DXR495 876 FSM-71 908.0 L4M-341 882.0
DM11499 1036
DEEP MAROON DEEP MAROON DEEP MAROON DEEP MAROON

35.31510 34-31510
F5S-74 80.0 L4S-343 22.7
.FSP-92 224.0 L48-320 107.7
N/A P58-81 384.0 L4M-321 312.0
V6V-175 429.0 N/A T1C-324 538.0
F5M-71 908.0 L4M-341 878.0
STEEL GRAY STEEL GRAY STEEL GRAY STEEL GRAY

DAR3374 35-31511 34 -3 15 11
DMR482 2 F5W-80 7.0 L4L-339 2.2
DMR474 5 FSL-68 15.4 L4M-321 6.7
DM11414 13 F5M-78 28.0 N/A L4N-342 22.5
DMR49O 129 P55-102 70.1 L4S-345 67.5
DM11435 400 P58-81 1820 L4B-302 202.0
DX11495 420 V2V-269 434.0 L4S-343 494.0
DM11499 1030 V6V-175 479.0 T1C-324 - 876.0
F5S-101 8990
____________________
ORIENTAL RED ORIENTAL RED ORIENTAL RED ORIENTAL RED

35-31512 DDL3375 34-31512
F5W-80 7.4 DMA358 4 L4W-301 2.7
F5B-81 31.6 DMA333 132 L4B-302 14.6
NIA F5P-92 423.0 DMA359 506 L4M-321 406.0
V6V-175 468.0 DMA362 1058 L4E-317 9180
F5E-86 953.0
8O.136.BSJ
Subject: Paint Information - Application: 1980 Jeep Vehicles File: BODY
All Jeep Vehicles Metal Repair-
Painting-Water
Leaks/Wind Noise
No. 80-1 Sept. 27,1979
Attached is the 1980 DuPont color chart. Color required, contact your Zone Service Manager, or
names and code numbers are included in each chart. Service Manager, or Service Representative.
This bulletin is being sent to all Jeep dealers in

reduced quantities. If additional quantities are
8O*006-21A!J

S.rvlc. Englnnrlng D.partm.nt * 14250 Plymouth Road * D.trolt, Michigan 48232
Additional copies of this bulletin are available through your zone office-
80-88
nomoiw
fffl8 1980 COLORS
REFIflISH
EXTERIOR COLORS
Mtr. Cut LUCITE’ CUl° DU LBV Mtr. Cnde LUCITE’ OEKlMl’ 0111111W Mfr. Code LUCITE CEWIIt 00101
Usage and Color coot COlIC WOE Usage and Labor CODE CODE 000C tsage and Cuber coot COO! Coot
P1 OA OJ
S Black S Silver Mist Met. Teal Blue
Black C Silver Mist Met.
P Black P Siluer Mist Met.
Black C Silver Mist Met.
J Black 8*01010*0*0* 8*0*00 IIOBIL 11001* 1*09141
9A OB OK
J Alpaca Brown Met. C Smoke Gray Met. S Cnmeolan
Smoke Gray Met. I CameoTan
P Cameolan
C CameoTan
457001 4570CM 45700014 080*11 StOMA 1*0910 J CameuTan 0*0*91 5*0*6* 88*060
9B oc 01
S Olympic White S Cameo Blue S Medium Breve, Met.
Olympic White £ Cameo Blue Medium Brown Met.
P Olympic White P Cameo Blue P Mediom Brown Met.
C Olympic White C Cameo Blue Medium Brown Met
J Olympic White 457011 45701* 451010 110*21 88082* 880*20
9c OD OM
S Russet Mel. S Medium Blue Met Dark Brown Met.
0 Russet Met C Medium Blue Met C DaekBrownMet.
P Russet Met. P Medium Blue Met. P Dark Brown Met.
C Rumet Met C Medium Blue Met C DaikBruwuMeu.
J Russet Met. 45702LM 45702AW 457*208 080811*481 NOMO J Dark Brown Met.
9L DE OP
Sacom Yellow C Dark Green Met. $ Cardinal Red
Sauon Yellow j Dark Green Met. C Cardinal Red
P Saxon Yellow P Cardinal Red
C Saxon Yellow 1 Cardinal Red
J Saxon Yellow 457011. 45708011 u0* 1*0MM N0M J Cardiual Red
9P OH OR
S Bordeaux
C go,deana
Bordeaux
C Bordeaux
I Bordeaue
9z
Mtt
Met.
Met.
Met.
Met. 45711W 45711AW 457110W
S
I
P
C
Navy Blue
Many Blue
Mew Blue
Many Blue
May Blue 8*0451 8*0*5* 8*005001
I S Caramel
Caramel
Caramel
I Caramel
1*0901 88080* 8*0800
P Misty Beige Met. CC/CC
BET: S-Spirit, -Eagle, P-Pacer. C-Concord. I-Jeep

iuorc Mayint Ucgun, ctHTAR’ Acrnlxc cnamol. and DoLuu [namol are Reuculured t,adnmanls uuuhn Do Pnal Compwy.
Stliunsukeen am auàrcl In chaeau uton Fmmxtehma are flnibxod.
cola caspu endeared m paper cannot be cnc.dored untally acceralo car matS.. In .0km car makora aaaeSrdsm 0° Pmt maluna AUTOMOTIVE REFINISH COLORS Page 1
E-O1
80-89
AMEPICAN MOTORS CORPORATION
1977
Sir. Paint Lucitr Cataxla 0uhx Si,. PaW Lucite Ca,tani Ouhe°’
Coda
Cod. Color CS. Cede Code CS. Color CS. CS.
Cl Alpine White 434991 43499* 434990 70 Powder Blue 441921K 44192AH 44192DH
12 Brandywine Met. 435101M 4351MW 43510DM 71 Oak leaf Brown 451011 451DM -
Pt Black 991 99* 93-005 lIt MWniglit Blue Met. 44l931M 44193AH 44193011
60 Sand Tan 44111L 4411lA 441110 11. Loden Green Met. 44194111 44194*11 44194DM
Si SilverFrost Met. 441131. 44113* 441130 7M Golden Ginger Met. . 44195111 44195AH 44195DM
V FirecrackerRed 4411&IM 4411MW 441160W 7P LimeGreen 441961M 44196*11 441960K
6* Brilliant Blue 44117LH 44117AH 44t17D 1W Captain Blue Met. 44197111 44197AH 44197011
61 SunshineVellow 44119111 44119A11 441190 7! TawnyOrange 44198111 44198* 44198011
1* Misty Jade Met. 441901 44190* 44190DM 7Z Sun Orange 441991H 44199*11 44199011
78 Mocha Brown Met. 44191L11 44191AM 44191DM ID Claret Red Met. - 451001W 4SIOOAM -
7C Autumn Red Met. 44193LW 44793AW 44793DM
1978
MIt. Paint Lacitt dade l& M** Pe..t I.ucate CIIIIFJ° ralugu
Ct Color CS. CS. CS. Code Color Code CS. CS.
Black 991 99* 93-005 lIt Midnight Blue Met. 44193LM 44193*11 44193DM
67 Aine White 434991 43499* 434990 71 Loden Green Met. 44194LH 44194AH 44194011
GD Sand Tan 441111 44111* 441110 75 Golden GingerMet. 44195111 44195*11 44195DM
V Arecracker Red 44116LM 44116AW 441160W 7W Captain Blue Met. 441971K 44197AH 44197DH
6* Briliant Blue 44117LH 44117AH 44117D 7Z Sun Orange 44199111 44199*11 441990K
6* Sunshine Yellow 441191K 44119*11 441190 8* Khaki 451031 45103* 451030
lB Mocha Brown Met. 44191111 4419MM 44191DM SB British Bronze Met. 451021 45102*14 45102011
7C Autumn Red Met. 447931W 44793AW 44793DM SC Quicksilver Met. 451041 45104*11 4SIO4DH
70 PowderBlue 48192111 44192*11 44192011 *0 ClaretMet. 451001W 4510DAM 45100DW
1979
Nfr. Piat taaeir CatarP Dine MIt. Pint LaacitevCeaii Dulux’
CS. Ceder Usage Code Cod. CS. Cede Color Usage Cod. Code CS.
-r Black 5-C-P-i 991 99A
4411MW
93-005
441160W
91 Arrowhead Silver Met.
Sable Brown Met.
J
SC-P-i
45706L 45706*
457071K 45707AM
457090
45707DH
Sr Firecracker Red S-C-P-i 441161M Si
8* Khaki S-C-P 451031 45103* 45103D 9!. Saxon Yellow S-C-P-i 457081 - 457080K
88 Britisln Bronze Met. &C-P 451021 45102*11 45102011 SM Starboard Blue Met. S-C-P 457091 45709* 45709DH
IC QuickSilver Met. S-C-P 451041 45104*14 45104011 SM Morocco Buff S-C-P-i 45710L 45710* 457100
9* Alpaca Brown Met. 5-C-P-i 45700!. 45700*11 45700011 SP Bordeaux Met. S-CPJ 457 IILM 45711AW 45711DM
98 Olympic White S-C-P-i 457011 45701* 457010 ST Ensign Blue i 45713L 45713* 457130
SC
SE
Russet Met.
Wodgwood Blue
S-C-P-i
S-C-P-i
457021M
457041
45702AW
45704*
45702DM
457040
SW
IZ
MandarinOrange
Misty Beige Met. CC/CC 4 1
P
45714111 45714AH 45714011
45850LH 45850AW -
111 Caimberland Green Met S-C-P-I 457051 145705* 45705DH

KET S-Spirit, C-Concord, P-Pacer, i-Jeep
80-90
INTERIOR COLORS 1980 AMERICAN MOTORS CORPORATION
tillIth Brownn Flat dish Beige Flat 457151.11 Blan SC. 45113L Flax Rat
RI P25 RI RIS
u0401 Beige
P3
S-c- 451101 Desert Beige
R6J
Flat
- 451111 Dk. Desert Tan
nit
Flat 44281 Black
RU
Flat
CIO4WI Brown S-G 457161H Russt 8.6.

P1 RI

STRIPING COLORS
‘ft
PAIKI STOCK
CODE COLOR MIIMIER
P84 Red Gold BSO95LM
R40 Black 991
R80 Blue 43688LH
R122 Russet 45717L1-l
UloIrAcrylk ticqeni. CEeTI Mayli Exam.’, and BUilD En,m,Jnen eegiUntt.d Tred.nwkx.t the Dx Pcm Cimpan
saiffineauccein are njbiocU Ue drag. attn Fcrnnxlaxians are Um.Iized.
cderckqnsenpenEiced nfl pacer canwe becx.adered Id tynecanuin cede’ exxchamn ernie cnn riahexxaedardat. Dx Pnnt mitroni
1ffPIIR
AUTOMOTIVE REFINISH COLORS Page 2
80-91
9JeP
Service Technical Lette,r a I File: Service General

INo.8l-Io March 20,1981
I
Subject Information
Revision to Part Number In The part number for the front and rear output
ORB 81-I, Transfer Case Output seal listed in the subject bulletin has been
Shaft Seal Leak Diagnosis, Datec revised. The new part number for this seal is
February 23, 1981, and Filed 81331*32. Please note this change in your
Under CHASSIS Transfer Case/
-
copies of the subject bulletin.
Quadra-Ira c
Oil Return Channel Access Hole A rear bearing oil return channel access hole
Plug Servi ce - 1980-81 Jeep has been added to the rear case on 1980-81
Model 219 Quadra-Trac Transfer model 219 transfer cases as a running change.
Case A rubber plug, part number 8131617, is used
to seal the access hole.
When servicing the rear case on a 1980-81

Model 219 transfer case, the rubber plug which
is located in the upper side portion of the
rear case should also be inspected. If the
plug has become loose, damaged, or will not
seal properly, a replacement plug should be
installed. In addition, if the rear case is
replaced, be sure to install a plug as the
replacement case may not have a plug installed

Service EngineerIng Dept. * 14250 Plymouth Rd. * Detroit, MIch. 48232
Additional copies ot this letter are available through your zone office.
80-92
INo. 81-8 Feb.19, 1981
Subject Information
Windshield Wipers Inoperative On When checking for loose connections and ground
Low and Intermittent Speeds - circuit continuity,
be sure to check for a poor
1980-81 Cherokee, Wagoneer and ground between the windshield wiper switch and
Truck Models - Addition to dash panel. To correct this condition, remove
Windshield Wiper Service Diag the switch and install a 7/16 I.D. star washer,
nosis, Page 3T-ll In 1980-81 Jeep G178551, between the switch and dash panel to
Technical Service Manuals improve the ground.
Correction to Clutch Aligning Tool The clutch aligning tool number for four-, six-,
Number - 1980 Jeep Technical and eight-cylinder engines in the 1980 Jeep
Service Manual Supplement and Technical Service Manual Supplement and 1980-81
1980-81 Jeep Technical Service Jeep Technical Service Manuals is incorrect.
Manuals
The correct number for this tool is J-5824-Ol.

Please note this correction in Chapter 2A of the
1980 Jeep Technical Service Manual Supplement and
1980-81 Jeep Technical Service Manuals.
P1 American Motors Sales Corporation -
Service Engineering Dept. * 14250 Plymouth Rd. * Dtroit, MIch. 48232

80-93
SCN 340
PiJeep,
I
No. 81-6 Jan. Z3l9Sj
Subject Information
Water Leaks Caused By Dealer Some 1981 Jeep vehicles may have water leaking
Installed Radio Antenna 1981 - into the passenger compartment through holes
Jeep Vehicles made for radio antenna installation. This is a
result of water being routed along the antenna
lead-in cable and entering the compartment
through the dash panel which may not be sealed
by grommets or other suitable sealers.
When installing an antenna, be sure a grommet

is used where the antenna cable goes through the
dash panel and be sure the cable is properly
seated in the grommet hole.
Power Steering Pressure Test The pressure and return port fittings on 1980-81
Gauge Adapter Set Tool Number Jeep power steering pumps and gears have
Revision metric threads. In order to connect the pressure
test gauge J-21567 to these fittings, it will be
necessary to use Adapter Set J-5176-Z0. Please
note this information in Chapter ZL of your 1980
and 1981 Seep Technical Service Manuals.
Correction to 1980-81 Cherokee The fuel tank capacity for all 1980-81 Cherokee
and Wagoneer Fuel Tank Capacity and Wagoneer models is 20.5 gallons
Specification Charts 77. 6 liters. Please note this change in the
Fuel Tank Specifications Charts on page lJ-lO of
the 1980 Jeep Technical Service Manual, page
1J-1l of the 1981 Jeep Technical Service Manual,
page 88 of the 1980 Jeep Service Specifications
Handbook, and page 90 of the 1981 Jeep Service

80-94
Service Technical Letter Icont’d
Subject Information
Correction to 1980 Jeep Four- The following information should be used when
Cylinder Engine Piston Fit fitting pistons in 1980 Jeep four cylinder
Information engines:
Measure the cylinder bore at a point 2-1/4

inches from the top of the bore.
Measure the piston diameter at a point perpen

dicular to the piston pin and 1-13/16 inches from
the top surface of the piston.
Please note these corrections on pages 26 and 30

of the 1980 Jeep Technical Service Manual
Supplement.
Short Oil Pump Attaching Screw The torque specification for the short oil pump
Torque Specification Revision - attaching screw used on 1981 6-Cylinder engines
1981 6-Cylinder Engines has been revised as follows:
USA Foot/Pounds Metric Nm
Service Service
Service In-Use Service In-Use
Set-To Recheck Set-To Recheck
Torque Torque Torque Torque
17 12-20 23 16-27
Please note this revision in your 1981 AMC

Technical Service Manual and 1981 .AMC Speci
fications Handbook.
80-95 -
SCN 228

No. 81-4 Nov. 10, 1980
Subject Information
1981 6-cylinder Main Bearing The 1981 6-cylinder main bearing capscrew torque
Capscrew Torque Specification specification has been revised as follows:
Revision
U.S.A. Foot-pounds Metric Nm
Service Service
65 65-70 88 88-95
Please note this revision in your 1981 Jeep

Technical Service Manual and 1981 Jeep
Specifications handbook.
Reverse Gear Selector Pivot Pin If it is necessary to service a 1980-81 5R4

Service 1980-81 SR4 Four-Speed
- four-speed manual transmission for a gear jump-
Manual Transmission out or damaged gear condition, the reverse gear
selector pivot pin should be replaced in addition
to any other damaged components. The pin, which
is threaded into the transmission case and serves
as the reverse lever pivot, may have become bent
or damaged by the conditions described and should
be replaced to ensure proper shifting.
Fuel Feedback Modules Damaged It is important that the battery cables are
By Incorrect Battery Cable connected to the battery positive-to-positive and
Connection 1980-81 Jeep Vehicles
- negative-to-negative to prevent damaging the
Equipped With Fuel Feedback fuel feedback module. Reverse polarity may
System damage the alternator diodes and radios also.

80-96
SCN 253
I File: Service General

Service Technical Letter JNo. 80-19 Nov. 21, 1980
Subject Information
Revision to Diagnosis and Repair The service procedure in the subject D&RB is
Bulletin No. 80-6 Exhaust Gas correct. However, the second paragraph in the
Recirculation ECR System text should read as follows: Service revision
Revision, Dated October 27, 1980, involves replacing the EGR valve restrictor plate
Filed Under POWER PLANT - Fuel and forward delay valve, and adding a non-linear
and Exhaust Systems valve to the spark advance system.

80-97
No. 80-18 Sept. 25,1980
Subject Information
Sun Roof Sealer - 1980 Jeep On some late production Jeep vehicles equipped
Vehicles with a manually operated sun roof, a black butyl
sealer was used to seal the area between the sun
roof frame and roof panel.
Whenever the sun roof frame has been removed, a

butyl or silicone sealer may be used to seal the
area between the sun roof frame and roof panel.
Apply an even bead of sealer to the roof panel
surface approximately 1/8 inch from the edge of
the roof opening.
Standard Oil Filter Damaged During A new oil filter, part number 3240511, has been
Severe 0ff-Road Operation - released for use on 1974-80 Cherokee, Wagoneer,
1974-80 Jeep Cherokee-Wagoneer- and Truck models. The filter is longer in length
Truck Models With Six-Cylinder and has a smaller diameter for additional filter-
Engine to-engine mount area clearance during severe of f-
road operation.

80-98
Service Technical Letter L.8Ou.Ll9sO1
Subject Information
SR4 Four-Speed Manual Transmission The 5R4 transmission has been changed for the
Changed for 1980 Models 1980 models. The components and part numbers
affected by the change are as follows:
e A new design transmission case, part number

8132594;
* A new shorter length reverse idler gear, part
number 8132882;
* A new reverse idler shaft with modified angle,
part number 8133524.
The new shorter length reverse idler gear can be
used in either the new or old transmission case.
The new reverse idler shaft can be used in either

the new or old transmission case: and can also be
used with either the new or old reverse idler
gear.
The old design length reverse idler gear can be

used in the old transmission case only.
Revision to Diagnosis and Repair The service procedure in the subject DRB is
Bulletin No. 80-1, Transfer Case correct. However, new part numbers have been
Shift Lever and Shaft Replacement, assigned to the parts outlined in the bulletin.
Dated January 9, 1980, Filed Under The new numbers are:
CHASSIS - Transfer Case/Quadra-
Description Qty. Part No. Group
Trac
SHAFT, Transfer Case Shift 1 5362034 18.180
LEVER, Transfer Case 1 5362033 18.125
83-93 4-cyl. and 8R4
-
83 6- or 8-cyl. and T176

-
93 8-cyl. and T-l76

-
LEVER, Transfer Case 1 5362036 18.125

93 6-cyl. and SR4
-
NUT, Transfer Case Shift 1 4004837 18.180

Shaft Retaining
NOTE: The threaded end of transfer case shift
shaft, part number 5362034, is larger in diameter
than the previous design shaft. This shaft can
only be used with the above listed transfer case
levers and shift shaft retaining nut. In
addition, the transfer case shift shaft retaining
nut should be tightened to 40-45 foot-pounds
54-61 Nm torque.

Service Engineering Dept. * 14250 Piymouth Rd. * Detroit, Mich. 48232
80-99
No.80-lb July 28, 1980
Subject Information
Two-Stage Power Valve - Carburetor Some of the two-stage power valves used in subject
Models 2100 and 2150 - 1978-80 model carburetors have been replaced for what
Jeep Vehicles appears to be a leakage problem. Although a
small amount of fuel may enter the power valve
cover via the carburetor manifold vacuum chamber,
it does not constitute a leak problem. This
condition is normal and will not effect performance
or economy.
Tire Vibration 1979-80 131-Inch

- The subject tires may be the cause of unexplained
Wheelbase J-lO Truck Models vibration problems on 1979-80, long wheelbase
Equipped With H78-lS, Load Range B J-l0 trucks. If diagnosis and test procedures do
Firestone Town and Country Tires not reveal any type of runout or imbalance
condition, install a set of test tires other than
Firestone on the vehicle and road test again. If
the vibration is now corrected, contact the
nearest Firestone regional service center.

80.100
P1 Jeep.
Subject:
Cracked Co
Ordered f
Mv 31, 1
J
on B[
C
Pjo
Janu 1,
V180 27000
through
Date:
Application:
July 21. 1980
Tow
SE2127000 for CJ Models
File: Service General
Bar
Some Jeep accessory tow bars, part number

SE2127000, manufactured by the Dualmatic
Manufacturing Company, may have a cracked
coupler nut. This nut must be replaced
on all affected tow bars in dealer
inventory or sold after January 1, 1980.
Each Jeep dealer will receive a coupler
nut for every tow bar ordered from the
local Jeep PDC between January 1, 1980
and May 31, 1980. Additional nuts are
available from the Zone Field Service
Manager. Dealers are responsible for
notifying customers that may have
purchased one of the affected tow bars
from their dealership. These customers
must be instructed to return their tow
bar to the dealership to have the coupler
nut replaced.
PROCEDURE
1 Remove and discard original coupler
nut see Illustration.
2 Install replacement coupler nut.
Tighten nut until coupler threads
extend 1/8 to 1/4 inch beyond
shoulder of nut.
TOW BAR
I-. COUPLER
NUT

Cost Operation Year & Time Skill
Operation Description Code Number Model 80 and Prior Level
NUT, TOW BAR COUPLER- 35.215 15401 83-93 0.2 G
REPLACE

Service Engineering Department * 14250 Plymouth Road * Detroit, Mitbigan 48232
80-101
Service Technical Letter No. 80-14 July 1, 1980
Subject Information
Fiberglass Hardtop Interior Some fiberglass hardtops on 1980 CJ7 models may
Appearance - 1980 CJ-7 Models develop what appears to be a crack in the portion
of the hardtop that parallels the windshield
frame. However, this crack is not in the hardtop
but in the joint material applied to the area
where the hardtop side-panel and top-panel
overlap. If necessary, this condition can be
corrected by removing the joint material and
painting the overlap area.

Additional copies of this letter are available through your zone office
80-102
o. 80-13 June 16, 1980
Subject Information
Correction to Quadra-Trac The Quadra-Trac differential end cap attaching

Differential End Cap Attaching screw torque in step 22 on page 8-27 in the
Screw Torque - 1976 Jeep Technical 1976 Jeep Technical Service Manual is incorrect.
Service Manual Please change this step to read as follows:
"Tighten end cap attaching screws to 27 foot-
pounds 36 N.m torque."
-t
Engine Oil Capacity 1980 Jeep

- 1980 Jeep four-cylinder engines have an oil
Four-Cylinder Engines capacity of three quarts 2.84 liters with or
without an oil filter change.
Overfilling the crankcase on these engines will

result in oil aeration foaming, tappet noise,
and possible engine damage.
To ensure an accurate dipstick reading on 1980

four-cylinder engines, check engine oil level
after the engine has been shut down and the oil
has drained back into the pan.
Please note the four-cylinder engine oil capacity

on page B-l4 of the 1980 Jeep Technical Service
Manual and page 22 of the 1980 Jeep Service
Specifications Booklet.

Service Engineering Dept. * 14250 Piymouth Rd. * Detroit. Mich. 48232
Additional copies o this letter are available through your zone office.
80-103
No. 8012 June 9, 1980
Subject Information
Radiator Hose Clamp Torque Radiator hose clamps should be tightened to the
Specifications - 1980 Jeep following torque specification.
Automobiles
Service Service In-Use
Set-To Torque Recheck Torque
22 inch-pounds 18-26 inch-pounds

2.5 Nm 2-3 N.m
Please note these torque specifications in your

1980 Jeep Technical Service Manual.
Speedometer Adapter 0-Ring Seal The speedometer adapter 0-ring seal used in
1980 Cherokee, Wagoneer, and production of the subject models is black in color
Truck Models With Transfer Case and is reusable. If an adapter equipped with a
Model 208 or 219 black 0-ring seal is removed for service, the
adapter can be installed using the original black
color 0-ring seal.
The service parts replacement speedometer adapter

0-ring seal is orange in color and can be used
once only. This seal is designed to swell in
service to improve its sealing qualities and could
become damaged during adapter removal, or during
installation if reuse is attempted.
The part number for the orange color service parts

replacement seal is as follows:
0-Ring, Speedometer
Adapter I 4006574 3.591

Additional copies of this letter are available through your tone office.
80-104
Service Technical Letter FiIe:ServiceGeneral
No. 80-Il
1
May 23, 1980]
Subject Information
Revised Crankshaft Main Bearing The crankshaft main bearing clearance specifica-
Clearance Specifications for tions for 1980 six-cylinder engines have been
1980 Six-Cylinder Engines revised as follows:
Number 1 Main Bearing
Main Bearing Clearance: 0.001 to 0.0025 inch

Preferred Clearance : 0.0015 inch
Number 2 Through 7 Main Bearings
Main Bearing Clearance: 0.001 to 0.003 inch

Preferred Clearance : 0.0015 to 0.002 inch
Please note these revised specifications in your

1980 Technical Service Manual and Service
Revised Exhaust Pipe-to-Manifold The exhaust pipe-to-manifold bolts on 1980 49-

Fastener Torque Specifications - State four-cylinder engines with a dual outlet
1980 Four-Cylinder Engines pipe should be tightened to 35 foot-pounds
50 N.m toruqe. In-use recheck torque is 30-40
foot-pounds 40-60 N’m for these bolts.
Exhaust pipe-to-manifold nuts on 1980 California

four-cylinder engines with a single outlet pipe
should be tightened to 35 foot-pounds torque
50 N.m. In-use recheck torque is 30-40 foot-
pounds 40-60 Nm torque for these nuts.
Please note these specifications in your 1980

Technical Service Manual and Service Specifica
tions Handbook.

80.105
Service Technical Letter I r :t80
Subject Information
AW-FM Radio Right to Left Balance Some of the AN-FM radios in 1980 Jeep vehicles
Control Adjustment 1980 Jeep
- are not equipped with a slide switch above the
Vehicles station dial for right to left balance control
adjustment. On these radios, balance adjustment
is accomplished by gently pulling the volume
control knob outward and turning it right or
left to adjust balance as described in the 1980
Technical Service Manual. Before removing one
of these radios to correct a suspected balance
problem, be sure the balance control has been
adjusted properly and that the owner is aware of
this adjustment procedure.
Chrome Wheel Discoloration - 1980 Discoloration or surface rust may appear just
Jeep Models Equipped With Chrome inboard of the wheel spokes on 1980 Jeep chrome
Wheels wheels. If this condition occurs, it is possible
to improve wheel appearance by cleaning the
inside of the wheel and applying a silver or
aluminum colored enamel paint to the discolored
area. However, if the wheel is exposed to salt
or stone chips, this condition may reoccur.

Mich: 48232
SsrvIcO Engineering Dept. * 14250 Plymouth Rd. * Detroit.
available through your zone office.
Additional copies of this letter are
80.106
Service Technical Letter t?rt980
Subject Information
1980 CJ Oil Pressure Gauge The speci,fications for oil pressure gauge sending
unit resistance on page lL-40 of the 1980 Jeep
Technical Service Manual are incorrect.
The correct resistance values should read as

follows:
Oil Pressure Gauge

Sending Unit Resistance Ohms
I PSI I
Ohms
0 40
20
J 80
10 j
I
1980 Cherokee and Wagoneer The bumper jack in 1980 Cherokee and Wagoneer
Bumper Jack models built after March of this year will be
secured with a plastic tie-down strap. This strap
is for transportation use only and should be
removed before delivering each vehicle.

Ssqvlc. Engineering Dept. * 14250 Plymouth Rd. * Detroit,
Mid. 48232
Additional copies of this letter are available through your
zone office.
80-107
Service Technical Letter File: ServIce Genera’
No. 80-8 March 31, 1980
Subject Information
Correction to Diagnosis and Repair If the stereo radio rear speakers do not function
Bulletin No. 80-4, Stereo Radio properly after performing procedural step 8,
Rear Speakers Missing, dated under Vehicles With Power Tailgate, the vehicle
February 14, 1980, filed under may have an incorrect rear speaker wire harness.
BODY- Body Electrical Remove the glove box from the dash panel and
check the wire harness part number. If the
harness number is not 5751957, replace the harness.

80-108
Service Technical Letter IFIIe:ServiceGeneral__I
No. 80.7 March 27, 1980
Subject Information
Camshaft Spring Pin Correction - When performing the camshaft pin replacement
Six-Cylinder Camshaft Pin Breakage procedure, order spring pin G456384. Do not
on 1977-80 Jeep Vehicles - order pin GM456384.
DRB 80-3 dated February 4, 1980,
Filed Under POWER PLM1T-Engines

80-109
No.8O.6hi9,19S0
Subject InformatIon
Assembling Piston and Connecting When assembling the piston and connecting rod on
Rod- 1980 Four-Cylinder Engines a four-cylinder engine, the notch in the top of
the piston must be 1800 opposite the raised
notch in the large end of the connecting rod.

Additional copies of this loner are available through your zone office.
80-110
File: Service General 1
IINO.80.5
Service Technical Letter Feb.4,19801
Subject information
New Propeller Shaft-to-Yoke A new propeller shaft-to-yoke attaching bolt has

Attaching Bolt- all 1980 Jeep been released for service. The bolt features a
Vehicles 12-point head and increased length for improved
thread engagement. This bolt has already been
installed in some Jeep rear axle yokes to ensure
thread engagement in yokes with damaged threads.
The new bolts can be used to salvage other yokes
having damaged threads by tapping the yoke and
installing the new, longer bolt.
The tightening torque specification for the new

bolt remains at 15 bat-pounds 20 N.m torque
plus or minus 1 foot-pound 1 Nm torque.
The new bolts will be available the week of

February 18, 1980. Do not order bolts until this
date.
BOLT, Propeller AR 4006698

Shaft-to-Yoke
1/4-28 x 7/8
Revised Fuse Rating for Cigar Lighter The originally specified 10 amp fuse in the
Circuit- 1980 Jeep CJ Models cigar lighter circuit has been changed to a
With 4 and 6-Cylinder Engines. 20 amp fuse.

80-111
Service Technical Letter ‘File: Service General
INo.804
Subject information
Correction to In-Vehicle Torque Steps 2 and 3 of the In-Vehicle Torque Bias

Bias Check -1980 Cherokee, Check on page 147, Chapter 2D, of the 1980
Wagoneer, and Truck Models With Technical Service Manual Supplement have been
Model 219 Quadra-Trac Transfer revised.
Case
Step 2 should read: "Place transmission shift
lever in NEUTRAL and transfer case shift lever
in 4-HIGH position."
Step 3 should read: "Raise one FRONT wheel off

floor."
Correction to Camber Specifi Front wheel camber specifications for 1980

cations - 1980 Cherokee, Wagoneer Cherokee, Wagoneer and Truck models have been
and Truck Models changed. The camber specifications for CJ models
remains the sane.
The second sentence under Camber on page 214-4 of

the 1980 Technical Service Manual should read:
"Correct wheel camber of 00 + 1/20 for Cherokee,
Wagoneer and Truck models and +
1-1/2° Cf 1/2°
for CJ models is preset at time of manufacture and
cannot be altered by adjustment."
The camber specifications in the Front Wheel

Alignment Specifications Chart on page 2W6 should
read:
CJ +1-1/2° C’- 1/2°

Cherokee, Wagoneer and Truck 00 Cf 1/2°
Fl American Motors Sales Corporakn

80-112
Service Technical Letter INc80-3Dec.tL1979 I
Subject Information
Correct Tempatrol Fan Assembly To prevent silicone fluid from draining

Storage-1980 and Prior Jeep into the fan drive bearing and contamina-
Models ting the lubricant, do not place a Tempatrol
fan unit on a workbench or storage shelf
with the rear of the shaft mounting flange
pointing downward.
Part Number Change

- Service In the first item on the subject Service
Technical Letter Number 80-2, Technical Letter, the lock mode indicator
Dated November 10, 1979 switch part number given as 8130826, should
be changed to 8130829. Please note this
change on Service Technical Letter 80-2.

80-113
Ij5: Service Generai
Service Technical Letter INo.80-2 Nov.lO,19791
I
Subject information
Four Wheel Drive Indicator Lamp 1980 Jeep vehicles equipped with a model 219 or
Operation and Switch Usage - 208 transfer case have an indicator lamp which
1980 Jeep Cherokee, Wagoneer and lights in certain four-wheel drive ranges. The
Truck Models with Model 208 or model 208 and 219 require different switches to
219 Transfer Case operate the lamp. Although the two switches look
very similar, they operate differently. Refer to
the following descriptions to verify correct
operation and switch usage.
On vehicles with a model 219, .,he indicator lamp

should light when the lever isA4H LOCK position
only. If the lamp lights in any other shift mode,
remove the indicator switch and check switch
continuity. The switch is normally in a closed
position. If incorrect, install a model 219 lock
mode indicator switch, part number 8132843.
A correction should be made to the description of

the model 208 transfer case on page 2D-4 of the
1980 Technical Service Manual under Four-Wheel
Drive Indicator Lamp. On vehicles with a model
208, the indicator lamp is illuminated in four
wheel high range and four wheel low position, not
in high range only as was published. If the light
is on in any other position, remove the indicator
switch on the transfer case and check continuity.
The switch is normally open. The correct model
208 lock mode indicator switch part number is
8130826.
Model T-176 4-Speed Manual Trans The model T-l76 4-speed manual transmission will be
mission Released as a Production used as an option in production to the model SR-4
Option to Model SR-4 4-Speed Manual 4-speed manual transmission on 1980 CJ7 models
Transmission - 1980 CJ-7 Models built with a 6-cylinder engine.
Built With 6-Cylinder Engine and
Manual Transmission The model T-l76 transmission can be distinguished
from the SR-4 transmission by checking the shifter
location. The model T-176 transmission shifter is
located on top of the transmission case while the
model SR-4 transmission shifter is located in the
adapter housing attached to the rear of the trans
mission case.

80.114
Service Technical Letter Icont’dI
Subject Information
Related components such as propeller shafts, trans

fer case torque reaction bracket, clutch housing
and shift knob also differ when a model T-176
is used.
Note this change on the Power Train Combinations -
1980 CJ Models chart on page A-l2 of the General

Information section in the 1980 Jeep Technical
Service Manual.
Revised Clutch Overcenter Spring A revised procedure has been developed for removal
Removal Procedures - 1979 CJ of the heavier gauge clutch overcenter spring.
Models Built After Mid-April This spring was phased into production during mid-
April along with other clutch related components
as described in STL 9-12, dated August 23, 1979.
Revise DRB 9-02, dated July 18, 1979, and filed

under Chassis, Clutch-Manual Transmission’ Group
6.000 as follows. After step 4 of Clutch
Overcenter Spring and after step 7 of Clutch
Pedal Replacement add: Clamp vise ;rips on lower
end of clutch pedal support bracket, Bend
bracket downward to provide access to end of over-
center spring that is attached to bracket.
NOTE: Refer to the 1980 Jeep Technical Service

Manual for procedures on 1980 CJ models.

as published are not affected by this revision.
80-115
Subject Information
Tape Player Inoperative Caused The AM/FM/Cassette radio has a transit screw
By Transit Screw -1980 Jeep installed at time of manufacture to ensure that
Models AM/FM/Cassette Radio the tape transport mechanism is not damaged
during shipment. If this screw is not removed,
the cassette tape player will not operate. The
tape cartridge will only engage part way.
This screw must be removed before the radio is

installed. The screw is located on the top of
the radio and is identified by a label that
states:
"Warning--This screw must be removed before

installation".
Relocation of Safety Certifica- The Safety Certification and Emission Control

tion and Emission Control Labels - labels on 1980 Jeep CJ models have been relocated
from the instrument panel to the inside of the
1980 Jeep CJ Models
left lower body panel just below the door opening.
The Emission Control Maintenance Information

Label remains under the hood in front of the
radiator.

Service Engineering Dept. * Detroit, Mich. 48232
14250 Plymouth Rd. *
Additional copies ot this letter are available through your zone office.
on I I C
- ._....._-.-y-,...,.._*__________ --...-- . -.----..----,.....
FILE Engines-Fuel Systems
Jeep Engine Electrical-Cooling

POWER PLANT-Engines
No. 1-10-82 Sept. 8, 1982
TECHNICAL BULLETIN
PROBLEM AND The pushrods in some 1981-82 Jeep 258 CID six-cylinder engines
APPLICATION: built prior to May 1982, may disengage from the rocker arms
causing noise, backfire, or a miss. -
CORRECTION: Install the following replacement 0.070 inch longer pushrods as

outlined in the appropriate Jeep Technical Service Manual if any of
the original pushrods become disengaged or bent. The original
pushrods are 9.640 to 9.660-inches long. The replacement pushrods,
part number 3242395, are 9.710 to 9.730-inches long.
NOTE: The original shorter pushrods, jart number 3227329,

are still recommended for use in 1980 and prior Jeep 258 CID
six-cylinder engines.
PARTS: Description Quantity Part Number
ROD, Valve Push 12 3242395 1 .095

S.R.T. Consult the T.I.C. manual and appropriate S.R.T. manual.
INFORMATION:

REIMBURSEMENT:

Service Engineering Department 14250 Plymouth Road * Detroit, Mich4gan 48232
* 82-070-A/J
Additional copies of this butlehn are available through you’ zone oflce
RIA
FILE: Engines-Fuel Systems

POWER PLANT-Engines
No. 1-10-82 Sept. 8, 1982
TECHNICAL BULLETIN
causing noise, backfire, or a miss.

pushrods are 9.540 to 9.660-inches long. The replacement pushrods,
NOTE: The original shorter pushrods, part number 3227329,

are still recommended for use in 1980 and prior Jeep 258 CIII
six-cylinder engines.
PARTS: Description quantity Part Number Group
ROD, Valve Push 12 3242395 1.095
S.R.T. Consult the T.l.C. manual and appropriate S.R.T. manual.

INFORMATION:

REIMBURSEMENT:
__PR
FILE: POWER PLANT -
Jeep Engines
No. 81-4 May12, 1982
TECHNICAL BULLETIN
PROBLEM AND Engine knock may recur on some 1980-81 Jeep four-cylinder engines
APPLICATION: even after carbon buildup has been removed with Jeep Carburetor and
Combustion Area Cleaner.
CORRECTION: On 1980 engines, install a thicker head gasket and install a shim
between each rocker arm ball and retaining nut. On 1981 engines,
install a thicker head gasket and replace the original push rods
with the longer 1982 four-cylinder push rods.
NOTE: The use of rocker ball shims on 1980 engines or longer push
rods on 1981 engines are needed to compensate for the in
creased thickness of the replacement head gasket.
GASKET KIT, Cylinder 1 8130478 1.061

Head Includes Shims
ROD, Valve Push 8 8134133 1.095

Use on 1981 engine
with thicker head
gasket
WARRANTY Not affected

ELIGIBILITY:
SSO INFORMATION: Not Affected.
PROCEDURE:
1. Remove the cylinder head as outlined in Chapter 18 of the 1980-81 Jeep

2. Remove all carbon deposits from the cylinder head combustion chamber
and the top of each piston.
3. Position the thicker head gasket on the block and install the cylinder
head as outlined in Chapter 18 of the 1980-81 Jeep Technical Service
Manuals.
4. On 1980 engines, install a shim between each rocker arm ball and
retaining nut.
5. On 1981 engines, install the longer replacement 1982 push rods.
6. Complete cylinder head installation as outlined in Chapter lB of the

82-O50-A/J
81-2
Subject: Six-Cylinder Engine Cylinder Application: 1981 Jeep Vehicles File: POWER PLANT
Read Cover With Six-Cylinder Engine Engines
No. 81-3 June 30, 1981
The cylinder head covers for 1981 Jeep six-cylinder 5 Remove PCV valve from cylinder head cover grom
engines have been revised to improve sealing at the met and disconnect PCV shut-off valve vacuum
cylinder head. The revised covers entered production in hose, if equipped.
January of this year and have improved thermal stabil
ity and an 0.030-inch increase in the height of the out 6 Remove vacuum switch and bracket assembly from
board step on the cover flange sealing surface. The cylinder head cover.
revised coven can be identified by the three, small
pointed projections located on the front edge of the oil 7 Remove diverter valve and bracket assembly.
filler cap boss. These identifying projections are in addi
tion to the year/month build date chart located on the 8 Remove all necessary vacuum and air hoses to pro
top, inner surface of each cover. vide cylinder head cover removal/installation
clearance.
Service correction of a cylinder head cover oil Ileak con NOTE: Tag hoses for assembly reference.
dition on a 1981 Jeep six-cylinder engine built after
January 1981, involves resealing the cover using the 9 Remove cylinder head cover retaining nuts.
procedure outlined in this bulletin. On six-cylinder
engines built prior to January, correction also involves 10 Detach cover from cylinder head by breaking
replacing the original cylinder head cover with a revised silicone seal using putty knife or razor blade. Do
cover. not attempt to pry cover upward until seal has been
completely broken.
11 Rotate cylinder head cover to left and remove

Description Quantity Part No. Group cover.
COVER, Cylinder Head 12 Inspect cylinder head cover to determine if cover

Revised 1 3237808 1.068 was manufactured prior to January or is revised
PRIMER G.E. 1 8130453 1.068 model as follows:
SEALER, Gasket-In-A a If cover has three small pointed projections on
Tube 1 8993317 15.260 front edge of oil filler cap boss and year/month
SEAL, Cylinder Head build date chart on cover inner surface in
Cover-to-Attaching Stud 2 3237837 1.068 dicates cover was manufactured during or after
FABRIC CLEANER 1 8990968 15.050 January Fig. 1, proceed to step 13.
NUT, Locldng 2 4006926 1.068
b If cover does not have identifying projections
and build chart indicates cover was manufac
tured prior to January Fig. 1, obtain re
PROCEDURE
vised cover, and proceed to step 14.
MONTH
2 Remove air cleaner and PCV molded hose.
YEAR J F M A M J J A S 0 N D
3 Disconnect distributor vacuum advance hose at 80 e * * * * * * * * C C
distributor. 81 I
82
4 Disconnect fuel line at fuel pump. Rotate line as
necessary to provide cylinder head cover removal/
installation clearance. Fig. 1 Cylinder Head Cover Build Date Code Chart

St-vice Engineering D.portmsnt * 14250 Plymouth Road * Detroit. Michigan 48232
Aaditional copies of this bulletin are available through your zone office.
81-3
13 If cover is to be resealed only, remove old sealer CAUTION: Avoid any time delay between sealer set-up
from cover flange sealing surface and inspect and cover installatiot The sealer can become tack-free in
cover. Replace cover if cracked or damaged in any 10 to 15 minutes which will reduce its adhesive qualities.
way.
14 Transfer PCV valve grommet and oil filler cap 18 Install replacement seals on cylinder head cover
from old cover to replacement cover. attaching studs. Be sure studs are clean before in
stalling seals.
15 Remove old sealer from cover sealing surface of
cylinder head and clean surface using ANC Fabric
Cleaner, or equivalent. Remove all residue from 19 Install cylinder head cover on cylinder head as
sealing surface using clean, dry cloth. soon as primer and sealer have set-up. Do not allow
sealer to contact valve train or other components
16 Apply General Electric 584004 primer, or equiv to avoid smearing sealer.
alent, to cover sealing surface of cylinder head.
Allow 10 15 minutes for primer to set-up.
-
20 Install and tighten cylinder head cover nuts to

CAUTION: Thefollowing step involves the application of 28-inch-pounds 3 Nm torque.
Gasket.In..A -Tithe silicone sealer. For an effective repair,
it is required that the sealer be no more than twelve
months old at time of use. Before using the sealer, check NOTE: If the cover nuts are not the locking-type, replace
the date code stamped on the crimped seam at the tube than with locking nuts, part number 4006926.
bottom or on the sealer carton. The two-character letter
code can be deciphered using the Sealer Date Code Chart
Fig. 2. 21 Install diverter valve and bracket assembly on
cover.
First Character S econd Character
is Year of is Month of 22 Install vacuum switch and bracket assembly on
Manufacture Manufacture cover.
K 1980
- A January
- 23 Install PCV valve in cylinder head cover grommet
A 1981
- B February
- and connect PCV shut off valve hose, if equipped.
B 1982
- C March
-
C 1983
- D April
- 24 Install all vacuum and air hoses that were re
D-1984 E -May moved for cover removal/installation clearance.
E -1985 F -June
F-1986 G -July 25 Connect fuel line and distributor vacuum advance
G 1987
- H August
- hose.
H 1988
- J September
-
J 1989
- K October
- 26 Install air cleaner and molded PCV hose.
I K-1990 M -November
[ N December
- 27 Connect PCV hose to PCV valve.
Fig. 2 Sealer Date Code Chart 28 Connect battery negative cable.
29 Check and adjust engine oil level ii necessary.

17 Apply 1/8-inch diameter bead of Gasket-In-A-
Tube, or equivalent silicone sealer to sealing sur
faces of cylinder head and cylinder head cover. NOTE: It is recommended that the seater be allowed to
Allow approximately five minutes for sealer to cure for approximately one-to-two hours before starting
set-up. the engine.
The following standard servicing operations and work times will apply.
.
OPERATION DESCRIPTION ggg OR51N

MODEL
YEAR AND TIME
SO SI $2
t
COVER, ENGINE CYLINDER HEAD -
RESEAL 1.072 1011 6-Cyl. 1.4 6

COVER, ENGINE CYLINDER HEAD -
REPLACE 1.068 1012 6-Cyl. 1.3 G

81-CU-MAli
81-4
Subject: Carbon Knock Application: 1980-81 Jeep Vehicles File: POWER PLANT
with Four-, Six-, or Eight-Cylinder Engines
Engine
No.81-2 Feb. 19, 1981
The four-, six-, and eight-cylinder engines used in PROCEDURE

1980-81 Jeep vehicles may develop a knock caused by
carbonbuildup on the pistons and combustion chambers.
Carbon knock is more likely to occur on high mileage 1 Remove air cleaner top.
engines but may also occur on low mileage engines
depending on the typeof driving involved. Carbon knock is 2 Operate engine until it is at normal operating
not sensitive to engine loading and is most noticeable temperature.
when the engine is not under toad. Carbon knock maybe
loudest when the engine is cold and may continue after the 3 Operate engine at fast idle speed and spray
engine warms up. cleaner directly into carburetor venturi until
container is empty.
Servicecorrection involves removing carbon buildup using
Jeep Carburetor and Combustion Area Cleaner, or 4 Stop engine when container is empty and allow
equivalent, if the knock is not sensitive to engine load. cleaner to penetrate carbon for five minutes.
The following part may be required. 5 Start engine and open and close throttle rapidly
for two minutes.
Description Quantity Part No. Group 6 Install air cleaner top.
CLEANER, Carburetor Case of 8993813 15.410
and Combustion Area 12
COMBUSTION CHAMBERS, CYLINDER

IIEAD CLEAN
-
81-039-O1AIJ

S.rvlc. Enginnrlng D.portm.nt * 14250 Plymouth Rood s Detroit, MichIgan 48232
81-5
Subject: Engine Noise Diagnosis Application: 1981 Jeep Ci Models Pile: POWER PLANT -
With Four-Cylinder Engine Engines
No. 81-1 Nov. 27, 1980
The four-cylinder engines used in 1981 Jeep Cl models Connecting Rod Bearing/Torque Converter Bolt
generally produce a higher level of operating noise than Noise
1981 six-cylinder engines. This is due to design dif
ferences that primarily affect operating clearances. For Connecting rod bearing noise knock caused by ex
example, cold engine piston slap or knock that ceases cessive bearing clearance is generally noticeable when
after a few minutes of operation is normal on 1981 Jeep the engine is not under load. Loose torque converter
four-cylinder engines. bolts can also produce a noise similar to connecting rod
bearings with excessive clearance.
Because some engine operating noise is normal, it is im
portant that this fact be taken into consideration when However, converter bolt noise is generally more
diagnosing suspected engine noise. Some known sources noticeable when the transmission is in Neutral and
of abnormal engine noise are: excessive piston-to- engine is operating at fast idle speed. This noise may, or
cylinder wall clearance, excessive connecting rod bear may not be noticeable when the transmission is in gear
ing clearance, carbon buildup on pistons, loose or im and the engine at idle speed.
properly seated camshaft/crankshaft sprockets, and
loose torque converter-to-drive plate attaching bolts. 1 If noise is most noticeable with transmission in
Neutral and after throttle is opened and closed
rapidly several times, check for loose torque con
Service correction of a four-cylinder noise condition
should be performed only after the noise has been de verter bolts. Remove any loose bolts, apply Loctite
termined to be abnormal, and the source of the noise 211, or equivalent, and install and tighten bolts to
pinpointed through careful diagnosis. Refer to the 40 foot-pounds 54 N.m torque.
diagnosis procedures in this bulletin.
2 If noise is most noticeable with transmission in
The following parts are available and may be required. gear and engine under load, check connecting rod
bearing clearance. If clearance is excessive, 0.001
Description Quantity Part No. Group or 0.002 inch undersize bearings may be installed.
Refer to 1981 Jeep Technical Service Manual for
PISTON + 0.005 4 8133509 1.143 procedure.
RING SET, Piston
Engine +0.005 4 8133531 1.146
Piston Slap/Carbon Knock
BEARING, Connecting
Rod Including Upper Piston slap caused by excessive piston-to-cylinder wall
and Lower -0.001 4 8133438 1.138
BEARING, Connecting clearance occurs in both low and high mileage engines.
Rod Including Upper Carbon knock is more likely to occur on high mileage
8133439 1.138 engines but may also occur on low mileage engines. Car
and Lower -0.002 4
bon knock is not sensitive to engine loading and is most
SPROCKET,
1 8132270 1.132 noticeable when the engine is not under load. Carbon
Crankshaft
SPROCKET, knock may be loudest when the engine is cold and may
1 8132271 1.134 continue even after the engine warms up.
Camshaft

Srvla Englnnring D.portm.nt * 14250 Plymouth Rood * D.troit, Michigan 48232
office,
Additional copies ot this bulletin are available through yoid zone
81-6
NOTE: Cold engine piston slap that ceases after afew NOTE: piston-to-watt clearance should be
minutes operating time is normal on. 1980-81 four- 0,0027-0.0033-inches 0.0685-0.0838 mm. Measure piston
cylinder engines. diameter at the pin centerline 1-3/16-inches below the
piston pin on the piston. skirt. Measure the cylinder bore
at a point 2-1/4-inches below the top of the bore. Cylinder
1 If noise is not sensitive to engine load, clean engine taper should be no more than 0.001-inch 0.0508 ‘nnU.
piston tops and combustion chambers with AMC
Combustion Chamber cleaner, or equivalent. Camshaft/Crankshaft Sprocket Noise
Loose or incorrectly seated camshaft/crankshaft

2 If noise ceases after using combustion chamber sprockets are generally most noticeable when the engine
cleaner, return automobile to owner. is warm. Sprocket noise is sensitive to engine speed but
not load. Sprocket noise is also evident at warm idle and
sounds similar to a loose timing chain.
3 II noise does not cease, check piston-to-cylinder
wall clearance. If clearance is excessive, pistons 1 Remove accessory drive belts and position sound
may be knurled to provide desired clearance. detection tool on timing pointer to verify noise.
However, if knurling service is not readily
available, 0.005-inch oversize piston and ring sets 2 If sprocket noise is detected, repair or replace cam
may be installed to obtain desired clearance, Refer shaft/crankshaft sprockets. Refer to 1981 Jeep
to 1981 Jeep Technical Service Manual for piston Technical Service Manual for sprocket servicing
servicing procedures. procedures.
The following standard servicing operation and work times will apply:
YEAR AND TIME

OPERATION
LEVEL
80 81 82
PISTON-KNURL 1.143 1131 4-Cyl. P

One 0.3
TWO 0.6
Three 0.9
Four 1.2
81-O17-OIA/J
81-7
Subject: Air Conditioning Back Idler Application: 1981 California Jeep File: POWER PLANT
Pulley Noise Cherokee, Wagoneer and Truck Cooling System
Models Built Prior to
YIN 1JTNA25NSBTO15SO2
Equipped with Six-Cylinder
Engine and Air Conditioning No. 814 Mar. 16, 1981
On some 1981 California Jeep Cherokee, Wagoneer, and b Check for idler pulley being installed in reverse
Truck models built prior to YIN 1JTNA25N5BTO155O2 position. Deepest counterbore in pulley hub
and equipped with a six-cylinder engine and air condi should be facing forward see illustration. Cor
tioning, the air conditioning back idler pulley or the rect pulley position if necessary.
pulley attaching components may have been installed or PULLEY LOCK WASHER
assembled incorrectly. This condition could result in a GUARD
chirp noise from the idler pulley assembly during vehicle
acceleration, or whenever engine speed is increased SPACER
rapidly.
Service correction involves inspecting the back idler LOCK WASHER

pulley components to determine if they have or have not
been properly assembled and assembling the pulley com
ponents correctly if necessary.
PROCE DIJRE PULLEY

DUST MOUNTING
COVER BRACKET
1 Inspect idler pulley attaching bolt and note if lock PULLEY
washer has or has not been installed between bolt ATTACHING
BOLT
head and idler pulley dust cover see illustration.
Air Conditioning Back Idler Pulley Assembly
2 Loosen alternator adjusting bolt and release tension
on serpentine drive belt. 5 Assemble idler pulley, dust cover, spacer, and pulley
attaching bolt and lock washer. Refer to illustration
3 Remove nut and lockwasher from idler pulley at for correct assembly sequence. Be sure pulley is cor
taching bolt aS remove bolt and pulley components rectly positioned and that lockwasher is installed on
as assembly. pulley attaching bolt.
4 Carefully disassemble idler pulley components and 6 Position idler pulley assembly on mounting bracket
inspect as follows: and install tockwasher and nut on pulley attaching
bolt. Tighten nut to 36 foot-pounds 49 N .m torque.
a Check to see if flat washer was incorrectly instal
led between idler pulley dust cover and idler 7 Adjust serpentine belt tension to 140.160 pounds
pulley. Discard flat washer if a washer was in 623-712 Newtons force and tighten alternator ad
stalled. justing bolt to 18 foot-pounds 24 N.m torque.
YEAR AND TIME

CODE NUMBER I LEVEL
J I
SC SI 82
PULLEY, AIR CONDITIONING BACK

IDLER R& R
- 13.421 13137 6-Cyl. j 0.2 G
Subject: Serpentine Drive Belt Application: 1981 California Jeep File: POWER PLANT
Vehicles with Six-Cylinder Engine, Cooling Systems
Power Steering, Air Conditioning
and 55 or 63-Amp Alternator
No.81-i Feb. 20, 1981
Some 1981 California Jeep vehicles with six-cylinder 4 Place alternator adjusting bracket in full up posi
engine, power steering, air conditioning and a 55 or 63 lion and finger-tighten alternator pivot and ad-
amp alternator may be equipped with a serpentine drive justing bolts.
belt that cannot be adjusted to the proper tension.
5 Remove backside idler and shield.
6 Remove original serpentine drive belt.

Service correction involves replacing the sepentine drive
belt with the following replacement belt and adjusting the 7 Install replacement serpentine drive belt. Be sure
new belt to the proper tension as described in this bulletin. belt is seated in all pulleys.
8 Install backside idler and shield.

The following part is required and available:
9 Position power steering pump so that clearance of
1.2-inches exists between upper corner of steer
ing pump and flat area on underside of air pump
Description Quantity Part No. Group and tighten pump adjusting bolts to 30 foot-
pounds 41 N.m torque.
BELT, Serpentine Drive 1 3241096 2.015
10 Adjust serpentine belt tension by adjusting
alternator position. Use 1/2-inch square drive
hole in alternator mounting bracket to move
PROCEDURE alternator and adjust belt to correct tension.
Tighten alternator pivot and adjusting bolts to
28 foot-pounds 38 N.m torque when adjustment
1 Loosen alternator pivot and adjusting bolts. is completed.
2 Loosen power steering pump adjusting bolts. The staixlani servicing operations and work times publish
ed in the current SSO manual are not affected by this
3 Place power steering pump in full down position. bulletin.
81.05 7-O2AIJ
SCN 255

Application: 1981 Jeep Six-Cylinder ‘File: POWER PLANT
Subject: Six-Cylinder Engine Block Cooling
Heater Engines Equipped With Engine
Block Heater -and Built Prior to
Engine Build Date Code O11CO1
No. 81-2 Dec. 15, 1980
On some 1981 Jeep six-cylinder engines equipped with ENGINE

an engine block heater and built prior to engine build BLOCK
WALL
date code O1ICO1, the block heater 0-ring seal may not
contact the block properly and allow coolant to leak past SPACER
the seal. This condition is due to variations in engine
block wall thickness which may cause heater installation
depth to be too great.
Service correction involves checking engine block wall

thickness and installing a spacer between the block
heater and engine block surface if necessary.
The following part is available and required.
SPACER, Engine ENGINE

Block Heater 1 8133736 15.145 BLOCK
HEATER BLOCK HEATER
0-RING SEAL
PROCEDURE
WARNING: Do not attempt to drain coolant from the

engine or radiator while the cooling system is hot and under
pressure. Hot coolant can cause serious bunts. Engine Block Heater Compression Nut-type and
Spacer Installation
1 Drain coolant from engine.
5 Check block heater 0-ring seal for damage.
NOTE: Do not waste reusable coolant. If the solution is
clean and is being drained for service purposes only, 6 Install block heater and spacer assembly, if re
drain the coolant into a clean cont amer for reuse. quired, in engine block.
2 Disconnect electrical cord from block heater. CAUTION: Use care when tightening the block heater at
taching parts. Improper tightening may damage the
0-ring seal or allow the heater to loosen resulting in
3 Remove block heater from engine block. coolant loss and possible engine damage.
4 Measure thickness of engine block wall at horizon 7 Tighten T-bolt type heater fastener to 20 inch.
tal center of machinedboss. If wall thickness is less
pounds 2.3 N.m torque. Tighten compression nut-
than 0.36 inch, it will be necessary to install a
spacer on engine block heater see illustration. type heater fastener to 10 foot-pounds 14 N.m
torque.
NOTE: The machined boss surface of the block varies 8 Connect electrical cord to block heater.
from top to bottom. Be sure to measure wall thickness at
horizontal center of machined boss surface. 9 Fill cooling system with coolant drained previously.

81-10
YEAR AND TIME

CODE NUMBER * I LEVEL
$0 I 81 I 82
SPACER, ENGINE BLOCK
INSTALL
HEATER -
16.200 15147 6-Cyl.

I 0.4 G
S1-02!-02A1i
81-11
Subject: New Voltage Regulator Tester Application: 1975-81 Jeep Vehicles File: POWER PLANT -
Engine Electrical
No. 81-1 June 11, 1981
A new voltage tester that will verify the condition of condition of a replacement regulator before installation.
voltage regulators used with 10-SI series Delco, Ki Also, when using the tester to diagnose a suspected
series Bosch, Motorcraft, and 8-AL series Motorola voltage regulator malfunction, be sure to follow the test
alternators is now available through the amserv pro procedures outlined in the instruction manual supplied
gram under code number OT 60884. Because the new with each tester.
tester is capable of simulating the field, stator, battery,
ground, and indicator light circuits, the tester is able to The standard servicing operations and work times as
perform a complete cheek on all of the regulator published in the current 550 manual are not affected by
operating modes. this bulletin.
The new tester should be used to verify voltage
regulator condition before replacement or to verify the
SI-095-O3A1J
Subject: Catalytic Converter Heat Shield Application: 1981 California Six- File: POWER PLANT
Cylinder Cherokee and Wagoneer Fuel and Exhaust
Models Built Prior to System
YIN IJCNE 15N7BT033109
No. 81-3 March 19, 1981
1981 California six-cylinder Cherokee and Wagoneer PROCEDURE

models built prior to YIN 1JCNE15N7BTOSS1O9 were
equipped with a secondary catalytic converter heat
shield in addition to the shield welded to the vehicle
underbody. On occasion, the secondary shield clamped 1 Raise vehicle.
to the converter may contact the underbody or con
verter causing a ratthng-type noise to occur. If inspec- 2 Remove exhaust pipe clamps that attach secondary
tion indicates thatthe secondary shield is contacting the heat shield to catalytic converter. Shield is posi
underbody or converter, the shield may be removed to tioned over top of converter.
correct this noise condition.
3 Remove and discard secondary heat shield.
NOTE: The secondary shield was phased out of produc
tion in December, 1980, and is not used on 1981 GaIt/or- 4 Install exhaust pipe clamps.
nia six-cylinder Cherokee and Wagoneer models built
after yIN 1JCNE15N7BTOSSIU9. 5 Lower vehicle.
YEAR AND TIME

COST OP TION
OPERATION DESCRIPTION CODE NUMBER MODEL
80 81 52
SHIELD, CATALYTIC CONVERTER

SECONDARY HEAT REMOVE - 4.190 4443 6-Cyl. 0.2 M
81-069-04J
SCN 374

Subject Heated Intake Manifold Application: 1981 Jeep Vehicles File: POWER PLANT
Diagnosis with Six-Cylinder Engine Fuel and Exhaust
No. 81-2 Jan. 12, 1981
This bulletin is being issued to provide additional infor DIAGNOSIS PROCEDURE

mation which supplements the 1981 Jeep Technical
Service Manual- Intake Manifold Heater Diagnosis
1 Inspect intake manifold heater wiring for damage

The intake manifold on 1981 Jeep vehicles has an and repair wiring if necessary.
electric heater located in the plenum chamber below the
carburetor. The heater improves fuel vaporization by 2 Inspect connections at intake manifold heater,
preventing fuel condensation during engine warmup manifold heater relay, water temperature sending
and also shortens choke operation. When engine coolant unit, and oil pressure sending unit. Repair connec
reaches operating temperature, the heater shuts off and tions if necessary.
coolant flowing through the manifold then aids fuel
vaporization. When checking coolant flow, electrical 3 Test for presence of battery voltage at manifold
circuits, and intake manifold heater operation, use the heater wire 12 gauge orange with engine
diagnosis procedure provided in this bulletin. running. Voltage should not be present at this wire
when engine is not running.
4 Start engine and test for battery voltage at

The following parts may be required and are available: manifold heater wire. With engine coolant
temperature below 80°F room temperature,
battery voltage should be present at manifold
heater wire.
5 When coolant temperature reaches 160°F, coolant
HEATER, Intake temperature switch should open and break circuit
Manifold 3233718 1.067 between relay and intake manifold heater. Battery
PLUG, Intake voltage should not be present at orange heater
Manifold 1 4200413 1.067 wire at this point.
0-RING, Intake
Manifold Heater 1 4200431 1.067 6 Test for battery voltage at dark blue with tracer
GASKET, Intake wire at oil pressure sending unit with engine
Manifold Heater 1 3238909 1.067 running. This is feed wire for manifold heater
RELAY, Intake relay.
Manifold Heater 1 3239095
MANIFOLD, Intake 1 8133011 1.067 7 With engine running and at operating
GASKET, Intake temperature, disconnect light green with tracer
Manifold-to-Cylinder wire from coolant switch and ground this wire to
Head 1 3237775 1.067 complete circuit for manifold heater relay. Battery
SWITCH ASSEMBLY, voltage should now be present at orange wire lead
Intake Manifold Heater at intake manifold heater.
Switch Calif. 1 3239126 1.067
SWITCH ASSEMBLY, 8 If intake manifold heater is found to be inoperative
Intake Manifold Heater after thorough testing, replace intake manifold
Switch 49 State 1 3239065 1.067 heater, heater gasket, and 0-ring. Tighten intake
SENDING UNIT, Oil manifold heater attaching screws to 7 foot-pounds
Pressure 1 3212004 3.605 9 N-rn torque.
PU American Motors Saks Corporation

Snvic. Engineering D.partin,nt * 14250 Plymouth Rood * Detroit, Michigan 48232
Additional copies of this bulletin are available through you’ zone office.
81-14
NOTE: The intake manifold must be removed to gain ac 5 Continue pouring water into funnel until container
cess to the intake manfoid heater. Refer to page lB-fl of is empty, then continue timing water flow until
1981 Jeep Tecknwal Service Manual Jbr manifold funnel is empty.
replacement procedure. In addition, the intake manifold
heater must have no more than one entire pin missing or 6 If water flows through intake manifold coolant
heat output will be marginal. passage in 25 seconds or less, coolant flow is cor
rect and passage is not restricted.
Intake Manifold Coolant Passage Diagnosis 7 If water takes longer than 25 seconds to flow
through intake manifold, cheek manifold inlet for
1 Install 12-inch length of 5/8-inch inside diameter casting flash or other restrictions, correct as
heater hose on intake manifold inlet nipple. Then necessary, and proceed to next step.
insert funnel in hose. Funnel must have minimum
outlet size of 3/8-inch inside diameter. 8 Check length of pipe plugs in intake manifold
coolant passages, Plugs must not be so excessive in
length that coolant flow is restricted. Replace
2 Disconnect heater inlet hose from rear fitting on plugs if length is excessive.
intake manifold.
NOTE: Do not waste reusable coolant. If the coolant is
acceptable for reuse, drain the coolant into a clean
3 Fill container with 1/2 gallon of water. container.
9 If intake manifold coolant passages are restricted

4 Begin pouring water into funnel and time water and cannot be cleared, replace intake manifold.
flow through manifold when water starts flowing Refer to replacement procedure on page 1B-42 of
down funnel. 1981 Jeep Technical Service Manual.
YEAR AND TIME

CODE NUMBER MODEL
LEVEL
80 81 02
4
HEATER, INTAKE MANIFOLD- TEST - - 3.830 4221 6 Cyl. 0.2 G
Includes testing intake manifold heater
relay
Coolant flow, intake manifold - Cheek for
Restriction 1.066 A 0.1 6
81.O18-04AJJ
81-15
SCN 30

Subject: Altitude Performance Application; 1981 Jeep Vehicles File: POWER PLANT
Adjustments Fuel and Exhaust
No. 8 1-1 Dec. 12, 1980
This bulletin is being issued to outline the altitude per 4,000 feet, the ignition timing, as shown on the vehicle
formance adjustments for 1981 Jeep vehicles required emission control label located in the engine compart
under a newly established Federal standard. The ad ment, should be advanced °.
The engine idle speeds
justments will improve driveability performance as well should be reset according to the procedures outlined in
as emissions performance at altitudes other than that the 1981 Jeep Technical Service Manual. After perform
for which the vehicles were designed. ing these adjustments, 511 out and attach emission con
trol label, part number EF8130446, to the engine com
partment dash panel.
Any Jeep vehicle that has been so adjusted must have a
unique emission control information label installed. These adjustments apply to all 1981 Jeep vehicles that
These unique labels are available in a kit, part number were sold for principal use at altitudes below 4,000 feet.
8130450, from the following facility: Refer to the vehicle emission control label in the engine
compartment to identi these vehicles.
Distribution Services On CJ models with six-cylinder engine and manual
37200 Amrhein Road transmission originally sold for operation at altitudes
Livonia, Michigan 48150 above 4,000 feet that are being operated below 4.000
feet, the fuel metering rods should be adjusted one fÜR
turn clockwise richer and the engine idle speeds reset
The adjustment procedures and unique labels must be as specified on the original vehicle emission control label
made available at no cost to independent repair facilities or in the 1981 Jeep Technical Service Manual. After per
and the general public. A notification is also provided in forming these adjustments, fill out and attach emission
current owner manuals to make customers aware of control label, part number FF8130448, to the engine
these adjustments. compartment dash panel.
These adjustments apply only to 1981 CJ models with

ADJUSTMENT PROCEDURES six-cylinder engine and manual transmission that were
sold for principal use at altitudes above 4.000 feet. Refer
On Jeep vehicles originally sold for operation at to the vehicle emission control label in the engine com
altitudes below 4,000 feet that are being operated above partment to identify these vehicles.
81-129.O4AhJ

S.rvlc. Engineering Department * 14250 Plymouth Road * Detroit. Michigan 40232
Addition8 copes of f/ns bulletin are available through
your zone ottice
Subject: SRI Four-Speed Manual
Transmission Vent 1 rApplication: 1980-81 CJ and Pile: CHASSIS
_J
-
Scrambler Models With 5R4 Pour Clutch Manual
-
{ei Manual Transmission Transmission
No. 81.1 June 15, 1981

On some 1930-81 CJ and Scrambler models equipped
with an SM four-speed manual transmission built DRILL ift"
prior DIAMETER
to March 1981, a small amount of transmission HOLE
lubricant
may occasionally escape from the transmission vent HERE
located in the transmission adapter. This condition
occurs primarily during cold weather warmup and may
be caused by the normal increase in working pressure
within the transmission during operation.
FRONT
If inspection indicates that a small amount of lubricant

occasionally escapes from the vent, service correction
involves drilling a 1/16-inch diameter auxiliary vent hole
in the transmission top cover.
HORIZONTAL SCRIBE MARK MUST VERTICAL SCRIBE
BE IN LINE WITH TOP OF MARK MUST BE
CASTING LETTERS IN LINE WITH
PROCEDURE
TRAILING EDGE
OFCASTING
1 Remove transmission and transfer case shift lever LETTER R
knobs. Locating Auxiliary Vent Hole
In SRI Transmission Top Cover
2 Remove floor carpeting, if equipped.
6 Apply generous coating of grease to 1/16-inch dia
meter drill bit to contain chips and carefully drill
3 Remove screws attaching transmission access vent hole in transmission top cover. Clean chips
cover to floorpan and remove access cover and shift from cover after drilling vent hole.
lever boots as assembly.
CAUTION: There is only a small clearance between the
4 Clean transmission top cover surface thoroughly. s/nflfork retainer and the cover. Do not allow the drill bit
to contact the retainer when the bit penetrates the cover.
5 Locate, mark, and centerpunch position of 7 Install transmission access cover and shift lever
additional vent hole in transmission top cover see boots.
illustration. Scribe vertical mark in line with trail
ing edge of letter R on casting and be sure horizon 8 Install floor carpeting, if equipped.
tal mark is scribed 5/8-inch upward from top edge
of casting letters as shown in illustration. 9 Install shift knobs on transmission and transfer
case shift levers.
NOTE: Itisimpo nt that the vent hole be located as
accurately as possible. Use an accurate steel rule and a 10 Check and adjust transmission lubricant level if
sharp scriber only to locate and mark hole posttwn. necessary.
YEA RAND I IME

CODE NUMBER LEVEL
80 Si 82
COVER, TRANSMISSION TOP - ADD

AUXILIARY VENT HOLE 6.009 7717 CJ 0.3 0.3 G
Withcarpet-Add 0.1 0.1
S1-097-OGA/J
TI American Motors Sales Coiporation
________
P1 Jeep
Diagnosis and_Repair Bulletin No._2-03-82
Subject: C[ir’ Date: July 13, 1981
ss Thr rol Rod
H Pi ery Application: 1981 Jeep CJ7,
Cherokee, Wagoneer & Truck
SA lh589 File: CHASSIS-Auto Trans
This is a Type 0511 Campaign involving safety related elements. A copy of the owner
notification is shown in Figure 2.
On some 1981 Jeep CJ7, Cherokee, Wagoneer and Truck models with six-cylinder engines
and automatic transmissions, the automatic transmission throttle control rod spring
and spring hitch pin may be improperly installed causing the throttle to close slower
than expected. This condition could result in longer stopping distances or higher
than normal braking effort.
Vehicles affected by this campaign are:
CJ7 models built between VIN 1JCCEB7A7BT00001O and 1JCCE87EBBTO2O494;
Cherokee and Wagoneer models built between VIN 1JCCE17COBT000021 and
1JCCE17D9BTO198O6; and Truck models bui1t between VIN 1JTCE26N8BT000034
and 1 JTCA26NXBTO1 8529
Service correction involves inspecting and correcting throttle control rod spring and
hitch pin position, if necessary, and checking the throttle linkage operation.
Detroit will provide you with a VIN list of involved vehicles. Campaign procedures
apply to all dealers. On all undelivered campaign-involved vehicles, the campaign
action must be performed before the vehicles are sold or otherwise put in service.
INSPECTION AND REPAIR PROCEDURE

1 Open hood and inspect throttle control rod spring
position.
2 If spring is attached to bellcrank and to hitch pin, as
is correctly installed. Proceed to Step 4. shown in Figure 1, spring
3 If spring is incorrectly attached at either the bellcrank

correct, as shown in Figure 1, and check throttle or the hitch pin,
linkage operation.
4 Place yellow paint mark on bellcrank to
inspection/repair procedure. indicate completion of campaign
5 Close hood and return vehicle to owner.

Service
EngIneering Department * 14250 Plymouth Road * Detroit, MIchigan
48232
-2-
The following standard work times will apply:

Alpha Service Year and Time Skill
Operation Description Code for Claim Model -81- Level
SPRING & HITCH PIN, A 6-cyl 0.2 G
THROTTLE CONTROL ROD -
INSPECT/RELOCATE
Includes drive-in!
drive-out time
CLAIM HANDLING
The dealer will be required to complete a Campaign Notice and Claim Form AM 4251
for each vehicle serviced. Upon completion, submit the CCD copy of the form to CCD
in Milwaukee.
Based on the alpha box checked, the dealer will automatically be credited on the
mid or end-of-month memorandum of warranty transactions code 40 referencing the
claim number on the form. The single credit shown will include Drive-in/Drive-out
and corresponding labor costs.
B ELLC RAN IC
THROTTLE
CONTROL
a- ROD SPRING
PIN MUST BE INSTALLED POINTING DOWNWARD
ROD
Figure 1 - Throttle Control Rod Spring Position
81.19
-3-
Campaign No: 8102
NHTSA No: 8l-0l5

American Motors
fl SSesCorporatIon
Amerc,n Center
2777 fr,nkhfl Roed
SajihipeLd Micilican 4803
Dear Jeep Vehicle Owner:

This notice is sent to you in accordance with the requirements of the National
Traffic and Motor Vehicle Safety Act.
Jeep Corporation has determined that a defect which relates to motor vehicle
safety exists in certain 1981 Jeep vehicles equipped with a six-cylinder engine
and an automatic transnission. Your vehicle may have an improperly installed
transmission throttle control rod spring.
An improperly installed transmission throttle control rod spring could cause
the throttle to close more slowly than expected. If you experience a slower-
than-normal return to idle, this may be a warning of the spring condition and
could cause longer-than-normal braking distance leading to a possible vehicle
crash. If you experience a slow return to idle speed, exercise extreme caution
In driving and take your vehicle to your dealer for service as soon as possible.
Please contact your Jeep dealer now to arrange an appointment to assure that each
end of the spring is correctly positioned. Please present the enclosed fom to
your dealer when you tender your vehicle for service. He will complete the form
after servicing your vehicle and will give you a copy for your records. This
correction usually requires no more than one-half hour and will be performed at
no charge to you.
If you no longer own the vehicle described, or you have moved, please complete
the change of address or ownership form attached to the back of the enclosed form
and return it to us so that we may update our records accordingly.
If your dealer does not perform this service on your ntttually arranged appointment
date or within five days thereafter and without charge, please contact the local
Zone Office listed in your Owner’s Manual or American Motors Sales Corporation,
Owner Relations, 14250 Plymouth Road, Detroit, Michigan 48232, Telephone 313
493-2341. If you are unable to obtain this campaign service within a reasonable
time or without charge, you may contact the National Highway Traffic Safety
A&ninlstration, 400 Seventh Street, S.W., Washington D.C. 20590 or call the toll
free Auto Safety Hotline at 800-426-9393 Washington D.C. area residents may call
426-0123.
We regret any inconvenience this may cause you; however, we have taken this action
in the interest of your safety and your continued satisfaction with our products.
We again wish to thank you for your continued confidence in purchasing our ASIC
products and may you have nany happy miles of pleasant motoring. If we can be of
any further service to you, please feel free to contact your local ASIC dealer.
D. M. Semann
General Manager-Service
Enclosure
Figure 2 - Owner Notification

_
-

Subject: Torque Convener Turbine Hub Application: 1981 Jeep CJ Models
and Transmission Input Shaft Splines File: CHASSIS
with Four-Cylinder Engine and Automatic
Model 904 Automatic Transmission Transmission
No. 81-2 Feb. 27, 1981

This bulletin is being issued as a supplement to the 2 Check for broken or disconnected gearshaft link
automatic transmission diagnosis section in Chapter 2C age components.
or the 1981 Jeep Technical Service Manual. The infor
mation in this bulletin provides an additional possible 3 Verify that vehicle will not move forward or in
cause for diagnosis of a vehicle that will not move for reverse and that condition occurs in all gear ranges.
ward or in reverse. If automobile will move in any one gear range, con
dition is not result of spline damage.
On some 1981 Jeep CJ models with a four-cylinder
engine and model 904 automatic transmission, the tor 4 Remove converter housing inspection cover. Check
que converter turbine hub and transmission input shaft for broken or missing converter or drive plate bolts,
splines may not engage properly and become damaged. and check for broken drive plate. Repair as neces
If spline damage is severe enough, the vehicle may not sary.
move. In December, 1980, a new transmission input
shaft with longer splines was phased into production and 5 Perform hydraulic pressures tests 1, 2, and 3 as
is now available for service see illustration. The new outlined in 1981 Jeep Technical Service Manual.
shaft provides increased spline contact to ensure proper If pressures are within specifications in Hydraulic
input shaft-to-converter hub spline engagement. Pressure Test Diagnosis and Specifications Charts,
proceed to Transmission Repair Procedure.
Service correction involves: Verifying the condition us
ing the diagnosis procedure provided in this bulletin, TRANSMISSION REPAIR PROCEDURE
replacing the torque converter, installing the new
longer spline input shaft, replacing the oil pump bushing 1 Remove transmission and torque converter as out
and seal if diagnosis indicates this is necessary, and lined in Technical Service Manual.
replacing the transmission fluid and filter. The oil
cooler, cooler lines, oil pan, and oil pan magnet must 2 Remove oil pan attaching bolts and remove oil pan.
also be flushed and cleaned if diagnosis indicates that
repairs are necessary. 3 Remove oil filter.
The following parts are available and may be required: 4 Loosen front band lock nut and tighten front band
adjusting screw.
5 Remove oil pump attaching screws and remove
CONVERTER, Torque 1 3234274 16.030 pump using tool J.-7004-3 and Slide Hammer
SHAFT, Input 1 8133780 16.405 J-6585-1.
SEAL, Oil Pump 1 8122838 1&380
BUSHING, Oil Pump 1 8120854 16,380 6 Loosen front band adjusting screw and remove
GASKET, Oil Pan 1 8120983 16.315 band strut and front hand.
FILTER, Oil 1 8123042 16.345
7 Remove input shaft and front and rear clutch
assemblies.
DIAGNOSIS PROCEDURE
8 Lift front clutch upward and off rear clutch
1 Verify condition. Refer to preliminary diagnosis retainer.
in automatic transmission diagnosis and test
procedures section of 1981 Jeep Technical Service 9 Remove input shaft snap ring.
Manual and check conditions causing’ ‘will not move
in forward or reverse" that do not require trans 10 Remove input shaft from rear clutch using arbor
mission removal. press.

S.rvlc. Engineering D.portm.nt * 14250 Plymouth Road * Detroit, Michigan 48232
is worn or
replacement 21 Inspect oil pump bushing. If bushing seal as out
11 Install replacement seal rings onnew-type with scored, replace bushing and oil pump
input shaft. Be sure shaft is
lined in Technical Service Manual.
longer spline see illustration.
shaft support
teflon 22 Install thrust washer on reaction
NOTE: The input shaft front seal ring is made of hub.
and the rear seal ring ofcast iron.
oil pump
23 Thread two Pilot Stud Tools J-3387-2 into
opening in case.
over pilot
24 Install replacement oil pump gasket
studs.
groove on
OLD SHORT SPLINE INPUT SHAFT 25 Install replacement rubber seal ring in seal is not
outer flange of pump housing. Be sure
twisted.
jelly.
26 Coat pump housing seal ring with petroleum
assembly
27 Install pump assembly in case. Tap pumpasembly if
lightly with rawhide mallet to seat
necessary.
NEW LONG SPLINE INPUT SHAFT
28 Install replacement seals on oil pump attaching
bolts.
Transmission Input Shaft Comparison -
Model 904 4-Cylinder 29 Install four oil pump attaching bolts. Tighten bolts
finger-tight only.
30 Remove pilot studs and install remaining oil pump

12 Install replacement input shaft in rear clutch bolts finger-tight only.
retainer using arbor press.
31 Rotate input aDd output shafts. Shafts must not
13 Install replacement snap ring on input shaft. bind. Correct any bind as necessary.
14 Align front clutch inner splines and position 32 Tighten all oil pump attaching bolts evenly to 175
front clutch assembly on rear clutch. inch-pounds 20 Nm torque.
NOTE: Be sure the front clutch plate splines are frilly NOTE: After pump installation, check input shaft end
engaged in the rear clutch hub. play as outlined in the Technical Service Manual.
15 Coat number 3 selective thrust washer with 33 Clean oil pan, oil pan gasket surface, case gasket
petroleum jelly and install washer on output shaft, surface, and oil pan magnet.
16 Align rear clutch inner splines. 34 Install replacement oil filter.
17 Install clutch assemblies in transmission case. 35 Install replacement oil pan gasket and install oil
Install assemblies using circular turning motion pan. Tighten oil pan bolts to 150 inch-pounds
and be sure to engage rear clutch splines with 17 N-m torque.
splines of front annulus gear.
36 Adjust front band as outlined in Technical Service
NOTE: Be sure the front clutch drive tugs are frilly Manual.
engaged in the driving shell slots.
37 flush oil cooler and cooler lines as outlined in
18 Install front band on front clutch assembly. Technical Service Manual.
19 Install front band strut. 38 Install replacement torque converter.
20 Tighten front band adjusting screw just enough to 39 Install transmission as outlined in Tethnical
hold band and linkage in place. Service Manual.
YEAR AND TIME

OPERATION DESCRIPTION COS’! OPERA11ON SKILL
CODE NUMBER MODEL LEVEL
80 81 82
TRANSMISSION - B &B 16200 2-7 1.7 G

Includes transmission and transfer case
removal as assembly
Input Shaft - Replace 36.405 Z 0.6 G
Pump Bushing and Seal -
Replace 36.882 44 0.2 41
St-055-16AJ1
FILE: Axles-Suspension-
P1 Jeep
Brakes-Steering CHASSIS -
Transfer Case/Quadra-Trac
No. 3-04-82 Mar. 8, 1982
TECHNICAL BULLETIN
PROBLEM AND Transfer case shift lever rattles or makes a buzzing noise in some
CORRECTION: Install a flat washer and rubber bumper on the transfer case shift
lever ball-end see illustration.
WASHER, Flat 1 Gl31016 17.814
BUMPER, Rubber 1 637936 35.300

ELIGIBILITY:
SSO INFORMATION:

SHIFT - MODIFY 18.135 18019 CJ 0.2 0.2 0.2 G
PROCEDURE:
shift lever.
3. Lift the shift lever upward and out of the shift control link.
th. shoulder at tne ball-end of the shift lever.
continued
PU Amedcan Motors Sales Corporation
Service EngineerIng Department * 14250 Plymouth Road * Detroit, Michigan 48232
81-24
-2-
Et
FLAT
WASHER
RUBBER
BUMPER
SHIFT LEVER
BALL-END

82-057-J
81-25
_________

jubject: Chirp Noise Capsed by
Application: 1981 Jeep Cherokee, I File: CHASSIS
‘Thansfer Case/
-
Wagoneer, and ‘fruck Models

‘fransler Case Input Gear Thrust with Model 219 Quadra-’lIac Quadra-frac
Bearing Race or Front Output Shaft ‘fransfer Case Built Prior to
Thrust Bearing Races
June 5, 1981.
No. 81-2 Oct. 5, 1981
diagnosis will be required. Refer to 1981 Jeep

Some 1981 Jeep Cherokee, Wagoneer and 1Iuck models Thchnical Service Manual.
equipped with a model 219 Quadra-’frac transfer case
built prior to June 5, 1981, may develop a repetitive in
chirp noise that occurs in the 30-55 mph speed range. 2 Road test vehicle to verify chirp noise condition
30-55 mph speed range.
This noise may be caused by a rough or chipped surface
on the transfer case input gear thrust bearing race or on a If repetitive chirp noise is not evident, return
one or both of the front output shaft thrust bearing vehicle to owner.
races. b If repetitive chirp noise occurs, proceed to next
Service correction involves checking the transfer case step.
build date, verifying the chirp noise condition, and
replacing the input gear thrust bearing and race and 3 Remove and disassemble transfer case as outlined
front output shaft thrust bearings and races if neces in 1981 Jeep Thchnical Service Manual.
sary.
The following parts may be required. 4 Inspect condition of input gear thrust bearing race.
If either surface or race is rough, chipped, cracked,
Description Quantity Part No. Group pitted, or damaged in any way, discard thrust bear
ing and race and install replacement thrust bearing
BEARING KIT, and race, 8130875.
Input Thrust 1 8130875 18.812
5 Inspect front output shaft thrust bearings and races.
BEARING ASSEMBLY, If either surface of front or rear thrust bearing race
Front Output 2 8130819 18.840 is rough, chipped, cracked, pitted, or damaged in
any way, discard thrust bearings and races and
PROCEDURE install replacement thrust bearings and races,
1 Check transfer case build date stamped on identifi 8130819.
cation tag attached to rear case.
6 Assemble and install transfer case as outlined in
a If transfer case was built on or prior to June 5, 1981 Jeep Thchnical Service Manual.
1981, proceed to step 2.
b If transfer case was built on or after June 5,1981 7 Check transfer case operation to verify noise correc
and owner described some type of noise, further tion.
The following standard servicing operations and work times will apply.
YEAR AND TIME

MODEL -
CODE NUMBER LEVEL
80 81 82
ROAD TEST C 0717 0.3 G

INPUT GEAR/FRONT OUTPUT SHAFF
THRUST BEARINGS AND RACES
- REPLACE 18501 Cke-Wag-Thk G
8-Cyl. 3.3
6-Cyl. 3.7
Input gear 18.230
Front output shaft 18.366
8I-116018A/J
P1 American
Motors Sales Corporation
ServIce Engineering Department * 14250 Plymouth Road * Detroit, Michigan 48232
R1-9A
Subject: Transfer Case Output Shaft Seal Application: 1980-81 Jeep Vehicles File: CHASSIS
Leak Diagnosis Equipped with Model 219 Transfer CaselQuadra
Quadra-Trac Transfer Case Trac
No. 81-1 Feb. 23, 1981
On some 1980-81 Jeep vehicles with a model 219 5 Remove and discard transfer ease rear yoke nut
Quadra-Trac transfer case built prior to 10-28-80, the and seal washer. Use toól .1-8614-01 to hold yoke
adhesive tape strip on the vent chamber seal may while removing nut.
separate from the seal and block the rear retainer vent
passage. If the vent passage becomes blocked, pressure 6 Remove rear yoke using tools .1-8614-01, 02, 03,
buildup within the transfer case could cause lubricant to if necessary.
leak from one or both output shaft seals and be incor
rectly diagnosed as S seal problem. Model 219 transfer 7 Remove speedometer cable and adapter from rear
cases built on or after 10-28-80 have a new self adhering retainer. Discard adapter seal, it is not reusable.
vent chamber seal that does not require an adhesive tape
strip. 8 Mark rear retainer and rear case half for assembly
alignment reference and remove rear retainer
Service diagnosis and correction of a leak condition in bolts and retainer. Tap retainer with rawhide or
volves first checking the transfer case build date, replac plastic mallet to loosen and pry retainer from case
ing the vent chamber seal if necessary, and replacing using slots in retainer only.
one or both output shaft seals if diagnosis indicates this
is necessary. 9 Remove vent chamber seal from retainer interior
and clean seal mating surface in retainer
thoroughly. Clean mating surfaces of retainer and
The following parts are available and required: rear case and dry both surfaces thoroughly.
10 If diagnosis indicated that rear output seal in

retainer was leaking, remove seal and clean seal
Description Quantity Fart No. Group
bore in rear retainer thoroughly.
SEAL, Vent Chamber 1 8133748 18.000
18.000 11 Coat outer edge of replacement output seal with
SEAL, Front and Rear AR $130808 silicone sealer and install seal in retainer using
tool J-29162.
12 Install replacement vent chamber seal. Remove

seal adhesive protector strip and position seal over
PROCEDURE vent hole inside retainer. Be sure hole in seal is
aligned with hole in retainer and that length of
vent seal is parallel with front face of retainer.
Vent Chamber and Rear Output Shaft Seal 13 Coat retainer mating surface of rear case with
Replacement silicone sealer,
1 Raise vehicle on hoist. Align rear retainer and rear case reference marks
14
and install retainer on case.
2 Remove transfer case fill and drain plugs and
drain lubricant from transfer case. 15 Install and tighten retainer attaching bolts
to 23
3 Mark rear propeller shaft and transfer case yoke
for assembly alignment reference. Install rear yoke, replacement yoke seal washer,
16
and replacement nut. Tighten nut to 120 foot-
4 Disconnect rear propeller shaft at transfer case pounds 163 N.m torque.
yoke and secure shaft to underside of vehicle.
i Aanedca’ MSs Sales CovpersSn Michigan 48232

* D.troit,
Piynionth flood
5.qvIce Engin..rhle DspertnISItt * 14250 avaIlable through OW Zone otticS.
Additional copies of this bulletin are
Q1J7
CAUTION: Do not attempt to reuse the original - 2 Disconnect front propeller shaft from - and
nut This nut is a self lodcing design and should not be secure thaft to underside of vehicle.
3 Remove and discard transfer case front - nut
17 Install replacement speedometer adapter seal and and seal washer. Use tool .1-8614-01 to hold yoke
install speedometer driven gear assembly in franz- while removing nut.
fer case.
4 Remove transfer case front yoke using tools
NOTE: Do not reuse the adapter 0-ring sea4 it is design- .1-8614-01,02,03, if necessary.
ed to swell in service to provide improved sealing
qualities and could be cut or tons if reuse is attempteL 5 Remove front output shaft seal. Clean seal bore
thoroughly.
foot-pounds 24 N.m torque. 6 Coat replacement front output seal outer surface
with silicone sealer.
19 Align and connect rear propeller shaft to yoke
using assembly alignment reference markt 7 Install replacement output seal in front case bore
Tighten clamp strap bolts to 15 foot-pounds using tool .1-29162.
20 N.m torque.
8 Install front yoke, replacement yoke seal washer,
NOTE: If diagnosis indicated that thefront output shqft and replacement yoke nut. Tighten yoke nut to 120
seal ass leaking, proceed to Front Output Shaft Seat foot-pounds 163 Nm torque.
Replacement
CAUTION: Do not attempt to reuse the original -
20 Fill transfer case to edge of fill plug opening with nut It is a selfloSing design and should not be reuseeL
10W30 motor oil, API grade SF or SE.
9 Align and connect front propeller shaft to yoke
21 Install and tighten transfer case fill plug to 18 using assembly reference marks. Tighten clamp
foot-pounds 24 N.m. strap bolts to 15 foot-pounds 20 N.m torque.
22 Lower Vehicle. 10 flU transfer case to edge of fill plug bole with
10W30 motor oil, API grade SE or SF.
Front Output Shaft Seal Replacement 11 Install and tighten fill plug to 18 foot-pounds
24 N.m torque.
1 Mark front propeller shaft and transfer case yoke
for assembly alignment reference. 12 Lower vehiclt
The following standard servicing operations and work times will apply
Ott YEAR AND flME

OPEMIl DE5CP11OW
SEAL, VENT CHAMBER - REPLACE.... 18.436 18009 Cke-Wag -Trk OS OS G

Includes rear bearing retainer R & R
and rear output shaft replacement if
necessary
SEAL, FRONT OUTPUT SHAFT - 18S18 18007 Cke-Wag-Trk 0.6 0.6 G
REPLACE
S14ISIWJ
81-28
Subject: Parking Brake Lever to Equalizer Application: 1981 Cherokee, File: CHASSIS
Cable May Contact Transfer Case Wagoneer, and Truck Models With Brakes Wheels
- -
Six-Cylinder Engine and Automatic Tires

Transmission
No. 81-1 July 20, 1981

On some 1981 Cherokee, Wagoneer, and Truck models TRANSFER
with six-cylinder engine and automatic transmission, CASE
the threaded end of the parking brake lever to
cable may contact the transfer case.
Service correction involves inspecting and shortening PARKING BRAKE LEVER TO
the threaded end of the cable by approximately 112-inch EQUALIZER CABLE
if necessary. This inspection should be performed during
any normal service visit.
PROCEDURE
2 Inspect threaded end of parking brake lever to
equalizer cable see illustration.
a If there is at least 1/2-inch clearance between
cable threaded end and transfer case, lower and
b If cable threaded end is contacting transfer case
or there is insufficient clearance, proceed to step
3.
3 Cut approximately 1/2-inch from threaded end of
cable, using hacksaw or bolt cutter only see illustra
tion.
CAUTION: Do not use an acetylene torch to shorten the 1,2-INCH FROM ThREADED
cable threaded end as the cable or transfer case END OF CABLE IF NECESSARY
aluminum housing could be damaged. Useahacksawor
bolt cutter only. Parking Brake Lever to Equalizer Cable
4 Remove supports and lower vehicle. Lnspection/Modiflcation
YEAR AND TIME

COST OPERATION
80 81 52
CABLE, PARKING BRAKE LEVER TO Cke-Wag

EQUALLZER-MODIFY 8.053 8183 Trk 0.1 G
81.104-os,
Service Engineering Department * 14250 Plymouth Road * Detroit. Michigan 48232

.Aciclitional comes of this bulletin are available through your zone o/fice.
81-29
PILE: Windshield-Windows-
Jeep Body Hardware BODY-Body

General
No. 5-03-82 Oct. 8, 1982
TECHNICAL BULLETiN
PROBLEM AND Revisions made to certain parts has improved the operation
APPLICATION: of the lock button and latch on CI models with metal doors and
remote door handles, If the door handle or lock button in the
metal doors of 1981-82 CJ models require service or become
difficult to operate, use the following procedure to determine
proper servicing.
CORRECTION: Inspect and repair the door lock button and latch mechanism as
outlined in the Procedure portion of this bulletin.
PARTS: The following parts may be required.
Description Quantity Part Number Group

LATCH ASSEMBLY, 1 23.050
Front Door
Left 5758177
Right 5758176
ROD AND BUSHING ASSEMBLY, 1 per door 5758179 23.074
Outside Door Handle
CLIP, Lock Button 1 per door 4007207 23.055

Pivot Pin Retaining
S.R.T. INFORMATION;
Operation
CO. FRONT DOOR LATCH AIR 5-224 5999
ROD AND BUShING ASSEMBLIES -
INSPECT
One door 0.1
Both doors 0.2
SO. FRONT DOOR LATCH - 5-121 5999
REPLACE
One door 0.3
Both doors 0.5
continued

81-30
-2-
Operation
SO. ROt AND BUSHING 5-130 5999

ASSEMBLY, OUTSIDE
DOOR HANDLE -REPLACE
One door 0.1
Both doors 0.2
CO. CLIP, LOCK BUTTON 5-130 5999

PIVOT PIN RETAINING -
INSTALL
One door 0.2
Both doors 0.3

REIMBURSEMENT
PROCEDURE:
1. Remove the front door window regulator handle, door pull

strap, and lower trim panel.
2. Inspect the latch assembly and control rods, and the J-shaped
outside door handle rod and bushing.
a. Replace the latch assembly if damaged or if the nylon

spacer between the lock and release levers, as
shown in Figure 1, is damaged or missing.
b. If the latch control rod is bent or binding, it must

be replaced. Do not attempt to straighten it.
c. Inspect the J-shaped outside door handle rod and bushing

assembly. If it is bent or damaged, it must also be
replaced. The rod must be equipped with a solid-type
bushing as shown in Figure 2.
LATCH
ASSEMBLY
Fig. 1 - Latch Assembly Inspection
81-31
-3-
3. Install any necessary replacement components as indicated in
the previous inspection step. Refer to the appropriate Jeep
Technical Service Manual for procedures.
4. Lubricate the latch mechanism and the outside door handle

rod and bushing with Lubriplate or an equivalent lubricant.
5. Roll the front door window down.
6. Remove the remote control handle attaching screw and rock the
handle out of the door.
SOLID-TYPE
BUSHING
OUTSIDE
DOOR
HANDLE
ROD
Fig. 2 - Outside Door Handle Rod and

Bushing Inspection
7. Install retaining clip, part number 4007207, over the remote

control handle lock button pivot pin and pin boss Fig. 3.
Re sure the clip notch is fully seated on the plastic pin and
pin boss.
8. Install the remote control handle in the door and install the
handle retaining screw.
9. Install the door lower trim panel, door pull strap, and window
regulator handle if not already installed.
RETAINING
CLIP
PIVOT
PIN
Fig. 3 - Lock Button Pivot Pin Retaining 82-091-J

Clip Installation
81-32
FILE: Windshield-
Windows-Body Hardware
BODY - Body General
No. 5-02-82 Sept. 10,1984
TECHNICAL BULLETIN
PROBLEM AND Discoloration or peeling of the finish coat on wood side rails in-
APPLICATION: stalled on some 1981-82 Scrambler and Sportside Truck models.
CORRECTION: Strip and refinish both wood side rails as outlined in this bul
letin.
PARTS: Not affected.
S.R.T. INFORM&TION:
Operation
CO. WOOD SIDE RAILS -
BOTH 9-350 5999 5.1

Material allowance
for paint, sandpaper,
stripping agents, sealer
and bleach is $20.00 for
both sides

REMIBURSEMENT: a
PROCEDURE:
1. Remove the side rails from the vehicle.
2. strip the original finish from the rails using a quality chemical
stripping agent such as Savogran, BIX, Zip-Strip, or an
equivalent varnish remover.
3. sand the side rail surfaces with medium grit sandpaper to smooth the
surfaces and remove all traces of the old finish.
4. Wash the side rails with a 50/50 solution of household bleach and water
to remove and prevent mildew formation. Allow the rails to dry
thoroughly after washing.
5. Apply one or two coats of wood sealer to the side rails and allow the
sealer to dry thoroughly.
6. Repaint the decorative grooves in the side rails with an air dry-type
enamel. Have the owner select paint color if necessary.
7. Apply a minimum of two coats of an exterior grade polyurethane or

marine spar varnish to the side rails. Be sure to follow the man-
ufacturers instructions for varnish application.
a
8. Install the side rails when the varnish coats have dried thoroughly.
PU Ainerkan Motors Sales Corporation 82-079-J
Service Engineering Department . 14250 Plymouth Road * Detroit, MIchigan 48232
81-33
FILE: Windshield-Windows
fl Jeep
-Body Hardware BODY -
Body General
No. 5-01-82 Feb. 15, 1982
TECHNICAL BULLETIN
PROBLEM AI4D Power windows on some 1980-82 Wagoneer, Cherokee, and Truck models
CoRRECTIoN: Install a polypropylene wedge at each end of the door glass bottom
PARTS:
Part Description Quantity Part Number Groqp
WEDGE, Door AR 5762644 25.030

Glass Bottom
Channel

ELIGIBILITY:
550 INFORMATION:


DOOR CLASS BOflOM
INSTALL WEDGES.... 25045 Wag-Cke-Trk C
One door 0.8 0.8 0.8
Each additional
door Add
-
0.7 0.7 0.7
Replace bottom
channel Add....
- 0.2 0.2 0.2
Front 25.030
Rear 25.032
PROCEDURE:


the wedges to the bott?m of the channel as shown in the illustration.
-2-
4. Install the door glass and bott channel as outlined in chapter 3.1 of
DOOR GLASS
BOTTOM CHANNEL
SEAl.
POLYPROPYLENE
WEDGE

Subject: Improved Method For Retaining Application: 1979-81 Cherokee and File: BODY -
Electrically Operated Tailgate Glass In Wagoneer Models With 5/32.Inch Body General
Lower Channel Thick Electrically Operated
Tailgate Glass
No. 81-3 July 3, 1981
This bulletin supercedes Diagnosis and Repair Bulletin 4 Cut two 53- 112-inch long strips of sealer from roLl.
Number 9-01, filed under BODY - Body General, and Place one strip of sealer over the other with ad
dated May 15, 1979. Discard all copies of bulletin 9-01 hesive sides together to form one double thickness
and replace it with this current bulletin. strip of sealer that is 53-1/2 inches in length.
On some 1979-81 Cherokee and Wagoneer models equip 5 Position tailgate glass so bottom edge of glass
ped with electrically operated tailgate glass, the tailgate
faces upward. Support opposite edge of glass on
glass may separate from the channel. This bulletin pro
vides an improved method of retaining the glass in the cushioned surface to avoid damaging glass.
channel.
6 Remove silicone treated liner from one side of
Service correction involves inspecting the tailgate glass double thickness sealer strip.
assembly, replacing any damaged components if
necessary, installing a double coated foam tape seater to 7 Center sealer strip over bottom edge of tailgate
retain the glass in the channel, and installing a stop glass. Starting at one end, install sealer along
bumper and bracket at each side of the lower channel. entire length of glass- Be sure to keep sealer
The following parts are required and will be available centered on edge of glass during installation.
the week of July 27, 1981. Do not order parts before this
date. 8 Remove silicone treated liner from opposite side of
sealer strip and install channel on bottom edge of
Description Quantity Part No. Group tailgate glass. Press or tap channel into position
carefully. Be sure channel is fully seated before
CHANNEL, Tailgate continuing.
Glass, Lower 1 5455959 25.033
SEALER, Tailgate 9 Drill two 1/4-inch mounting holes for stop bumper
Glass 1 8130418 25.033 brackets at each lower corner of tailgate inner
BRACKET, Stop 2 959614 25.054 panel as follows:
BUMPER, Rubber Stop 2 968734 40.088
SCREW, 10-24 x 1/2" a Position right side template on driver side
Pan Head 2 G0159920 17.598 lower corner of tailgate inner panel Fig. 1.
SCREW, 1/4.20 x 3/4" Align template edges with bottom and side of
Flat Head 4 G0156253 17.586 tailgate inner panel, and tape template in place.
NUT, 10.24 2 G0271166 17.412 Mark hole locations indicated on template using
centerpunch and remove template.
PROCEDURE
b Turn template around and position left side
1 Remove tailgate glass. Refer to appropriate Jeep template on passenger side lower corner of
Technical Service Manual for procedure. tailgate inner panel. Align template edges with
bottom and side of tailgate inner panel and tape
2 Inspect tailgate glass operating components. Re template in place. Mark hole locatiorts indicated
place any components that are bent or damaged. on template using centerpunch and reMove
template.
3 Clean lower portion of tailgate glass using
isopropyl alcohol. c Drill two 1/4-inch holes at each lower corner of
tailgate at locations marked with centerpunch.
CAUTION: If the vehicle is eqzipped with a rear window
defogger, do not wipe or rub the defogger grid and do not d Remove metal chips generated by drilling
aVow the window cleaning agent to contact the grid. operations using magnet.
I Americwi Motors SSss Corporation

S.rvics Englnnrlnq D.purtm.nt . 14250 Plymouth Rood * Detroit, MIdilgan 45232
AdOitrona! copies of this bulletin are available through pour zone office.
81-36
TEMPLATE 12 Loosen original tailgate glass center stop, move
INSTALLED ON
DRIVER SIDE stop to lowest position, and tighten stop.
OF TAILGATE
INNER PANEL
13 Install tailgate glass but do not install access or

trim panel at this time. Refer to appropriate Jeep
Technical Service Manual for glass installation
procedure.
14 Lower tailgate glass and verify proper channel-to-

stop-bumper contact. Reposition nibber bumpers
as necessary to obtain proper contact.
15 Install tailgate access and trim panels.
Fig. I Positioning Template on

Tailgate Inner Panel
10 InstaU rubber bumpers on stop brackets Fig. 2.
Use 10-24 x 3/4-inch pan head screws and nuts to
attach bumpers to brackets.
NOTE: The stop bracket may have a rubber or plastic in

sert in the screw slot at the top of the bracket. Remove and
discard this inert before installing the rubber stop
bumpe’.
11 Install one bumper and bracket assembly at each

lower corner of tailgate inner panel Fig. 2. Work
through the tailgate access panel opening to install SIDE VIEW
brackets and secure brackets to panel using 1/4-20
flat head screws. Fig. 2 Stop Bumper Installation
YEAR AND TIME

OPERATION DESCRIPTION CODE NUMBER sooa LEVEL
SO SI
STOP BUMPER Assembly, 25.033 25157 Cke-Wag 0.5 0.5 0.5 C

TAILGATE GLASS INSTALL-
81-089-ESJ
81-37
SLVU IIV.L it UUd
WOLLOB HJ.IM NOI1Y
3iVldW3J.
3015 .1431
13NVd U3NNI
3iYO1IYI 40 3003
3019 HUM NOI1Y
3U3H
SB1OH %l3i.3WVIO
JII iiiua ONY
H3NflclU3.LN33
CENTERPUNCH
AND DRILL 114"
DIAMETER HOLES
HERE
RIGHT SIDE
TEMPLATE
ALIGN WITH
SIDE EDGE OF
TAILGATE INNER
PANEL
ALIGN WITH BOTTOM

EDGE OF TAILGATE
INNER PANEL
I
_______

Subject 1981 Jeep Anti-Corrosion Application: All 1981 Jeep Vehicles File: BODY
flna Body General
No. 81-2 April 29, 1981
The Jeep Corporation Anti-Corrosion Program has been 2 Clean inner surface of panel using DuPont Prep
improved and expanded for all 1981 Jeep vehicles. The Sol, Ditaler Acrylic Clean, or equivalent, and allow
program is perfonned entirely at the factory and surface to dry.
features increased use of one and two-sided galvanized
panels, electrostatically applied enamel primers, and ad 3 Apply two or three coats of Galvicon Coating over
ditional petroleum base waxes that are black, amber, or heated or drilled areas of panel inner surface as
gray in color depending on application. follows:
The types of corrosion protection used on the various a Stir Galvicon Coating thoroughly.
body componenta are outlined in the Corrosion Pro
tection Chart at the end of this bulletin. As changes or b Brush first coat of Galvicon over heated or
improvements in the corrosion protection program drilled areas of panel inner surface. Extend coat
occur, updated information will be published in bulletins ing at least three inches beyond heated or drilled
or service letters. areas of panel.
If it becomes necessary to repair or replace a body panel c Allow first coat of Galvicon to become tacky then
on any 1981 Jeep vehicle, the panel area affected must apply second coat. Be sure second coat also a-
be coated with protective materials in order to maintain tends at least three inches beyond hated or
corrosion protection. drilled areas of panel.
Service protection of a repaired or replaced panel in d If third coat of Galvicon is necessary, allow sec
volves the application of brushable Galvicon Costing and ond coat to become tacky before applying third
Jeep aerosol spray-type rustprooflng material. coat.
Whenever holes are drilled or heat has been applied to a
panel, the protective materials are removed. Galvicon 4 AJlow final coat of Galvicon to become the.ky before
Coaling must be applied to the - inner surface and proceeding.
Jeep Rustprooflng applied over the Galvicon Coating.
Jeep Rustprooflng should also be applied whenever the 5 Shake rustprooflng aerosol container to mix con
factory rustprooflng material has been removed for any tents thoroughly.
6 Hold aerosol container 1O-th-14 inches from panel

inner surface area to be coated and spray panel inner
The following parts are available and required: surface until desired coverage is achieved.
Deecriplion Quantity Part No. Group
COATING, GALVICON NOTE: Apply the njstproofing material in a coating

Iqusr AR 8130436 30.080 that is thick enough to cover the panel repair area an
RIJSTPROOFING pletely. Metal and Galvicon Coating must not show
11 oz. aerosol con- through the nistproofing coating.
CORROSION PROTECTION CHART
Component Mode! Protection
Grille Face Panel Cke-Wag-Trk One side galvanized, enamel primer
Fender Cke-Wag-Trk One side galvanized, enamel primer
Fender CS-Scrambler One side galvanized, enamel primer
Hood Cke-Wag-Thc Enamel primer
Hood CS-Scrambler Enamel primer
Cowl Cke-Wag-Trk One side galvanized, enamel primer
Jowl Cl-Scrambler Enamel primer
Front Door Hinge Pillars Cke-Wag-Trk Enamel primer, petroleum base wax
Front Door Cke-Wag-Trk One side galvanized, enamel primer, petroleum base wax
Front Door CS-Scrambler Enamel primer
Rear Door Cke-Wag One side galvanized, enamel primer, petroleum base wax
Pillars Cke-Wag-Trk Enamel primer, petroleum base wax
Roof Panel Cke-Wag Enamel primer
Drip Rail Cke-Wag One side galvanized, enamel primer
Floor Pan Cke-Wag-Trk Enamel primer
Floor Pan CS-Scrambler One side galvanized, enamel primer
Rocker Panel Cke-Wag-Thc Two side galvanized, enamel primer, aluminized wax
Quarter Panel Cke-Wag-Thc One side galvanized, enamel primer, petroleum base wax
Quarter Panel CS-Scrambler Enamel primer
Rear Wheel House Cke-Wag One side galvanized, enamel primer
Rear Wheel House Cl-Scrambler Enamel primer, petroleum base wax
Rear Quarter Extension Cke-Wag Two side galvanized, enamel primer
Tailgate Cke-Wag-Trk One side galvanized, enamel primer, petroleum base wax
Tailgate CS-Scrambler One side galvanized, enamel primer
Box Front Panel Trk Two side galvanized, enamel primer
Box Side Panel Trk Two side galvanized, enamel primer
Box Floor Panel Trk Two side galvanized, enamel primer
siai-sai
81-40
___ -- __________

Subject: New Inside and Outside Door Application: 1981 CS-? Models with File: BODY
Handles Metal Doors Body General
No. 81-1 Jan. 23, 1981

New design inside and outside door handles have been 2 Tap locks downward lightly to tighten handle.
phased into production of the metal doors used on 1981
CJ-7 models. A new design door striker and striker 3 Install lock-to-handle rod and lock pin.
mounting bracket are also used see illustration.
4 Install outer weatherstrip on top of door.
When servicing 1981 models equipped with metal doors
that have the new design door handles, refer to the 5 Position window glass in door.
service procedures provided in this bulletin.
6 Install divider bar and adjusting screws,
PROCEDURE
7 Attach window glass to regulator.
Outside Door Handle
8 Install door lock cover.
Removal
9 Install watershield paper and door trim panel.
1 Remove door handle assist and window regulator
handle, 10 Install window regulator handle.
2 Remove door trim panel and watershield paper 11 Install door handle assist.
from door.
3 Remove door lock cover attaching screws. DOOR LOCK CYLINDER
4 Disconnect lock-to-handle rod from outside door Removal

handle.
1 Remove door trim panel and watershield paper.
5 Close window completely, release spring on each
outside door handle lock and tap locks upward. 2 Remove door latch cover screws and remove cover.
6 Remove window door glass from regulator. 8 Remove retaining clip and remove lock-to-cylinder
rod.
7 Remove division channel by removing adjusting
screws. 4 Remove lock cylinder spring retainer and remove
lock cylinder and gasket.
8 Remove window glass from door.
9 Remove outer weatherstrip from door. Installation
10 Remove locks from outer door handle using 1 Install gasket and lock cylinder in door.
needlenose pliers and remove handle from door.
2 Install lock cylinder spring retainer and install
lock-to-cylinder rod and clip.
Installation
3 Install door latch cover and cover screws.
1 Install outside door handle and slide handle locks
into door handle from top. 4 Install watershield paper and door trim panel.
TI Amotican Motors Sales Corporation

48232
Service Engineering Department * 14250 Plymouth Road i Detroit, Michigan
Additional copies of this bulletin are available Through your zone office.
81.41
Door Lock Cylinder Coding 5 Install latch cover and tighten cover screws.
A lock cylinder service kit is available which includes an 6 Install watershield paper and door trim panel.
uncoded cylinder, housing, and dust cover. Whenever
lock cylinder replacement is required, the uncoded ser
vice cylinder can be coded to match the existing key. Striker Adjustment
Refer to the key coding procedure in the 1981 Jeep
Technical Service Manual. The door striker is fully adjustable and can be moved up,
down, in, or out, or shimined forward or rearward to
Door Latch and Remote Control Rod align the door.
1 Remove door trim panel and watershield paper. The door striker should be adjusted so that the door does
not bind, provides secure retention, and provides proper
2 Remove latch cover. door movement when the door is opened and closed.
3 Disconnect remote control rod and lock-to’handle WARNING: It is possible to adjust the striker so far
,rod from latch. inward that the door closes tightly but does not lock
completely. In this case, only the safety catch may be
4 Connect lock-to-cylinder rod to latch. engageL
OUTSIDE DOOR
HANDLE LOCKS
OUTSIDE
DOOR
HANDLE
UPPER HINGE
‘½,
LOOP
REMOTE
BRACKET CONTROL
ROD
WATERSHIELD
/
REMOTE
/
HANDLE
RESTRAINT cONTROL ROD
PAPER HANDLE
PIN STRAP o97
CJ-7 Metal Door Assembly Type II
81-42
YEAR AND TIME

OPERATION DESCRIPTION COST OPERATION
MODEL
HAI"lDLE, DOOR OUTSIDE -
REPLACE 23.074 28142 87 0.5 G

HANDLE, DOOR INSIDE -
REPLACE 23.058 28174 87 0.3 G

LATCH ASSEMBLY, DOOR -
REPLACE 23.050 28144 87 0.3 G

CYLINDER, DOOR LOCK -
REPLACE 23.081 23080 87 0.3 G

STRIKER, DOOR LOCK - REMOVE
AND REPLACE
Includes Adjustment 23.087 23040 87 0.2 G
S1-033-BSJ
81-43
FILE: Body/Chassis
Electrical BODY Body
-
Electrical
Ni.. 8-O5-R2 Sept. 1O 1982
TECHNICAL BULLETIN
PAEFS: Description Quantity Part Number Group
GAUGE, Oil 1 5750279 3.605

Pressure
S.R.T. INFORMATION:
Operation

REPLACE 8-352 8999 0.3

REIMBURSEMENT:
PROCEDURE:
1. Remove the original oil pressure gauge as outlined in Chapter 1L of the appro-
stallation to be sure it is one of the improved gauges. The code must be B20l
2-01-82 or later.
D foi April. The first nuaber indicates the year, which in this case is
code C217 would represent March 17, 1982 and code D208 would represent
3. Install the replacement oil pressure gauge as outlined in Chapter 1L of the appro-!
82-064-J

ServIce Engineering Department * 14250 Plymouth Road * Detroit, Michigan 45232
81-44
Subject: Air Control Cable Operation Application: 1978-81 CS-S and CS-I File: BODY
Models Heater - Air
Conditioning
No. 81-1 April 13, 1981
cable and intake duet vent operation and can also be 11 Disconnect heater control cables.
used on all 1978-81 C.J5 and CJ-7 models.
Installation
PROCEDURE
Removal
panel. Move housing away from panel and dis- evaporator housing on instrument panel.
bracket.
14 Refill radiator.
published in the appropnate SSO manual are not

ServIce Englne.ring Department * 14250 Plymouth Road * Detroit, Michigan 48232
FILE: Paint-Corrosion
Protect ion-Decals-Misc.
BODY -Instrument Panels-
Seat Assemblies
No. 9-02-82 Mar. 16, 1982
TECHNICAL BULLETIN
PROBLEM AND The odometer on some 1981-82 Wagoneer, Cherokee, and Truck models
APPLICATION: may generate a high-pitched squeaking noise that occurs only occa
sionally and at any speed.
CORRECTION: Remove the speedometer/odometer assembly and lubricate the forward

pivot bearing area of the odometer drive gear with Dielectric Com
pound, 8126688 see illustration.
DIELECTRIC AR 8126688 3.038

COMPOUND

ELIGIBILITY:
SSO INFORMATION:

Description Code Number Model -80- -81- -82- Level
GEAR, ODOMETER
DRIVE-LUBRICATE 3.505 3493 Wag-Cke-Trk 0.6 0.6 G
PROCEDURE:
1. Remove the speedometer/odometer assembly as outlined in Chapter 3C of

2. Apply Dielectric Compound to the forward pivot bearing area of the

odometer drive gear as follows: Rotate the odometer driven gear rear
ward slightly, lift the drive gear upward in its retaining slot, and
work the compound into the pivot bearing area see illustration
NOTE: The odometer drive gear forward pivot bearing area should also
be lubricated on a replacement speedometer/odometer assembly
before it is installed.
continued
81-46
-2-
3. Clean the odometer numeral wheels and speedometer face plate of any
traces of compound.
4. Install the speedometer/odometer assembly as outlined in Chapter BC of

JAPPt.Y DIELECTRIC
/ COMPOUND TO
7 FORWARD PIVOT
/ BEARING AREA
/ OF DRIVE GEAR
Odometer Drive Gear Lubrication
82-056-A/J
81.47
Subject: Driver’s Side Front Seat Application: 1981 CJ-7 Models File: BODY
Abrasion With Padded Roll Bar and Instrument Panels -
Shoulder Belt System Seat Assemblies
No. 81-2 July 15, 1981
On some 1981 CJ-7 models equipped with a padded roli 4 Install padding cover on roll bar tube.
bar and a shoulder belt system, the rear edge of the 5 Move driver seat fully rearward and check for seat-
driver side front seat back may contact the roll bar pad to-roll bar padding contact.
ding when the seat is in the full rearward position. This
could result in seat back cover abrasion. a If contact is now eliminated, install storage bag
Service correction involves removing a section of the and return vehicle to owner.
roll bar padding material and installing additional b If contact still exists, proceed to step 6.
spacers at the rear of the driver side front seat if 6 Remove Toni-head bolts that attach rear of seat
necessary. adjuster slides to seat cushion frame and remove
The following parts are available and may be required. original spacer Fig. 2. Retain original spacers but
discard bolts.
Description Quantity Part No. Group 7 Raise rear of seat and install original spacer plus
additional 3/8-inch thick spacer between each seat
SPACER 3/8" Thick, adjuster slide and seat cushion frame Fig. 2.
Cushion Frame-to-Seat
Adjuster Slide 2 5455277 29.105 8 Lower seat and install longer replacement Torx
BOLT, Cushion Frame- head cushion frame.to.seat adjuster slide bolts.
to-Seat Adjuster Slide Tighten bolts securely. Be sure spacers are pro
Torx-Head 2 4004927 29.105 perly positioned before tightening bolts.
PROCEDURE 9 Connect storage bag lower strap.
1 Move driver seat forward and disconnect storage 10 Verify correction of seat back-to-roll bar padding
bag lower strap, if equipped. contact condition.
2 Remove padding cover from roll bar tube at rear of
driver side seat back.
3 Remove 3-inch x 11-inch section of padding mat SEAT
erial from contact area using razor blade or sharp SEAT BACK
knife Fig. 1. CUSHION
SEAT
ORIGINAL
SPACER
II MODIFIED
ROLL BAR
PADDING
REMOVE 3" xli" TORX-HEAD ADJUSTING

SECTION OF SLIDE-TO-SEAT
PADDING MATERIAL CUSHION FRAME BOLT
FROM THIS AREA
Fig. 2 Installing Additional Seal Cushion Frame to
Fig. 1 Roll Bar Padding Modification Adjusting Slide Spacers

Service Engineering Department e 1425D Plymouth Road * Detroit, Michigan 48232
81-48
The following standard servicing operations and times will apply:
YEAR AND TIME

oPERATIoN DEscRIpTION COST OPERATION SKILL
CODE NUMEER MODEL LEVEL
50 51 52
PADDING, ROLL BAR COVER - MODIFY 35.261 29057 CJ-7 Od G

SPACERS, FRONT SEAT ADJUSTER
SLIDE TO CUSHION FRAME INSTALL - 29J3i 29049 CJ-7 0.2 G
81-096- B Si
81-49
________________________
Vi Jeep
Subject: Date: March 24, 1981
CJBELT Type "5" Campaign
Incorrect Rear Seat Belts May Have Been Installed Appliciliom Jeep 1981 CJ5 & CJ7
Body Instrument Panels
SCN-525 - File: and Seat Assembl ies -
This is a Type "SI’ Campaign subject to all campaign procedures and involving safety
related elements.
Some 1981 Jeep CJS and CJ7 models built between yIN’s 1JCCMB5EXBTOO6568 and
IJCBMBSA7BTOZ3742 may have been equipped with incorrect rear seat belts. The belts
may have tongue-ends only instead of a tongue-end and a buckle-end.
Service correction involves inspecting and replacing the rear seat belts if incorrect
belts were installed.
BELT, Rear Seat With Buckle AR 8130513 27.290
The zone will provide a VIN List for each dealer with any vehicles involved. However,
the campaign procedures apply to all dealers. On all undelivered, campaign involved
vehicles, the correction must be made before the vehicle is sold or otherwise put in
service.
Campaign parts can now be ordered, only as necessary, from your Zone Parts Distribution
Center. Because campaign parts supplies are limited, replacement parts are not to be
ordered for dealer stock.
PROCEDURE
1 Inspect rear seat belts, Iwo inboard belts should have buckle-ends and two
outboard belts should have tongue-ends.
a If vehicle is equipped with correct belts, return vehicle to owner.
b If vehicle is equipped with incorrect belts, proceed to step 2.
2 Remove shoulder bolts and washers that attach rear inside seat belts to floorpan
and remove arid discard belts.
Position replacement rear seat belts in vehicle.
4 Install washers and shoulder bolts that attach belts to floorpan. Tighten bolts
to 30 foot-pounds 41 N.m torque.

Servce Engineering Department * 14250 Plymouth Road * Detroit, MIchigan 48232
81-50
-2-
Alpha ServIce Year & Time Skill
beration Description Code for Claim Model -81- Level
8ELTS, REAR SEAT INSPECT
- A 83-93 0.2 G
Includes drive-in/drive-out
BELTS, REAR SEAT REPLACE IdlE
- B 0.3 G
Includes Inspection & drlve-in/
drive-out
BELTS, REAR SEAT REPLACE TWO
- C 0.3 G
Includes inspection & drive-in/
drive-out
CLAIN HAMOIING & CAMPAIGN REPORTING
Owners of record will be mailed the ASIC and Jeep combined Product Recall Campaign
Notice and Claim Form. This form is to be used in place of a warranty claim and a
campaign reporting card.
This Product Recall Campaign Notice and Claim Form is a six-part form that is prE
printed with the customer’s name and address and the campaign name and ntmiber. The
entire form will be mailed to the owner of record along with a cover letter see
Fig. 1 outlIning the defect and instructions to present the complete form to the
The six copies are:
Cover Sheet: Contains instructions for the owner and shows the dealer where
to imprint his dealer plate see Fig. 1.
CCD Copy: To be sulnitted to CCD for campaign reporting and crediting.
Factory Copy: To be used as a packing copy for returnable parts when required.
Dealer Accounting/Dealer Service/Owner File Copy: This copy is for the dealer
file.
Customer Copy: To be given to the customer as a record of the campaign service
performed.
Reply Card: To be used by the owner if ownership or address has changed.
Upon presentation of this form by an owner, the dealer should:
* Imprint the combined notice and claim form in the upper right hand corner
with his dealer plate and romove the cover sheet.
* Clete the header information boxes.
* Have the owner sign the form on the owner signature line.
* Perform the required campaign service as outlined in the DRB.
81-51
-3-
* Complete the form by entering the R.O. date, mileage and placing an X in
the appropriate alpha code box indicating the campaign service which was
performed. The alpha code, which takes the place of the cost code and
operation number, can be found on page 2 of this ORB. A sample claim Is
shown in Fig. 2.
a Sign the form in the area provided and mail the CCD copy to CCD in
Milwaukee.
In the event the owner misplaces or neglects to bring in the campaign notice and
claim form, the dealer must use a blank ASIC and Jeep Campaign Notice and Claim
Form NI 4251. Should you need fans, they are available from your Zone Service
Department.
Before providing campaign services for a vehicle where the owner fails to present
the campaign notice and claim form, the dealer must check the Vehicle Identifica
tion Number yIN against his Campaign VIN List or the total campaign VIN range
contained in the Campaign ORB to ensure the vehicle is eligible to receive campaign
services.
When using a blank form, be sure to enter the owner’s name and address, YIN, Zone
PVC and Dealer Code, campaign name or number, date of compliance and dealer’s
signature in the areas provided and X the appropriate service box as outlined in
the Diagnosis and Repair Bulletin
Based on the alpha box checked, the dealer will automatically be credited on the
mid or end-of-month memorandum of warranty transactions code 40 referencing the
claim ntinber on the form. The single credit shown will include Drive-in/Drive-out,
corresponding labor, parts cost and applicable parts mark-up.
"I
- -
ml. tla l.sa - I. scc.Snt. Ia - ‘tl’ts. t *,s.l
Inffk t41 .- ask. lfrt tL
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mtt t.lt .ul In. a. is, ,-t 5.11 t - tad.
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asia. if - - iS ml inkI. fl - I... . puss.
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-
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sews. Ildif I. -
I’d ilt iml, p14141 ‘atIlt SM Wa
5..e. 11 Sept... ,. lISt C.iI.
Istlas. 14115 fl5 5usd. t..lt. 51th14 *P31. T.1 1131
Ia-nc. Itj.. lit an. a .5434. tIlt s1 ISsue s15.1p
P5_Ilt Se I, .1 mit Serpe. _ -7 caMel S. il.r.I M*. 15*1111
1.I44p lMu.1.tstia, Sn iaa SM..t. 5.1.. S*1. s.c Ma - 1.11 5*
.i4frtf Stil.. S -4k4111 4 P.C. 1.5 .nSnt. -v
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I. ml 1sf-at at safety , cash_s .fllsfltLl.. elM 1s.
.. I -
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I.
Figure 1
Owner Notice
-4-
n C It1t EEê2" Iiao rA 106563

OEAt
PRODUCT RECALL Altec the reqpAred campaign service has beet, pedonned,
CAMPAIGN NOTICE AND please imprint your plate to the ,9’,t aid sugn the cleAn end
CLAIM FORM con’splete the applicable iWos,nation below. Allow the in ° 030180
stiuctlons in theDiagnosis aid Repair eudletin DAB lot ess
I ajthSze that the twa soda be’ campaign. Pins, be accurate aid legible siic.thetinlonna D.. Salman Ui. Spe,
pednd a., the debited W ton wifi be ised for Campaign s’epotling and creduting. Mail
vehicle. The vehicle may be operated by this claim to CCD is Miwasee. U returnable pats are RED CARPET MOTORS
you Of YCUf lot tell and involved, follow the applicable bulletin ineinjollons. 0000O NtRICA
ANYTaIN. MI 00000
See Campaign Bulletin No. 00-0000 w’M 10.00
Os..u Scnat.jr.
mMb DATE I ICIag,,lao Ivel ICVSOIIOINO lXAe,mpnasP.laosdfldn I
k
Kabsusie., C I
I
jt.s Duegnoee aw Aece. Sans
3" I "
_fvwItSnI 1065631 A 5 C 0 £ F
i
Authorized
Dealer Signature X .
‘q
Ft
/t.,_ OWNER INFORMATION
NAME Ann Osmer
This is to cenMy that the reqtired campaign seNice ha bees,
peftOmied tree o’ charge to len Gene, of the above veI*I. ADDRESS 1234 1eans Road
CITY, STATE. ZIP Aoytot.n, USA 12345
VEHICLE IDENTIFICATION NO. JOE18NN000048
Upon complebon this form should be submitted with your
Warranty Claims to CCD.
CalnpaqnNenleaiIdNo JEEPAXIE 8003
Figure 2
Sample Completed Combined Product Recall
Campaign Notice, and Claim Von
FILE: Paint-Corrosion"
protectioirDecalrflisc
BODY Headlining
- Ext.
-
Decals and Overlays

No. 9-0362 June 16, 1982
TECHNICAL BULLETIN
touches hardtop outer panel on

PROBLEM AND Hardtop inner panel headliner
a buzz or flutter noise.
APPLICATION: some 1981-82 Scrambler models causing
inner panel see

CORRECTION Drill four 1/4-inch diameter holes in the hardtop
illustration, spray an expandable foam, part number 8130438, be
install button plugs
tween the two panels to prevent touching, and
in the drilled holes afterward.
Quantit.y Part Numbe! Group,

PARTS: Description
1 8130438 30.051
TOUCH-N-FOAM
PLUGS, Button 4 8134258 28.608
WARRANTY Not affected.

ELIGIBILITY:

HARDTOP -REPAIR 28.412 28167 88 0.2 0.2 G

Material allowance
for foam is $2.40
PROCEDURE:
1. Locate, mark, and drill four 1/4-inch diameter holes in the hardtop
inner panel headliner. Refer to the illustration for hole locations.
CAUTION: Be very careful to avoid drilling through the outer panel

when drilling holes in the inner panel.
82-063-J
TI American
Service Engineering Department e 14250 Plymouth Road * Detroit, MichIgan 48232
-2-
2. Attach a three inch long section of 1/4 inch O.D. hose to the hose on
the Touch-N-Foam can.
3. Insert the 1/4-inch O.D. hose into each hole drilled in the inner
panel and spray foam into each hole for 45 seconds.
4. install the button plugs in the drilled holes.
5. Allow the foam to cure 12 hours.
WINDSHIELD
HEADER
FRONT
2"
I ¼" HOLE
I
I I 4 REaD.
I
22"
-1 $
3", t
I
HARDTOP
INNER
$ PANEL
I RISOF HEADLINER
INNER
PANEL
I
+1 :
2"-jn
I
2"
REAR
Spray Foam Hole Locations in Hardtop Inner Panel

Headliner Viewed From Passenger
-
Compartment
Subject: Hardtop Squeak Caused By Application: 1981 Jeep Scrambler File: BODY -
Access Cover Position Models Build Prior to VIN Headlining Hardtop -
IJXXXXXXXXX0TOO34 Equipped Enclosure Exterior

-
With Hardtop Decals and Overlays
No. 81-1 Aug. 10, 1981
On some 1981 Jeep Scrambler models built prior to YIN CAUTION: Do not allow the drill to penetrate any more
1JXXXXXXXXXO700S4 and equipped with a hardtop, than J/2.inch in depth
one or both of the hardtop access covers may contact the
body side panels and cause a squeak noise. 5 Install access covers in new location.
Service correction involves moving one or both access
covers upward to eliminate cover-to-body side panel con ACCESS COVER ACCESS COVER HARDTOP
tact if necessary. LEFT SIDE SCREWS
SHOWN
PROCEDURE
1 Inspect left and right side access coven to deter
mine if one or both covers are contacting body side
panels.
2 Remove screws that attach access covers to hard
top and remove covers see illustration.
NOTE; Attaching bolts are not used nor needed to anchor
the hardtop aides to the body on Scrambler models. Ifit is
discovered that bolte have been installed at the hardtop
sides after rem.oving the access covers, these bolts must be
removed.
3 Using pencil, mark position of new access cover
attaching screw holes 0.350-inch 9 mm above ex
isting screw holes.
4 Drill new access cover attaching screw holes to max
BODY SIDE PANELS
imum depth of 1/2-inch uAng 0.136-inch 3 mm
diameter drill. Access Cover Location
COST OPERATION YEAR AND TIME

OPERATiON DESCRIPTION SKILL
CODE NUMBER MODEL
LEVEL
I 51 52
COVER, HARDTOP ACCESS -
RELOCATE ONE OR BOTH 28.390 28101 88 0.1 G
51.1w-Baa

-I-.__.-a- n___ - e-I flk1 Afig
Subject: Sun Roof Glass Frame Seal Application: 1980-81 Cherokee, File: BODY
Wagoneer and Truck Models With Headlining Hardtop -
Manual Sun Roof Enclosure Exterior

-
Decals and Overlays

No. 81-2 March 2, 1981
A new sun roof glass frame seal for the pop-up sun roof 2 Apply 3M Release Agent, or equivalent, to seal and
used on 1980-81 Cherokee, Wagoneer, and Truck allow several minutes for penetration.
models has been released for production and use.
The new seal has an improved configuration for increas- 3 Apply second application of release agent to seal and
ed compression and sealing ability and entered produc- allow several minutes for adhesive bond to soften.
tion on January 5, of this year.
4 Remove seal from frame.
If it becomes necessary to replace the sun roof glass
frame seal on a 1980-81 Cherokee, Wagoneer, or Truck 5 Remove all adhesive residue from frame using 3M
model pop-up sun roof, the new seal should be used. General Purpose Adhesive Remover, or equivalent.

Installation
1 Apply thin bead of 3M Super Weatherstrip Ad-
SEAL, Sun Roof Glass 1 8133809 28.811 hesive, or equivalent, in frame channel.
Frame
2 Position and install replacement seal in channel.
PROCEDURE
3 Apply thin film of petroleum jelly to seal and glass
Removal contact surfaces.
1 Remove glass assembly. 4 Install glass assembly.
The following standard service operation and work times will apply:
YEAR AND TIME

CODE NUMBER I LEVEL
80 SI
SEAL, SUN ROOF GLASS TO 2&417 15.375 Cke, Wag, 0.4 I 0.4 I G
FRAME REPLACE
- Trk.
I
81065-B SI
Subject Hardtop Rear Window Application: 1981 Jeep FileS. BODY Metal
-
%Wter Leaks Scrambler Models With Repair Painting

- -
Hardtop Water LeakslWind

Noise
No. 81-5 Oct. 2, 1981
Some 1981 Jeep Scrambler models with a hardtop may 3 Remove old weatherstrip from hardtop rear win-
develop water leaks around the hardtop rear window. dow opening. Discard old weatherstrip.
Service correction involves installing the following new 4 Remove old sealer and any other residue from
weatherstrip to correct a water leak condition, edges of glass and rear window opening.
The following part may be required: 5 Install new weatherstrip in rear window opening
with aid of helper. Be sure weatherstrip locking
- seam faces rear of vehicle.
6 Prepare and apply solution of liquid detergent
WEATHERSTRIP, and water to glass channel portion of new
Hardtop Rear Window 1 5761760 28.587 weatherstrip.
7 Install rear window glass in new weatherstrip.

PROCEDURE Start one end of glass into weatherstrip channel
and work remaining portion of glass into weath
1 Verify and pinpoint water leak using procedures erstrip channel using wood or plastic tool.
outlined in Chapter 3A of 1981 Jeep Thchnical
Service Manual. 8 Close weatherstrip locking seam using wood or
plastic tool. Start at corners and sides first; then
2 Remove hardtop rear window glass from weath- close top and bottom seams.
erstrip by gently pushing against corner of glass
from inside vehicle until glass begins to separate 9 Water test rear window to verify water leak
from weatherstrip. Complete glass removal by correction.
carefully pulling glass outward until completely
free of weatherstrip. 10 Clean rear window glass and surrounding area.
VEARANOTIME
OPERATION SKILL
OPERATION DEscRIPTION MODEL LEVEL
82
WEATHERSTRIP, REAR
WINDOW GLASS REPLACE
- 25.028 25121 88 0.6 6
5i-ii7-BSJ

Service Engineering Department . 14250 Plymouth Road * Detroit, MichIgan 48232
81-58
Subject 1981 Phase-Out/1982 Phase-In Application: 1981 Jeep Vehicles File: BODY -
Program Pain t Information Metal Repair -
Painting Water
-
Leaks/Wind Noise
No. 81-4 July 30, 1981
As part of the 1981 Phase-0ut11982 Phase-In Program, six new 1982 colors may be used on 1981 Jeep vehicles.
They are:
1982 Paint Code Color
2A Mist Silver Metallic

2B Sun Yellow
2C Slate Blue Metallic
2D Deep Night Blue

2H Topaz Gold Metallic
2J Jamaican Beige
NOTE: Some intermix jbrmulaa are marked N/A because they were not available at time ofpublication. Contact
your local paint jobber for information not contained hereit
MIST SILVER MIST SILVER MIST SILVER MIST SILVER

DAR 3466 35-32385 DDL 3466 34-32385
DM.R 450 6 F5W-80 3.6 DMA 311 10 L4L-315 1.1
DMR 414 32 F5L-68 7.2 DMA 346 20 L4M-321 3.2
DMR 431 242 F5T-92 12.1 DMA 321 30 L4W-301 6.4
DMR 433 642 V6V-175 57.0 DMA 312 120 L4L-305 9.6
DXR 495 662 P55-69 901.0 DMA 323 300 L4S-316 124.0
DMR 499 1002 DMA 310 980 L4S-350 368.0
T1C-324 878.0
PU Ameñcan Motors Sales Corporation

81-59
SUN YELLOW SUN YELLOW SUN YELLOW SUN YELLOW
35-32257 DDL 3481 34-32257
F5B-81 1.7 DMA 346 26 L4R-304 Gd
N/A F5E-84 21.4 DMA 356 76 L4W-301 440.0
F5Y-89 112.0 DMA314 126 L4Y-303 924.0
F5Y-93 445.0 DMA 382 636
V6V-175 490.0 DMA 311 1056
F5W-80 979.0
SLATE BLUE SLATE BLUE SLATE BLUE SLATE BLUE

MATALLIC METALLIC METALLIC METALLIC
DAR 3468 35-32283 DDL 3468 34-32283
DMR 401 80 FSR-100 28.6 DMA 357 4 L4M-318 29.4
DMR490 180 F5W-80 64.7 DMA375 27 L4W-301 98.4
DMB 433 384 F5L-68 169S DMA311 66 L4L-309 176.2
DMR 414 814 F5B-81 317.0 DMA358 140 L4B-302 296.0
DXR 495 834 V6V-175 362.0 DMA321 292 L4S-316 590.0
DMR499 1034 F55-74 905.0 DMA 386 820 T1C-324 88&0
DMA 310 990
DEEP NIGHT BLUE DEEP NIGHT BLUE DEEP NIGHT BLUE DEEP NIGHT BLUE
DM1 3469 35-32251 34-32251
DMR 401 36 F5R-100 17.6 L4W-301 27.5
DMR 490 202 F5W-80 43.4 N/A L5B-320 60.8
DMR 450 582 F5B-81 155.0 L4Y-334 270.0
495 602 F5Y72 284.0 L4L-313 892.0
DMB 415 1022 V6V-175 329.0
F5L-94 915.0
TOPAZ GOLD TOPAZ GOLD TOPAZ GOLD TOPAZ GOLD

DAli 3471 35-32386 DDL 3471 34-32386
DMR 482 280 FSB-81 51 DMA311 4 L4W-301 3.5
DMR 476 750 F5E-84 3&6 DMA386 18 L4B-302 8.2
DXR 495 770 F5N-76 87.0 DMA 383 124 L4E-306 58.9
DMR 433 1030 F5S-101 188.0 DMA312 318 L4S-316 117.9
F5Y-72 494.0 DMA 384 720 L43-335 212.1
V6V-175 539.0 DMA 310 980 T1C-324 448.0
F58-74 91L0 L4Y-334 884.0
81.60
JAMAICAN BEIGE JAMAICAN BEIGE JAMAICAN BEIGE JAMAICAN BEIGE
DM1 3472 35-32243 DDL 3472 34-32243
DMR 490 6 P5B-81 13.4 DMA 392 15 L48-320 6.6
DMR 476 70 F5E-99 29.6 DMA 346 69 L4R-804 17.0
DMR 486 250 F5Y-93 148.0 DMA 393 289 L4Y-303 166.0
DM11 400 760 V6V-175 193.0 DMA 311 1049 L4W-301 944.0
DXR 495 780 F5W-80 1000.0 DMA 310 1099
DM11499 1220
S1-11O-BSAFJ
81-61
P1Jeep

Subject: Paint Peeling Off Road Wheels Application: 1981 Jeep Vehicles File: BODY
Built Between YIN 1JXXXXXXX Metal Repair -
XX015701 and YIN 1JXXXXXXX Painting Water

-
XX042000, and Equipped With Leaks/Wind Noise

Painted-White Road Wheels
No. 814 June 12, 1981
On some 1981 Jeep vehicles built between YIN 1JXXX- 4 Remove wheel balance weights from wheels. Tag
XXXXXXO157O1 and YIN 1JXXXXXXXXXO42000, weights for installation reference.
and equipped with painted-white road wheels paint code
Al - snow white, the white paint may not adhere pro 5 Using sand blasting equipment, remove all paint
perly and begin peeling off the wheels. This condition and primer from both sides of each wheel.
may occur on one or on all of the vehicle road wheels.
6 Inspect wheels to make sure all traces of paint and
Service correction involves sand blasting to remove the primer has been removed. Only bare metal should
original enamel paint and primer and applying a new be visible. Clean wheels thoroughly to remove all
coat of epoxy primer and acrylic enamel color coat to the sand blasting residue.
wheel.
The required epoxy primer and white acrylic enamel 8 Apply Ditzler Metal Prep 79 DX-579, or equiv
paint code Al code numbers for each manufacturer are alent to both sides of wheels according to
as follows: manufacturer’s instructions.
Code
Manufacturer Paint Type Number 9 Mask both sides of tire carefully to avoid paint ad
hering to tire.
DuPont Color Coat 5213
Epoxy Primer 8255 10 Mix epoxy primer and activator according to manu
Activator 8268 facturers instructions and apply to both sides
of wheels.
litzler Color Coat DAR 2265
Epoxy Primer DP 40 11 Mix Acrylic enamel color coat according to manu
Activator DP 401 facturers instructions.
Sherwin-Williams Color Coat J3-3679 12 Apply enamel color coat to both sides of wheels and
allow to air dry.
PROCEDURE
13 Remove masking material from tire surfaces.
14 Install wheel balance weights at marked locations.
2 Remove all five wheels from vehicle.
15 Install wheels on vehicle.
3 Mark size and location of wheel balance weights on
tire using grease pencil. 16 Remove supports and lower vehicle.
YEAR AND liME

CODE NUMBER MODEL LEVEL
-
so ii u
BASIC PAINT - PREPARATION 21701 0.4 G

WHEELS, SET OF FIVE -
STRIP AND PAINT 21.835 21713 4.4 G

Material allowance $24.50
Fl American Motors Sales Corporation 81-082483

81-62
-
:LsFi
- - --
Fl trcep1

Subject Water Leak or Wind Noise Application: All 1980-81 Jeep File: BODY
Recuanaended Sealing Producta. Vehicles Metal Repair -
Painting - Water
Leaks/Wind Noise
- No. 81-2 Jan. 21, 1981

Some 1981 vehicles may exhibit some water leak and The following chart describes some of these typical
wind noise problems. Locating the leak can be water leak and wind noise areas and recommended pro-
accomplished by following the test procedures described ducts which can be used to seal these areas.
in chapter 3A of the Technical Service Manual.
Water Leak or Wind Noise Recommended Sealing Products

Body _, Stw
Wdd ws Joiws Fb& p, ‘_
Bn HdSS M as Pt.g k st-,n,s s,i r. . SW
sn - s wa.,a .
3M Products
&ushtleSeanset S * * a
Jofl aid Sean Sear S S S
All-Around Auto Body Sealant S S S
Ej, Check Set S S
-y CS * S S S
ftab Bedthig aid aazuig Ccxd S
W Set S
Rese S S
Kant industdus Products
aa th check . S S S S
Ses-aSean a S
averses S
We’JThy Resesait . a
LaSSeS
Maibc S *
LApS Hitter S
8ethkig aid azit Compo.aid S
81-036-BSAJJ
Fl Aanehcai Motors Sales Corporation

Service Enghwerlng Dsponnient * 11250 Plymouth Rood * Detroit. MIdilgon 48232
Additional copies of this bailetin are available through yaw zone office.
81-63
SCN 114

File: BODY
Metal Repair
Paintintwater Leaks/
Wind Noise
No. 81-1 Oct. 24, 1980
Attached is the 1981 Dupont color chart. Color names quantities. If additional quantities are required,
and code numbers are included in each chart. This contact your Field Service Manager or District
bulletin is being sent to all Jeep dealers in limited Service Manager.
81O14-21A/J
Amvmow
a
[AMERICAN MOTORS
‘ CORPORATION
CONCORD EAGLE *
SPIRIT * JEEP
EXTERIOR COLORS
* Code caliMi’ Mfr. Code cEMMI’ DIOUIP Mfr. Code ixnr CEJIIMt° Dour
Usage and Color Coot CoOt Usage end cODE coot tOOt Usage and Color coot coot
P1 OM IH r
$ Black S Dark Brown Met. i Chestnut Brown Met.
Black I Dark Brown Met.
C Black C Dark Brown Met.
i Black j Dark Brown Met.
99 is 93X5 asia uou lieu
8c ii
$ Quirksiluer Met. Montana Blue S Vintage Red Met.
C Quicksdvec Met. F Vintage Red Met.
C Quicksilver Met. C Vintage Red Met.
Vintage Red Mel.
45504 45104 45104 cites wee csise C8194 CiteS Cliii
9B lB 1K
$ Olympic Vfliite S Moonlight Blue S Deep Maroon Met.
Olympic White C Moonlight Blue F Deep Maroon Met.
C Olympic White C Mooailigtnt Blue C Deep Maroon Met.
i Olympic Vflnete Moonlight Blue Deep Maroon Met.
45701 45701 45702 Cliii C$191 Cliii csiei citti cliii
OD ic 11
S Medium Blue Met. S Sherwood Green Met. S SteelGray Met.
Medium Blue Met. F Sherwood Green Met. F Steel Gray Met.
C Medium Blue Met. C Sherwood Green Met. C Steel Gray Met.
Sherwood Green Met. Steel Gray Met.
Cain li92 S192 cuss cites csiis
OK lD 1M
S Cameo Tan S Autumn Gold S Oriental Red
E Caneolan I Autunin Gold C Oriental Red
C Comeolan C Autumn Gold C Oriental Red
I CameoTan Autumn Gold Oriental Red
ciiii c5193 cl193 cites CuSS Cliii
01 lE
S Medium Brown Met. $ Copper Brown Met.
Medium Brown Met F Copper Brown Met.
C Medium Brown Met. C Copper Brown Met.
Copper Brown Met
51037 05W 510*7 cuss csisi ciiS
AMERICAN MOTORS CORPORATION
1978
Mfr p. tacitc C.u,r Oiler Mfr. Paint lacitE Cantad’ tuluC
&s Cio. Code Cede Cede Code tiler Cede Cede Cede
Pt Black 99 99 93-005 Ill Midnight Blue Met. 44193 44193 44193
V Alpine White 43499 43499 43499 71 Loden Green Met. 44i94 44194 44194
SD Sandlan 44121 44121 44111 iN GoldetiGingerMet. 44195 44195 44195
6p FirecrackerRed 44116 44116 44116 7W CaptainBlueMet. 44097 44197 44197
SR Brilliant Blue 44217 44!!? 44117 77 Sun Orange 44199 44199 44199
SY Sunshine Yellow 44219 44119 44119 5* Khaki 45103 45103 45103
lB Mocha Brown Met. 44191 44191 44191 50 British Bronze Met. 45102 45102 45102
7C Autumn Red Met. 44793 44793 44793 IC Quicksilver Met. 45104 45104 45104
10 Powder Blue 44192 44192 44192 SD Claret Met. 45200 45100 45100
1979
hi Paint Laacitr Cuutad DIU Mi. Pilot Lathe D.iliC
ted. Color Uuee Cede Code Cede Cede Color llue Cede Code I Cede
P2 Black 545J 99 99 93-005 Si Arrowhead Silver Met. j 45106 45706 45106
OP Firecracker Red S-C-P-i 44116 44116 44116 SE Sable Brown Mel. S-C-P-i 45707 45707 45707
IA Khaki S-C-P 45103 45103 45103 SL Saxon Yellow SCP1 45708 - 45708
It British Bronze Met. SC-P 45102 45102 45102 SM Starboard Blue Met, SC-P 45709 45709 45709
IC Quick Silver Met. S-C-P 45104 45104 45104 itt Morocco Buff SC-P-i 45710 45710 45710
5* AlpacaBrownMet. S-C-P-i 45700 45700 45700 * BordeauxMet. S-C-P-i 45711 45721 45111
98 Olympic White S-C-P-i 45701 45101 45701 ST Ensign Blue J 45113 45713 45713
SC Russet Met. S-C-P-i 45702 45702 45702 SW Mandarin Orange 1 45714 45714 45714
*jiajoodBlui S-C-P-i 45704 45704 45704 57 Misty Beige Met. CCiCC P 45850 45850 -
Cumberland Green Met SC-P-i 45705 45705 45705
1980
Lacltfl CeMnte Det° MkPalt LucitE Ceotan Oiler
Cede Cole. Mug. Cede Cede Cede Code Cdii Usage Cede Code Code
*PT Black S-C-P-C-i 99 99 99 5 Med. Blue Met. S-C-P-C 88083 B8083 B8083
SC Quick Silver Met. SE-P-C 45104 45104 45104 tIC Ok. Green Met. C-I B8084 B8084 B8084
9A Alpaca Brown Met. i 45700 45700 45700 014 Navy Blue SE-P-C-i B8085 88085 B8085
98 Olympic White SEP-C-i 45701 4570! 4570! Oi Teal Blue i 8809! 68092 6809!
jff Rusaet Met. S-F-P-C-i 45702 7Oi 45702 OX Cameo Tan S-C-P-C-i 88086 68086 68086
SI. Saxonyellow S-C-P-C-i 45708 45708 45708 Med. Brown Met. S-C-P-C 68087 1äOF 087
SP Bordeaux Met. S-F-P-C-i 45711 4571! 45712 ör Ok. Brown Met. SE-P-C-i 88088 ëäO 88088
97 Misty Beige Met. C/C P 45850 45850 - OP Cardinal Red S-C-P-C-I B808ifB8089 88089
00 Smoke Gray Met. C-i B808! 8808! 88081 OR Caramel S-C-P-i 88090 B8090 88090
OC Cameo Blue S-F-P-C
KEY S-Spirit C-Concord, P-Pacer, I-ieep
68082 B8082 88082
f’
I
INTERIOR COLORS 1981 AMERICAN MOTORS CORPORATION

STRIPING COLORS
urn.
PAINT STOCI
CODC cOLOR NUMBER
P38 Nutmeg C8185
P84 Red Gold B8095
R40 Black 99
R80 Blue 43688
SCN 115

Subject: Interior Wind Noises Application: 1980-81 Cherokee, File: BODY
Wagoneer and Truck Models Metal Repair
Paint-Water
Leaks/Wind Noise
No. 80-3 Oct. 9, 1980

Some 1980-81 Cherokee, Wagoneer, and Truck models 5 Repeat sealant application on opposite front
may develop an interior wind noise or air leak that door division channel.
may be the result of air entering the vehicle in the
following areas:
* Front Door Division Channel
* Intersection of Cowl-A-Pillar-instrument Panel
* Holes in Inner Cowl Panels
Service correction involves performing the repair

procedures outlined in this bulletin at each of these
areas.
Description Quantity Part No. Group DIVISION

CHANNEL
BUnON, Plug 3 4001716 27.038
TOUCH-N-FOAM AR 8130438 30.051
GASKET-IN-A-TUBE AR 8993317 15.260 81181
PROCEDURE FigA
Front Door Division Channel

Intersection of Cowl-A-Pillar-instrument Panel
Noise from this area can be isolated by using a
stethoscope placed along the rolled edge of the An air leak at this area can be detected from inside
division channel inside the vehicle during road testing. the vehicle using a stethoscope placed at the lower
corner of the windshield at both A-pillars during
1 Insert small flat blade screwdriver in gap between a road test. In severe cases, an air leak can be detected
rolled section and fiat section of front door division by placing a hand in the windshield lower corner area
channel. Insert blade at top and bottom Fig. 1, and to feel the air flow.
open gap slightly to allow application of sealer.
1 Raise hood.
2 Apply black silicone sealer, Gasket-In-A-Tube,
or equivalent, along gap in division channel. 2 Using grease pencil, place mark on both outer
cowl panels 1-inch below horizontal flange and 5/8-
3 Remove screwdriver. inch outboard of vertical flange Fig. 2.
4 Wipe off excess sealer. 3 Centerpunch and drill 1/2-inch diameter hole in
each panel at marked locations.
NOTE: Steps 1 through 4 are to be performed on
both the inside and outside surfaces of the division 4 Shake Touch-N-Foam container and install
channel. nozzle and tubing on container.

S.rvlc. Enginoring Dpartm.ns * 14250 Plymouth Road * D.trolt, MIchigan 48232
Addhonal copies of this bulletin are available through your zone oMits.
81-68
_______
DASH PANEL Holes in Inner Cowl Panels

HORIZONTAL The inner cowl panel holes may produce a draft on
the driver and passenger’s legs rather than an actual
wind noise. This condition can be detected by a visual
inspection.
1 Open driver’s side door and view inner cowl

panel through upper hinge pocket in area where in
strument panel lower attaching bolt is located Fig. 3.
2 Locate weld nut hole in cowl panel that is
approximately 3-inches above and 1/2-inch to rear
of instrument panel lower attaching bolt Fig. 3.
OUTER COWL PANEL

3 Plug weld nut hole using 3M Strip-Caulk or
equivalent.
4 Plug 1/2-inch hole in inner cowl panel located
FLANGE above parking brake assembly. Plug hole using button
plug Fig. 3.
OUTER
COWL PANEL 5 Repeat steps 1 through 3 on passenger side
inner cowl panel.
Fig. 2
NOTE: The passenger side inner cowl panel has only
5 Turn Touch-N-Foam container upside down and one hole in it.
make trial application of foam on section of cardboard
or newspaper. INSTALL STRIP CAULK HERE DRIVER’S SIDE
INNER COWL
6 Insert container tube into holes drilled in cowl At’PANEL
panels until container tube contacts A-Pillar.
INSTALL BUTTON
PLUG HERE
7 Pull tubing out approximately 1-inch, aim for
A-Pillar, and press and hold nozzle for 8 to 10
seconds. /
8 Release container nozzle. Allow few seconds for
foam to stop flowing from container tube before
removing tuoe.
9 Repeat steps 6 through 8 on opposite outer

cowl panel.
NOTE: Uncured foam may be removed from painted
surfaces by carefully wiping the area with lacquer
thinner or an equivalent solvent.
10 Install button plugs in holes drilled in outer
cowl panels.
11 Close hood.
12 Allow foam to cure for 1-1/2 hours; then road

test vehicle to verify noise correction.
13 Remove excess sealer that may appear in lower
corner of windshield weatherstrip after foam has
cured. Use razor blade or similar tool to remove
excess sealer. Fig. 3
81-69
The following standard servicing operations and work times will apply;
YEAR AND TIME
cosi OPERATION MODEL
SKILL
OPERATION DESCRIPTION CODE NUMBER
-
LEVEL
80 81 82
CHANNEL, FRONT DOOR DIVISION -
SEAL 23.118 25011 10-20 0

Both 0.2
PANELS, COWL SIDE SEAL - 20.155 20121 10-20 0.2 0
COWL-A-PILLAR-INSTRUMENT PANEL
INTERSECTION SEAL - 20.195 20135 10-20 0.2 0
8O-149.BSJ
Sprvinn Tarhnirnl
w -- - * u*u
w
I altar
ttU *
IFu1eS0MceGeI%
No.81-18 Aug. 24, 1981
Subject Information
Revision to Diagnosis and Repair The amserv tool number used for the new voltage
Bulletin Number 81-1, New Voltage regulator tester has been revised. The revised
Regulator Tester, Dated June 11, tool number for the voltage regulator tester is
1981, Filed Under POWER PLANT - AllOT ET-401. Tool number 0T6O884 is a general
Engine Electrical. number for the tester adapter harnesses. Refer
to your new amserv catalog for specific harness
numbers. Please note this revision on your
Service Technical Letter [Fl
kg.
eMceGeneral
81-17 July 17. 19811
1
Subject Information
Oil Pump Release Relief Valve The diameter of release relief valve plunger,
Plunger - Six-Cylinder Oil Pump- part number 3241676, described in Service Tech
Revision to Service Technical nical Letter 81-15 has been changed. The new
Letter 81-15 Dated May 19, 1981 diameter for this plunger is 0.575 0.576 inches.
-
Please note this change in your copies of Service

Technical Letter 81-15.
Fabric Top Kit Components 1981

- The fabric top kits supplied with some of
Scrambler Moedis Built Between the subject 1981 Scrambler models may have
VIN 1JXXXXXXXXXO4O7I1 And contained incorrect components. These kits
yIN 1JXXXXXXXXXO63I79 Equipped may have included the horizontal support
With Fabric Top And Fabric Doors. rod sockets used with metal door installa
tions, instead of the combination horizon
tal support rod bracket/door seal assem
blies that are required on models with
fabric doors. These components are identi
fied in the instruction sheets supplied
with every top kit.
If horizontal support rod sockets, part

numbers 5754693 left side and 5754694 right
side have been installed, they should be
replaced with the combination horizontal
support rod bracket/door seal assemblies,
part numbers 5458874 right side and 5458875
left side.
PU American Motors Sales Capcration

81-72
Service Technical Letter INo.81-16
15,
June 19811
Subject Information
Plastic Front Frame Crosamember Because the holddown chain hooks used for shipping
Cover Attachment 1981 CJ Models
- could damage the plastic front frame crossmember
cover if the cover is fully attached, the two
cover rear attaching screws are not installed
during production. Instead, these screws are
placed in the vehicle glove box and are to be
installed at the dealership during pre-delivery.
Delco Air Conditioning Compressor NOTE: The following specification applies only
Mainshaft Rotating Torque when the compressor is off, not under load, and
Specification - 1981 Jeep Vehicles when there is no pressure in the system.
The mainshaft rotating torque for Delco air

conditioning compressors used on 1981 Jeep vehicles
should not exceed 10 foot-pounds 14 N.m torque.
This torque should be checked after overhaul to
verify correct repair and before replacing any
Delco compressor suspected of a seized condition.
In addition, before checking mainshaft rotating
torque, it is important that the mainshaft be
rotated approximately two complete revolutions to
be sure of an accurate torque reading.

81-73
ljjle Service General
Service Technical Letter INo. 8115 19, 1981
Subject Information
Oil Pump Release Valve Plunger - Two different diameter release valve plungers
1981 Six-Cylinder Oil Pump are used in 1981 six-cylinder oil pumps. Release
valve plunger, part number 3188661, is 0.560 -
0.561-inches in diameter and release valve

plunger, part number 3241676, is 0.570 0.571 -
inches in diameter. If it becomes necessary to

replace the release valve plunger in a 1981
six-cylinder oil pump, be sure to install the
correct diameter plunger.

81-74
Service Technical Letter trtTt9j
StiWect Information
Revision to 1981 Six-Cylinder The flow rate specifications for 1981 six-cylinder
PCV Valve Specifications PCV valves have been revised. Please change the
PCV valve flow rate information for six-cylinder
engines on page 1J-80 of your 1981 Jeep Technical
Service Manual and page 103 of the 1981 Jeep
Service Specifications Handbook to read as follows:
Engine Manifold Vacuum Air Flow

in Hg. kPa CR1 Liters/Second
High Limit Low
16 54 0.2 0.094 0.0 0.0
11 37 2.0 0.943 0.90.424
5 17 2.5 1.18 1.50.108
PU Amedcan Motors Sales Corporation

‘Ufl
S.eaice E,1’edug Dept. * 14250 Plymouth Rd. * Detrot, MISt.
Additional copöes of this letter we available through your zone office.
81-75
PU Jeep.

Subject: New Model Information Application: 1981 Jeep Scrambler File: Service General
No. 81-13 April 23,1981
GENERAL
This bulletin is being issued as a supplement to the 1981

Jeep Technical Service Manual and provides general
data, specifications, power train combinations, optional
equipment availability, and servicing procedures unique
to the new 1981 Model 88 Jeep Scrambler.
BODY/POWERTRAIN STANDARD FEATURES

The Scrambler is a 103.5-inch wheelbase, half-cab,
sport/utility vehicle with a truck-type cargo box at the
rear. Four body versions are available which are: a base
model with open top configuration, a fabric top model
with metal doors Fig. 1, a fabric top model with fabric
doors, and a hardtop model with metal doors Fig.2.
Fig. 2 Scrambler Model 88 -
Fabric Top with Metal Doors
The standard powertrain for Scrambler models is the

151 CID four-cylinder engine, SR4 four-speed manual
transmission, 3.54 ratio axles 49-State or 3.73 ratio
Axles California, and the model 300 transfer case. A
six-cylinder engine, model 904 or 999 automatic
transmission, different ratio axles, and a Trac-Lok rear
axle differential are all available as options. Refer to the
Powertrain Combination Chart in this bulletin for stan
dard and optional powertrain combinations.
The Scrambler frame utilizes new one-piece side rails

and an additional crossmember at the rear of the vehicle
for increased strength and frame stiffness. The extend
ed one-piece body side panels are flanged for increased
strength and stiffness also. In addition, the truck-type
Fig. 1 Scrambler Model 88 - cargo box features symmetrical interior wheel well
Hardtop with Metal Doors housings for maximization of cargo space.

Service Engineering Doportmsnt * 14250 Plymouth Road * Dtrolt, MIchigan 48232
Additional copies 0/this bulletin are available through your zone off/ce.
81-76
A half-cab back panel, steering damper and stabilizer speed manual transmissions or the optional model 999
bar, three-inch diameter roll bar, and tailgate mounted automatic transmission. All transfer case and transmis
swing-away spare tire are all standard equipment on sion models available in the 1981 Scrambler are the
Scrambler models. The roll bar is painted to match body same as those used in current 1981 CJ models. Refer to
color. The spare fire mount is similar to the swing-away the 1981 Jeep Technical Service Manual for all servicing
unit used on current CJ models Fig. 2. However, a dif procedures.
ferent upper hinge and latch reinforcement is required
for the tire mount to accomodate the cargo box corner AXLES/FRONT HUBS
inner panel that is unique to Scrambler models.
Scrambler models are equipped with the same Dana
model 30 front axle and AMC/Jeep rear axle that are
OPTIONAL EQUIPMENT used on 1981 CJ-5 and CJ-7 models. Refer to the Power-
train Combination Chart for standard and optional
A full range of optional equipment is available on ratios and to the 1981 Jeep Technical Service Manual for
Scrambler models. These include cargo box wood side all Axle servicing procedures.
rails, high-back bucket seats, air conditioning, AM]FM
stereo radio, tachometer and clock, two trim options WHEELS/TIRES
which are the SR and SL sport trim packages, a chrome
or painted rear step bumper, floor carpeting, power The standard wheelitire combination for Scrambler
steering and brakes, free-wheeling hubs, a cold climate models consists of a 15 x 5.5 steel road wheel and
group, optional wheel and tire combinations, and an op H78-15 polyester bias-ply tires. Styled steel wheels are
tional soft top or molded fiberglass hard top with metal available as an option along with a number of different
doors. Refer to the Powertrain Combination Chart in tire sizes and types including radial tires. Refer to the
this bulletin for optional engineltransmissionlaxle Tire Inflation Pressure Chart in this bulletin for
combinations. available tire/wheel sizes and recommended inflation
pressures.
FUEL SYSTEM
SERVICE PROCEDURES
The Scrambler fuel tank is similar to the unit used on
current CJ-7 models and is rear mounted in the vehicle This bulletin provides the service procedures that are
as is the fuel filler opening. The standard Scrambler fuel unique to 1981 Scrambler models. Refer to the 1981
tank capacity is 15 gallons. The remainder of the Jeep Technical Service Manual for all other specifica
Scrambler fuel system components are similar to those tions and service procedures.
used in current CJ models.
Fabric Top Installation
BRAKES This procedure outlines the method for installing a new
fabric top on Scrambler models that were not originally
The brake system and components used on Scrambler equipped with a fabric top open body configuration.
models are the same as used on 1981 CJ-7 models. Refer The procedure applies to models with metal or fabric
to the 1981 Jeep Technical Service Manual for all ser doors. On models that will be equipped with fabric doors,
vicing procedures. refer to the Fabric Door Installation procedure that
follows this procedure.
ENGINES
1 Position windshield as shown in figure 3.
Two engines are available in Scrambler models. These
are the 151 CID four-cylinder engine which is the stan 2 Align and center fabric top front former on top-
dard engine and an optional 258 CII six-cylinder front surface of windshield frame Fig. 4. Be sure
engine. These are the same engines used in current 1981 forward edge of former is flush with forward edge
CJ models. The emission control systems and com of windshield frame.
ponents used with these engines are also the same as
used in current CJ models. Refer to the 1981 Jeep
Technical Service Manual for four- and six-cylinder
engine servicing procedures.
TRANSMISSION/TRANSFER CASE
The model 300 part-time, four-wheel drive transfer case

is used in all Scrambler models. The SR4 four-speed
manual transmission is the standard equipment
transmission for all four-cylinder Scrambler models with
the model 904 automatic transmission available as an
option. Scrambler models equipped with the optional
six-cylinder engine will use either the T-176 or SR4 four- Fig. 3 Positioning Windshield
81-77
FRONT
FORMER
HORIZONTAL
SUPPORT
ROD REAR
BOWS
uio-ie x WiG
SCREW
‘ ‘.
I’ "
I
STORAGE
#8 x 112 POUCH
SCREW
#8 x 318
SCREW
SNAP
STUD 15
VERTICAL REAR BOW
SUPPORT
SUPPORT SOCKET 2
ROD 2
Fig. 4 Fabric Top Frame Components
3 Using front former as guide, centerpunch and drill 8 Position one footman loop on top center of back
seven 1/8-inch diameter holes in windshield frame panel. Using loop as guide, centerpunch and drill
for front former attaching screws. 5/32-inch diameter hole in panel and attach loop to
panel using number 10 x 1/2 self-tapping screws
4 Install and tighten front former attaching screws Fig. 4.
to 19 inch-pounds 2 N-rn torque.
9 Attach storage bag Fig. 5 to footman loop just
5 Install horizontal support rod sockets at upper left installed. Mark and drill holes for remaining foot
and right corners of windshield frame Fig. 5. Use man loops. Attach ioops to back panel and attach
sockets as guides and centerpunch and drill three storage bag to loops.
1/8-inch diameter holes in windshield frame for
socket attaching screws. Attach sockets to frame
using Number 10 x 1/2 self-tapping screws. NOTE: The storage bag is designed to contain the fabric
top plus all of the top support hardware.
6 On models with metal doors only, enlarge 1/4-inch
holes in body sides for vertical support rods. Holes
are located in top edge of body side panel behind
door opening. Enlarge holes to 3/8-inch diameter. 10 Assemble and install rear bow halves in bow sup
port sockets.
7 Install rear support sockets on body sides at cab
lower back panel Fig. 4. Use brackets as guides 11 Install bow pads on horizontal support bow rod
and centerpunch and drill 5/32-inch diameter holes halves and assemble both rods Fig. 4.
in body sides for support socket attaching screws.
Attach sockets to each side of body using number 12 Install vertical support blades on vertical support
10 x 1/2 self-tapping screws. rods Fig. 4.
81-78
22 Install fabric top snap studs at windshield corners.
Stretch top over corners, mark stud locations and
centerpwwh and drill 1/8-inch diameter holes for
studs. Attach snap studs using number 3 x 3/8 self-
tapping screws. Tighten screws to 12 inch-pounds
1 N.rn torque and attach top to snap studs.
23 Check fabric top fit. If fit is incorrect check bow
and support dimensions to be sure correct compo
nents were supplied in kit Fig. 7. Correct and
WINDSHIELD
FRAME adjust & if necessary.
24 On models that will be equipped with fabric doors,
HORIZONTAL refer to Fabric Door Installation procedure.
SUPPORT
ROD SOCKET
TAPE
STRIP HORIZONTAL
SUPPORT
ROD
Fig. 5 Positioning Horizontal Support Rod Socket

on Windshield Frame
13 Install horizontal support rods and attach vertical

support blades to horizontal support rods. Be sure
rods are also seated in rear bow Fig. 4.
14 Attach horizontal support rod bows to horizontal

support rods using 1/4 x 20 screws.
15 Close doors and adjust vertical blades. Position
blades so they are 3/8-inch away from inside of door VERTICAL
SUPPORT
frame. BLADE
16 Install vinyl tape on horizontal support rodsFigM.

Wrap 3-inch length of tape around each rod at point
where vertical blade tab contacts rod.
17 Position fabric top across bows and attach top to

rear bow using snap fasteners.
18 Remove horizontal support rods, insert rods Fig. 6 Vinyl Tape Installation
through sleeves at each side of top, and install rods.
Fabric Door Installation
19 Attach forward edge of fabric top to front former.
1 Remove plastic plugs from door lower hinge mount
20 Install fabric top snap studs in body sides. Starting ing holes in body.
at corner, stretch top, mark snap stud locations,
and centerpunch and drifi 1/8-inch diameter holes 2 Attach door lower hinges to body.
for studs. Attach snap studs using number 8 x 3/8
self4apping screws. Tighten screws t&. 12 inch- 3 Position door at 90° angle to body full open posi
pounds 1 N-m torque and attach top to snap studs. tion and insert door frame hooks into door hinges.
Be sure hooks are fully seated in hinges.
21 Install fabric top snap studs in back panel.
Stretch top over panel, mark stud locations, and
centerpunch and drill 1/8-inch diameter holes for NOTE: It is very important that the doorframe hooks be
studs. Attach snap studs using number 8 x 3/8 self- installed all the way down into the body hinges. Ifnot flU
tapping screws. Tighten screws to 12 inch-pounds ly installed, the door handle may strike the top above the
1 N-rn torque and attach top to snap studs. latch striker plate.
_________
[Io2e-1I2P
24-118"
HOOK END OF
108-114" TO 108-3/4"
1 24-1/4"
25-112"
TAPE MEASURE
9 TAPE MEASURE
Rear Bow
Measure perimeter by running tape
measure around outside of bow. Also
measure height of bow to underside of
crown.
28"
33-1/8" Vertical-Support-Rods
horizontal-Support-Rods Measure total length of rod.
Fig. 7 Bow and Support Rod Dimensions
4 Assemble door handles Fig. 8. Place 5/8 flat 3 Upon locating improper fit areas, start at lower
washer over outside handle shaft and insert shaft forward area of door and carefully spring door
through hole in door. Inside handle has cavity for frame as required to eliminate poor fit areas- Work
torsion spring. Left door spring is metal color. toward upper rear corner of door when springing
Right door spring is purple color. Insert applicable frame. Upper forward corner of door must contract
spring into each inside door handle end of spring door seal before door latch engages.
with tong tang inserted first. Position inside
handle so it maths with hexagonal end of outside 4 Top front corner of door may be adjusted by grasp
handle shaft. Rotate handles slightly until spring ing door frame in area of top hinge and springing
tang enters small slot at top of mounting plate hole. upper forward corner inward.
Rotate handles forward and compress together.
Secure handles with number 8 x 1-3/8 self-tapping 5 Repeat door frame springing process until desired
screw. Repeat procedure for opposite door handle. fit is achieved.
NOTE: If handles bind or do not rotate freely, loosen
screw slightly.
Door Handle Adjustment
5 Install black vinyl covers on door window zipper
pulls. Handles that do not rotate far enough rearward to latch
behind the vertical support rod can be adjusted as
6 Position black vinyl door trim on diagonal rod ad follows:
jacent to door lower window.
1 Disassemble handle.
Fabric Door Adjustment
2 Cut small amount of plastic from front side of in
1 Unzip door window and close and latch door. side handle tang. This allows handle to rotate
further rearward and latch behind vertical rod.
12 Identify improper fitting areas by standing outside
vehicle and looking through open door window. 3 Reassemble handle.
81-80
DOOR HANDLE
SPRING
FLAT WASHER
INSIDE DOOR
HANDLE
HANDLE
SUPPORT
OUTSIDE DOOR
HANDLE
90454
Fig. 8 Fabric Door Handle Assembly
WHEEL
Cab Back Panel Removal/Installation HOUSE
PANELS
REAR
1 Move both seats forward. PANEL
2 Remove storage bag, if equipped with fabric top. Fig. 9 Cab Back Panel
3 Remove back panel attaching bolts and removal Hardtop Removal/Installation

panel Fig. 9. 1 Remove screws attaching top to windshield.
4 Remove sealing material from back panel-to-cargo 2 Remove bolts attaching top to cab back panel.
box contact surfaces.
3 Remove top with aid of helper.
5 Apply new sealing material to cargo box contact
surfaces of back panel. Use a silicone-type caulk or NOTE: If the top is to be removed from the vehicle or
sealant to seal these surfaces. stored for any length of time, place a protective covering
over the top.
6 Install back panel and panel attaching bolts.
4 Position top on vehicle with aid of helper.
7 Install storage bag, if equipped with fabric top.
5 Align top attaching bolt and screw holes and install
8 Return seats to original positions. attaching bolts and screws.
Roll Bar Removalllnstallation Hardtop Repair
1 Remove wood side rails from both sides of cargo Holes, cracks or breaks in the hardtop can be repaired as
box, if equipped. outlined in Chapter 3L of the 1981 Jeep Technical Ser
vice Manual.
2 Remove roll bar attaching bolts.
Metal Doors
3 Remove roll bar from vehicle using chain hoist or
with aid of helper. The metal doors used on Scrambler models are similar
to the doors used on current 1981 CJ models and are
4 Position and install roll bar in cargo box. Use equipped with the new remote-type inside and outside
chain hoist or helper to raise and install roll bar. door handles Fig. IQ. The door glass, channels, and
window regulator mechanism are the same as used in
5 Install and tighten roll bar attaching bolts to 25 current IT models Fig. ii. The door handle, lock, and
foot-pounds 34 N-rn torque. striker service procedures are outlined in this bulletin.
Refer to the 1981 Jeep Technical Service Manual for all
6 Install wood side rails, if equipped. other door service and adjustment procedures.
81-8 1
OUTSIDE
DOOR
HANDLE t
REMOTE
CONTROL
RESTRAINT HANDLE
PIN STRAP
Fig. 10 Metal Door Assembly
Outside Door Handle 10 Remove locks from outer door handle using needle-
nose pliers and remove handle from door.
Removal
Installation
1 Remove door handle assist and window regulator
handle Fig. 10.
1 Install outside door handle and slide handle keeper
2 Remove door trim panel and watershield paper into door handle from top.
from door.
2 Tap keepers downward lightly to tighten handle.
3 Remove door lock cover attaching screws.
3 Install lock-to-handle rod and lock pin Fig. 10.
4 Disconnect lock-to-handle rod from outside door
handle. 4 Install outer weatherstrip on top of door.
5 Close window completely, release spring on each 5 Position window glass in door Fig. 11.
outside door handle keepers and tap keepers
upward. 6 Install divider bar and adjusting screws.
6 Remove window door glass from regulator Fig. 7 Attach window glass to regulator.
11.
8 Install door lock cover.
7 Remove division channel by removing adjusting
screws. 9 Install watershield paper and door trim panel.
8 Remove window glass from door. 10 Install window regulator handle.
9 Remove outer weatherstrip from door. 11 Install door handle assist.
81.82
lock cylinder replacement is required, the uncoded ser
vice cylinder can be coded to match the existing key.
Refer to the key coding procedure in the 1981 Jeep
Door Latch and Remote Control Rod
1 Remove door trim panel and watershield paper.
2 Remove latch cover.
3 Disconnect remove control rod and lock-to-handle
rod from latch Fig. 10.
4 Connect lock-to-cylinder rod to latch.
5 Install latch cover and tighten cover screws.
6 Install watershield paper and door trim panel.
Striker Adjustment
The door striker is fully adjustable and can be moved up,
down, in, or out, or shimmed forward or rearward to
align the door Fig. 10. The door striker should be ad
justed so that the door does not bind, provides secure
retention, and provides proper door movement when the
door is opened and closed.
WARNING: It is possible to adjust the striker so far im
ward that the door closes tightly but does not lock coin
HANDLE pletely. In this case, only the safety catch may be engaged.
DIVISION BAR DIVISION BAR
WEATHERSTRIP BRACKET Wood Side Rails/Step Bumper/Spare Tire Mount
Fig. 11 Metal Door Glass, Channel, The wood side rails, step bumper, and spare fire mount
and Frame Assembly are all serviceable components Fig. 12. The step
bumper is attached to frame brackets. The side rails are
Door Lock Cylinder attached to the body sides and cargo box, and the spare
Removal tire mount is attached to the cargo box rear panels Fig.
12. To service these components, simply remove the
1 Remove door trim panel and watershield paper. necessary attaching bolts and remove the component
from the vehicle.
2 Remove door latch cover screws and remove cover.
3 Remove retaining clip and remove lock-to-cylinder
rod Fig. 10. TAILGATE
4 Remove lock cylinder spring retainer and remove

lock cylinder.
Installation
1 Install lock cylinder in door.
2 Install lock cylinder spring retainer and install lock-

to-cylinder rod and clip Fig. 10.
3 Install door latch cover and cover screws.

4 Install watershield paper and door trim panel. REAR FUEL
/ MOUNTED FILLER
STEP BUMPER SPARE CAP
Door Lock Cylinder Coding TIRE
A lock cylinder service kit is available which includes an Fig. 12 Wood Side Rails, Step Bumper,
uncoded cylinder, housing, and dust cover. Whenever and Spare Tire Mounting
81-83
SPECIFICATIONS
4,
1981 Scrambler Tire Inflation Pressure Chart
Normal Load ® Maximum Load ®
Sustained Sustained
Under 65 Under 65
GVW Tire Load Driving Over MPH Driving Over MPH Wheel
Model Rating Size Range 65 MPH 65 MPH Size
105 KmJh 105 Km/h
105 Km/h 105 Km/h
lbs. kg. Front Rear Front Rear Front Rear Front Rear
H78-15 B 24 24 20 20 24* 28* 20 24 15x5.5
L78-15 B 24 24 20 20 24* 24* 20 20 15x7
88 4150 9-15LT B 20 25 20 20 30* 35* 30 30 15x7
P235/75R15 SL’ 30 30 20 20 30 * 35 * 20 25 15 x 7
H78-15 D 24 24 20 20 24 * 28 * 20 24 15 x5.5
-- L78-15 C 24 24 20 20 24* 24 20 20 15x7
NOTE: Inflate tires while cold and before driving. Do not reduce tire pressure if tires are warm.
* Speed Limited to 74 MPH 119 KmIh.
0 Normal Load: Frequently selected accessories plus driver and passenger.
® Maximum Load: Gross Vehicle Weight Rating GVWR.
SL is approximate metric tire equivalent of load range B.
1981 Scrambler Powertrain Combination Chart
41-Slate Vehicle California Vehicle 111gb Aluitiade V.1,1St Brake. IrnI Au. Mcdel
Eniae Transfer Tier

Ttrnmiauioa Irao.mI..ion innmis.io, Front Rear Front Ear
151 CID 5114 Model 3.54 aId. 5114 Model 3.73 aId. 8114 Model 3.73 ntd 1175 lOx 1.75 Model AMC
4-Cylinder 4-Speed 300 3.73 opt 4-Speed 300 4-Speed 300 loch Inch 341 Jeep
Disc Drum Open all
904 Model 3.73 std. 1104 Model 373 aId 904 Model 3.73 std.} all all End
automatic 800 automatic 800 automatic 300 all
230 CIII 1-176 Model 2.73 aId T-175 Model 2.73 atd. T-176 Model 3.31 aId.
6-Cylinder or 300 3.31 opt. or 300 3.31 opt. or 300
5R4 SR4 5R4
4-Speed 4-Speed 4-Speed
999 - Model 2.73 sad. 999 Model 278 utd 999 Model 3.31 std.
automatic 300 3.31 opt. automatic 300 3.31 opt, automatIc 300
General Dimensions Inches

Wheelbase 10&5
Tread Width:
Front 51.5
Rear 50.0
Front WI" styled wheel 535
Rear w17" styled wheel 52.0
Body Width max. 59.9
Body Width-Overall 68.6
Body Width-Overall w/enclosure 69.9
Length-Overall 177.3
Includes standard rear mount spare tire
Height-Overall 67.6
Height-Overall w/hardtop 70.5
Ground Clearance:
Front Axle 8.7
Rear Axle 7.6
81-079-SGJ
81-84
- ------z- - - - - -
I File: Service
-Service Technical Letter 1±2
General
April 6,1981
Subject Information
Additions to 1981 Four-Cylinder Three additional identification codes for 1981

Engine Identification Codes four-cylinder engines have been phased into
production as a running change. Please change the
three-character letter code information on page
18-1 of your 1981 Jeep Technical Service Manual
and page 31 of the 1981 Jeep Service Specifications
handbook to read as follows:
CJ Four-Cylinder Engine Codes
WCP, WFM - 49S, Man. Trans., WO/AC
WCT, WFP - 49S, Auto. Trans., WO/AC
WCU - Calif., Man. Trans., WO/AC
WCW, WFS - Calif., Auto. Trans., WO/AC

* 14250 Plymouth Rd. Detroit, MIch: 48232
*
Service Engineering Dept.
81-85
=
riJeep. - -

Service Technical Letter INo. 81-11 March 27,1981
Subject Information
Correction To Automatic Trans- The Stall Speed Specifications Chart on page 2C-19
mission Stall Speed Specifications of the 1981 Jeep Technical Service Manual and
Chart In 1981 Jeep Technical Ser page 126 of the 1981 Jeep Service Specifications
vice Manual and 1981 Jeep Service Handbook are incorrect. Please correct these
Specifications Handbook charts to read as follows:
Engine Transmission Engine RPM

Model
151 2.5 Liter 904 CJ-7 2050-2350
258/304 999 cJ-7 1850-2150
258 727 Clca-Wag-Trk 1950-2250
360 727 Cke-wag-Trlc 1700-2000

Service Engineering Dept. * 14250 Plymouth Rd. * Detroit, MIcti. 48232
Additional copies of this letter are availabl, through your zone office.
81-86
Service Technical Letter No.8l-O March 20,1981
Subject Information
Revision to Part Number In The part number for the front and rear output
ORB 81-1, Transfer Case Output seal listed in the subject bulletin has been
Shaft Seal Leak Diagnosis, Datec revised. The new part number for this seal is
February 23, 1981, and riled 8133432. Please note this change in your
Under CHASSIS Transfer Case/
-
Quadra-Trac
Oil Return Channel Access Hole A rear bearing oil return channel access hole
Plug Service -1980-81 Jeep has been added to the rear case on 1980-81
Model 219 Quadra-Trac Transfer model 219 transfer cases as a running change.
Case A rubber plug, part number 8131617, is used
to seal the access hole.
When servicing the rear case on a 1980-81

Model 219 transfer case, the rubber plug which
is located in the upper side portion of the
rear case should also be inspected. If the
plug has become loose, damaged, or will not
seal properly, a replacement plug should be
installed. In addition, if the rear case is
replaced, be sure to install a plug as the
replacement case may not have a plug installed

Strike Engineering Dept. * 14250 Plymouth Rd. * Detroit Mich. 48232
81-87
I File: Service General 1
Service Technical Letter 60. 819 Feb. 26, 1981!
Subject Information
Revision to Diagnosis and Repair The part numbers for the piston and piston ring
Bulletin No. 81-1, Engine Noise set has been revised. The part numbers should be
Diagnosis, Dated November 27, as follows:
1980, Filed Under POWER PLANT -
Engines Description Qty. Part No. Group
PISTON +0.005 4 8133160 1.143
RING SET, Piston

Engine +0.005 4 8133161 1.146
Please note this revision on your copies of the

subject bulletin.
Oil Leak From Distributor Base - When diagnosing the cause of an oil leak at the
1980-81 Four-Cylinder Engines rear of a 1980-81 four-cylinder engine, be sure
to check the condition of the distributor base
gasket. If the gasket is damaged, oil may travel
from the distributor base to the rear of the
block, where is could be misdiagnosed as a rear
main seal leak.
If inspection reveals that the distributor base

gasket is damaged, replace the gasket with an
0-ring seal, part number 8130451, which is
available for service use.
Fl Amedoan Motors Sales Corporation

81 -88
No. 81-8 Feb.19, 1981
Subject Information
Windshield Wipers Inoperative On When checking for loose connections and ground
Low and Intermittent Speeds - circuit continuity, be sure to check for a poor
1980-81 Cherokee, Wagoneer and ground between the windshield wiper switch and
Truck Models - Addition to dash panel. To correct this condition, remove
Windshield Wiper Service Diag the switch and install a 7/16 I.D star washer,
nosis, Page 3T-ll In 1980-81 Jeep G178551, between the switch and dash panel to
Technical Service Manuals improve the ground.
Correction to Clutch Aligning Tool The clutch aligning tool number for four-, six-,
Number - 1980 Jeep Technical and eight-cylinder engines in the 1980 Jeep
Service Manual Supplement and Technical Service Manual Supplement and 1980-81
1980-81 Jeep Technical Service Jeep Technical Service Manuals is incorrect.
Manuals
The correct number for this tool is J-5824-OL

Please note this correction in Chapter 2A of the
1980 Jeep Technical Service Manual Supplement and

81-89
Service Technical Letter I !te?’Lsi
Subject Information
Correction to Carburetor Numbers The numbers and usage for Model ZSE car-
and Usage - 1981 Jeep CJ Models buretors listed in the Specifications Chart on
With Four-Cylinder Engine page IJ-30 of the 1981 Jeep Technical Service
Manual and page 97 of the 1981 Jeep Specifica
tions Handbook are incorrect.
Carburetor number 17081790 is used on

49-State CJ-7 models with automatic trans
mission.
Carburetor number 17081791 is used on

49-State CJ-5 and CJ-7 models with manual
transmission.
Please note these corrections in your 1981

Jeep Technical Service Manual and Service

81-90
I
Service Technical Letter IFile: Service General
81-6 Jan. Z3,198l
Subject Information
Water Leaks Caused By Dealer Some 1981 Jeep vehicles may have water leaking
Installed Radio Antenna 1981
- into the passenger compartment through holes
Jeep Vehicles made for radio antenna installation. This is a
result of water being routed along the antenna
lead-in cable and entering the compartment
through the dash panel which may not be sealed
by grommets or other suitable sealers.
When installing an antenna, be sure a grommet

is used where the antenna cable goes through the
dash panel and be sure the cable is properly
seated in the grommet hole.
Power Steering Pressure Test The pressure and return port fittings on 1980-81
Gauge Adapter Set Tool Number Jeep power steering pumps and gears have
Revision metric threads. In order to connect the pressure
test gauge J-2l567 to these fittings, it will be
necessary to use Adapter Set 3-5176-20. Please
note this information in Chapter ZL of your 1980
and 1981 Jeep Technical Service Manuals.
Correction to 1980-81 Cherokee The fuel tank capacity for all 1980-81 Cherokee
and Wagoneer Fuel Tank Capacity and Wagoneer models is 20. 5 gallons
Specification Charts 77. 6 liters. Please note this change in the
Fuel Tank Specifications Charts on page lJ-10 of
the 1980 Jeep Technical Service Manual, page
1J-11 of the 1981 Jeep Technical Service Manual,
page 88 of the 1980 Jeep Service Specifications
Handbook, and page 90 of the 1981 Jeep Service
rI American Motors Sales Corporation

81-91
Subject Information
Correction to 1980 Jeep Four- The following information should be used when
Cylinder Engine Piston Fit fitting pistons in 1980 Jeep four cylinder
Information engines:
Measure the cylinder bore at a point 2-1/4

inches from the top of the bore.
Measure the piston diameter at a point perpen

dicular to the piston pin and 1-13/16 inches from
the top surface of the piston.
Please note these corrections on pages 26 and 30

of the 1980 Jeep Technical Service Manual
Supplement.
Short Oil Pump Attaching Screw The torque specification for the short oil pump
Torque Specification Revision - attaching screw used on 1981 6-Cylinder engines
1981 6-Cylinder Engines has been revised as follows:
USA Foot/Pounds Metric Nm
Service Service
17 12-20 23 16-27
Please note this revision in your 1981 AMC

Technical Service Manual and 1981 AMC Speci
fications Handbook.
81-92
SCN 27
TIJeep,

Service Technical Lette. r No. 81-5 Dec. 3, 19801
I
Subject Information
1981 Jeep Six-Cylinder Engine The water pump and Tempatrol fan drive
Water Pump and Tempatrol Fan assembly used on 1981 Jeep California six-
Drive Assembly Usage cylinder engines with serpentine belt drive
are different from those used on 1e9-State
engines. Before servicing the cooling system
on a six-cylinder engine, please note the
following Caution which appears on pages
1C-l0 and ic-il of the 1981 Jeep Technical
Service Manual.
CAUTION: 1981 six-cylinder engines

California with a serpentine single
drive belt have a reverse rotating water
pump and viscous Tempatrol fan drive
assembly. The components are identified by
the words "REVERSE" stamped on the cover of
the viscous drive and inner side of the fan,
and "REV" cast into the water pump body.
Do not install components that are intended
for non-serpentine drive belts.

81-93
I
Service Technical Letter INO. 814
Service General
Nov. 10, 1980
Subject Information
1981 6-cylinder Main Bearing The 1981 6-cylinder main bearing capscrew torque
Capscrew Torque Specification specification has been revised as follows:
Revision
U.S.A. Foot-pounds Metric N-rn
Service Service
Set-To Re c he cit Set-To Recheck
65 65-70 88 88-95
Please note this revision in your 1981 Jeep

Technical Service Manual and 1981 Jeep
Specifications handbook.
Reverse Gear Selector Pivot Pin If it is necessary to service a 1980-81 SR4

Service - 1980-81 5R4 Four-Speed four-speed manual transmission for a gear jump-
Manual Transmission out or damaged gear condition, the reverse gear
selector pivot pin should be replaced in addition
to any other damaged components. The pin, which
is threaded into the transmission case and serves
as the reverse lever pivot, may have become bent
or damaged by the conditions described and should
be replaced to ensure proper shifting.
Fuel Feedback Modules Damaged It is important that the battery cables are
By Incorrect Battery Cable connected to the battery positive-to-positive and
Connection -1980-81 Jeep Vehicles negative-to-negative to prevent damaging the
Equipped With Fuel Feedback fuel feedback module. Reverse polarity may
System damage the alternator diodes and radios also.

ServIce Engineering Dept. * 14250 Plymouth Rd. * Detroit, MIch. 48232
Additional copies of this leftor are available through your zone office.
81-94
SCN 164
,.
Service Technical Letter IFiIe:SeMceGeneral

I No. 81-3 Oct. 21, 1980
Subject Information
Front Wheel Alignment Specifica- The front wheel alignment specifications for 1981
tions for 1981 CJ Models CJ models have been revised. The revised
specifications are as follows:
Front Wheel Alignment Specifications
Caster +60 +10

Camber +1½0 +0
Toe-In 3/64 to 3/32 inch
Turning Angle 31° to 32°
Please note these changes in the 1981 Jeep

Service Specifications Handbook and in the
Front Alignment Specifications Chart on page 2M-6
of your 1981 Jeep Technical Service Manual.

Additional copies of this letter are available through your zone office
81-95
Service Technical Letter t!t
Subject Information
Stationary Center Armrest - 1981 The center armrest in 1981 Cherokee, Wagoneer,
Cherokee-Wagoneer-Truck Models and Truck models is not movable. The armrest is
designed to remain in a fixed horizontal position
and should not be altered in an attempt to make
it movable.

Service Technical Letter rn80
Subject Information
Valve Train Noise - 1981 Six- Some 1981 six-cylinder engines built prior to
Cylinder Engines Built Prior to engine code OO8COl may develop valve train noise
Engine Code OO8COl caused by contact between the rocker arms and
valve spring retainers.
Service correction involves measuring valve tip

projection above the spring retainer on all
valves, and replacing retainers and locks if
valve tip projection is not within specifications.
If any valve tip projects less than 0.010 inch

above the retainer, the original retainer and
locks must be replaced with valve spring retainer,
part number 3237482, and retainer locks, part
number 3180458 2 required.
If all valve tips project 0.010 inch or more above

the retainers, further diagnosis will be
necessary.
I
FILE: Engines-Fuel
Systems-Engine Electrical-
Cooling POWER PLANT-
ngine Electrical
o. 1-13-82 Nov. 11, 1982
TECHNICAL BULLETIN
PROBLEM AND An inoperative Cruise Command servo on 1981-82 Jeep vehicles
APPLICATION: may be due to a cracked or broken manifold vacuum hose connector
on the servo.
CORRECTION: It is not necessary to replace the servo if only the vacuum hose
connector is damaged. Instead, repair the servo by installing
the following released vacuum hose connector repair kit.
PARTS:
Description Quantity Part Number Croup
KIT, Servo Hose Connector 1 8130482 3.326

Repair Includes connector,
0-ring, and instruction
sheet
S.R.T. INFORMATION;
Operation
CO. KIT, SERVO VACUUM HOSE 8-760 8999 0.3

CONNECTOR REPAIR INSTALL
-

REIMBURSEMENT:
PROCEDURE:
1. Remove the servo as outlined in the applicable Jeep

2. Remove the servo mounting bracket and plate.
3. Remove the damaged vacuum connector and 0-ring from the servo.
4. Install the replacement 0-ring in the replacement connector

see illustration.
5. Install the replacement vacuum connector on the servo vacuum

outlet.
continued

Service Engineering Department S 14250 Plymouth Road * Detroit, Michigan 48232
Additional copies of this bulletin are avadabfe through you’ zone office.
82-1
-2-
6. Reinstall the servo mounting plate and bracket. Be sure to

avoid pinching any wires between the servo and mounting plate.
7. Install the servo as outlined in the applicable Jeep Technical

Service Manual.
.IrLACEMENT
REPLACEMENT VACUUM
0-RING CONNECTOR
VACUUM
INLET
SERVO
Replacement Vacuum Connector and

0-Ring lnst&Iation
82-090-AJJ
82-2
FILE: Engines-Fuel
-
Vl Jeep Electrical
No. 1-12-82 Oct. 11. 1982
TECHNICAL BULLETIN
PROBLEM AND Service procedures and S.R.T. times for the new separate coolant
APPLICATION: temperature and intake manifold heater EFE control switches and
wire harness adapter on 1982, six-cylinder Jeep models, with fuel
feedback system built after February 18, 1982.
CORRECTION: Whenever it is necessary to service the dual-function coolant

temperature/intake manifold heater switch on models built prior to
February 18, 1982, replace the original switch with the two new
switches and harness adapters as outlined in the Procedure portion
of this bulletin.
NOTE: The new intake manifold heater EFE control switch,

3242321, can also be used as a replacement for the original
control switch used on 1981-82 six-cylinder models not
equipped with the fuel feedback system.
PARTS: Description Quantity Part Number Grout
SWITCH, Coolant 1 3242318 1.067

Temperature -
SWITCH, Intake 1 3242321 1.067

Manifold Heater
EFE Control
ADAPTER, Wire 1 5763666 3.053

Harness
S.R.T. INFORNAflON:
Operation
SWITCHES, COOLANT 1-750 1999 0.6
TEMPERATURE AND
INTAKE MANIFOLD
HEATER INSTALL
-

REIMBURSEMENT:
PROCEDURE:
1. Drain approximately 3 quarts of coolant from the radiator.
NOTE: Allow the engine to cool down before starting repair.

continued

Service Engineering Department * 14250 Plymouth Road * Detroit, Michigan
48232
Additional copies of this bulletin are availab!e through your zone otl,ce
82-3
-2-
2. Disconnect the heated air tube and the air duct from the air cleaner.
-Then remove the air cleaner wing nut and move the air cleaner aside.
3. Remove the bolts that attach the accelerator cable bracket to the in
take manifold and move the cable and bracket aside.
4. Disconnect the coolant temperature/intake manifold heater switch wire

harness from the engine compartment wire harness and remove the switch
and harness from the manifoith
NOTE: The switch is at the rear of the intake manifold on early pro
duction models and at the front on later production models.
5. Remove the pipe plug from the front or rear port of the intake mani
fold.
6. Apply a sealer such as Perfect Seal No. 5., Loctite 592, or equivalent
to the threads of replacement intake manifold heater EFE control
swItch, 3242321, and install this switch in the rear port of the intake
manifold. Tighten the switch to 20 foot-pounds 27 N-rn torque.
7 Apply a sealer such as Perfect Seal No. 5, Loctite 592, or equivalent,

to the threads of replacement coolant temperature switch, 324 2318, and
install this switch in the front port of the intake manifold. Tighten
the switch to 20 foot-pounds 27 N-rn torque.
8. Connect wire harness adapter, 5763666 to the two switches and to the
engine compartment wire harenss. Route and secure the harness away
from hot engine components or any linkage components.
9. Position the accelerator cable bracket on the intake manifold and in

stall the bracket attaching bolts
10. Install the air cleaner and connect the air duct and heated air tube
to the air cleaner.
11. Refill the radiator with the coolant drained previously.
INTAKE
MANIFOLD
FRONT /
INSTALL INTAKE
MANIFOLD HEATER
EFE SWITCH IN
INSTALL THIS PORT
COOLANT
TEMPERATURE
SWITCH IN
THIS PORT
Coolant Temperature and Intake

Manifold Heater EFE Switch 82-075-A/i
Locations inlntake Manifold
82-4
VILE: Engines-Fuel Sys-
teas-Engine Electrical-
Cooling PalER PLANT -
Engine Electrical
No. 1-11-82 Sept. 10. 198:
TECHNICAL BULLETIN
PROBLEM AND The front housing of some 70 and 85 amp alternators on 1981-82
APPLICATION: Wagoneer, Cherokee, and Truck models with eight-cylinder engine and
air conditioning may crack at the upper mounting boss and cause a
vibration.
CORRECTION: Replace the alternator front housing if necessary and install the
following alternator bracket lower support to improve alternator
mounting see illustration.
NOTE: The alternator bracket lower support was phased into 1982
model production as a running change beginning with YIN
13CNE15N4CT044845. This support should be installed
whenever servicing a 1981-82 70 or 85 amp alternator not
equipped with a lower support.
SUPPORT, Alternator
Bracket Lower 1 5364256 3.018
SPACER, Alternator
Pivot 1 4006186 3.018
BOLT, Hex 1 4200434 1.004
WASHER, Lock 1 4004807 9.369
HOUSING, Alternator
Front 70 and 85 amp 1 8133276 3.016
S.R.T. INFORMATION:
Operation
CO. SUPPORT, ALTERNATOR

BRACKET LXJER -INSTALL... 1-630 1999 0.7
SO. Alternator front

housing Replace
- 0.4
Includes transfer
fan, pulley, and
front bearing assembly

REIMBURSEMENT:
continued
TI Amedcan Motors Sales Corporation

Additional copies of This bulletin are availab.’e tbrough your zone oThce. -
82-5
-2--
PROCEDURE:
1. Inspect the alternator and note if an alternator bracket lower support

has already been installed or if the alternator front housing has
cracked at the upper mounting boss.
a. If the alternator is not equipped with a lower support or if the

front housing is cracked, proceed to step 2.
b. If the alternator is equipped with a lower support and the front

housing is not damaged, but some type of problem occurred, further
diagnosis is necessary. Refer to Chapter IE in the 1981-82 Jeep
Technical Service Manuals for procedures-
2. Remove the alternator as outlined in Chapter 1E of the appropriate Jeep

Technical Service Manual, discard the original pivot spacer see il
lustration, and note the following.
a. If the alternator front housing is cracked, proceed to step 3.
b. If the alternator front housing is not cracked, proceed to step 8.
LOWER PIVOT UPPER

SUPPORT SPACER SUPPORT
MOUNTING
BRACKET
PIVOT
BOLT
/
ADJUSTING
BRACKET
Alternator Bracket Lower

Support Installation
82-6
-3-
3. Remove the alternator pulley nut and washer and remove the pulley, fan,
and outer collar.
4. Mark the alternator front and rear housings for assembly alignment
reference; then remove the front housing-to-rear housing bolts and
remove the front housing.
5. Remove the slinger, front bearing, inner collar, and front bearing re
tainer plate from the original housing and transfer these components to
the new front housing.
6. Align and install the new front housing on the rear housing and install
and tighten the front housing-to-rear housing bolts.
7 Install the outer collar, fan, pulley, pulley washer, and pulley nut..
Tighten the nut to 50 foot-pounds 68 Nm torque.
8. Attach lower support 5364256 to the rear of the alternator with bolt
420Q434 and lockwasher 4004807 see illustration. Do not tighten the
bolt completely at this time.
9. Position the alternator in the mounting bracket and install replacement

pivot spacer 4006186 see illustration.
10. Align the bolt holes in the alternator mounting bracket, front housing,
upper and lower supports, and the pivot spacer, and install the alter
nator mounting bolt see illustration.
11. Complete alternator installation as outlined in Chapter 1E of the

appropriate Jeep Technical Service Manual.
82-Oll-J
82-7
Engine Electrical-Cooling
POWER PLANT-Engines
No. 1-10-82 Sept. 8, 1982
TECHNICAL BULLETIN
causing noise, backfire, or a miss.

pushrods are 9.640 to 9-660-inches long. The replacement pushrods,
IflPW. ‘T’l,n nr-In4nal f..4-..- ...a.,_...o-..---’..... ,qn.flnn

FILE: Engines-Fuel
Jeep Systems-Engine Electrical

-Cooling
No. 1-09-82 Seat. 8. 1982’
TECHNICAL BULLETIN
PROBLEM AND Normal exhaust pulses may cause the front exhaust pipe support and
APPLICATION; mounting bolt to vibrate and produce a rattling noise on some 1982
Wagoneer, Cherokee, and Truck models with six-cylinder engine and
automatic transmission. The noise is most noticeable at
or just above idle speeds and occurs only on models built prior to
January 11, 1982.
CORRECTION: Install the following spring clip between the front exhaust pipe
support and torque reaction bracket to increase tension on the
mounting bolt and eliminate the noise see illustration.
PARTS; Description Quantity Part Number Group
CLIP, Spring 1 637 427 8.116
S.R.T. INFORMATION
Operation
Operation Description T.LC. Number S.R.T.
CO. CLIP, FRONT EXHAUST 1-961 1999 0.4

PIPE ANTI-RATTLE -
INSTALL

REIMBURSEMENT;
PROCEDURE:
1- Remove and retain the front exhaust pipe mounting bolt and locknut See
illustration.
2. Pry the front exhaust pipe downward slightly and insert the clip be
flieen the pipe support and the torque reaction bracket see illustra
tion.
3. Insert the exhaust pipe mounting bolt through the rear bolt hole in
the torque reaction bracket and the bolt hole in the exhaust pipe sup
port.
4. Align the exhaust pipe mounting bolt and torque reaction bracket front
bolt hole and insert the exhaust pipe mounting bolt through the torque
reaction bracket.
NOTE: It may be necessary to use a pry bar or C-clamp to help align the
mounting bolt and torque reaction bracket bolt hole.
continued
Service Engineerjqg Department * 14250 Plymouth Road * Detroit, Michigan 48232
A.-lditinnnl rnnips oLtttisbuflatfr, are available throvqh your zone oflica
-2-
5. Install the locknut on the exhaust pipe mounting bolt and tighten
the bolt and nut to 18 foot-pounds 24 N.m torque.
82-044 -J
P’I Jeep -Enflne Electrical-Cooling
No. 1-08-82 June 2, 1982
TECHNICAL BULLETIN
PROBLEM AND Improving performance of 1982 Jeep vehicles being operated at
APPLICATION: altitudes above or below that which the engine was originally cer
tified for and adjusted to.
CORRECTION: Perform the engine adjustments outlined in the Procedure portion of

this bulletin. In addition, any Jeep vehicle that has been so
adjusted must have a unique emission control information label
installed. These unique lables are available in a kit, part number

Distribution Services
37200 Amrhein Road
Livonia, Michigan 48150
The adjustment procedures and unique labels must be made available

at no cost to independent repair facilities and the general public.
A notification is also provided in current owners manuals to make
customers aware of these adjustments.
PARTS: Description Quantity Part Number
KIT, Emission 1 3242103

Control Information
Update Label
WARRANTY Not warranty eligible.

ELIGIBILITY:
SSO INFORMATION: Not affected.
PROCEDURE:
On 1982 Jeep vehicles originally certified for operation at altitudes below

4,000 feet that are being operated above 4,000 feet, the ignition timing,
as shown on the Vehicle Emission Control Information Label located in the
engine compartment, should be advanced 5°. The engine idle speed should be
reset to the specification shown on the Vehicle Emission Control Informa
tion Label and according to the procedures outlined in the 1982 Jeep Tech
nical Service Manual. In addition, on six-cylinder models with fuel feed
back system only, the altitude circuit ground wires must be grounded to
the vehicle body as follows.
continued

82-11
-2-
1. Remove the tape used to secure the two altitude circuit ground wires to
the MCU wire harness.
NOTE: Both wires are joined to a single ring terminal and are taped to
the harness approximately 6 - 8 inches back from the MCII harness
connector plug. One wire is black with a yellow tracer and the
other is black with a blue tracer.
2. Ground the wires by attaching the ring terminal to a convenient loca

tion on the vehicle body with a 1/4 14 zinc plated, hex washer head
-
self tapping screw. Use a 0.185 inch diameter drill for the self tap
ping screw hole.
3. After performing the adjustments and the circuit modification on six-

cylinder models equipped with MCU, attach the Vehicle Emission control
Update Label, part number EF813O455 tc the engine compartment dash
panel. Do not attach the label to any component that can be readily
removed from the vehicle.
These adjustments apply to all 1982 Jeep vehicles that were

originally certified for principal use at altitudes below 4,000
feet. Refer to the Vehicle Emission Control Information label in
the engine compartment to identify these vehicles.
On 1982 Jeep vehicles originally certified for operation at altitudes

above 4,000 feet that are being operated below 4,000 feet, the igni
tion timing as shown on the Vehicle Emission Control Information Label
located in the engine compartment, should be retarded 5 * The engine
idle speed should be reset to the specification shown on the Vehicle
Emission Control Information Label and according to the procedures
outlined in the 1982 Jeep Technical Service Manual. In addition, on
six-cylinder models with fuel feedback system only, the altitude cir
cuit ground wires must be disconnected and taped securely to the MCU
harness.
1. Remove the screw attaching the ring terminal of the two black with tra
cer attitude circuit ground wires to the body. The wires are grounded
near the MCU. Tape the ground wires to the MCU harness after removing
the attaching screw. Be sure the ring terminal is completely covered
with tape to prevent contact with the body
2. After performing the adjustments and attaching the altitude circuit

ground wire on six-cylinder models equipped with MCU, attach Vehicle
Emission Control Update Label, part number EF8130456, to the engine
compartment dash panel. Do not attach the label to any component that
can be readily removed from the vehicle.
These adjustments apply to all 1982 Jeep vehicles that were

originally certified for principal use at altitudes above 4,000
feet. Refer to the Vehicle Emission Control Information label
in the engine compartment to identify these vehicles.
8l-ll4-A/J
82-12
FILE: Engines-Fuel
Systems-Engine
Electrical-Cooling
ADDENDUM
No. l-aV-82 Mar.23, 1983
TECHNICAL BULLETIN
PROBLEM AND The attached bulletin on 6-cylinder valve cover oil leaks is being
APPLICATION: reissued in response to suggestions by members of the Dealer
Advisory Board. The key points of this bulletin are highlighted in
this Addendum and in the bulletin proper.
To ensure proper repair, it is most important that dealer service

personnel be thoroughly familiar with the contents of this bulletin.
CORRECTION: Follow the procedures outlined in the attached, reprinted copy of

bulletin 1-06-82 explicitly to avoid ineffective or unnecessary
repairs. Refer to these procedures when servicing the cylinder head
cover on 1982 AMC six-cylinder engines. Also pay particular
attention to the following key points from the bulletin procedure.
Step 3. Remove old sealer from the cover sealing surface of the
cylinder head and clean the surface using ANC Fabric
Cleaner 8990968, or equivalent. Remove all residue from
the sealing surface using a clean, dry cloth.
Step 4. Apply General Electric SS 404 primer 8130453, or

equivalent, to the cover sealing surface of the cylinder
head. Allow 10-15 minutes for the primer to set-up.
CAUTION: For an effective repair, Casket-In-A-Tube silicone

sealer must be no more than twelve months old at time
of use.
Step 5. Apply a 1/8-inch diameter bead of Casket-In-A-Tube, or

equivalent, silicone sealer to the sealing surfaces of
the cylinder head and cylinder head cover. Allow
approximately five minutes for the sealer to set-up.
Avoid any time delay between sealer set-up and cover
installation. The sealer can become tack-free in 10-15
minutes which will reduce its adhesive qualities.
PU Ametican Motors Sales Corporation

Service Engineering Department * 14250 Plymouth Road * Detroit, Michigan 4e232
82-13
-2-
Step 8. Install and tighten the cylinder head cover nuts to

28-inch-pounds 3 N.m torque,
NOTE: If the cover nuts are not the locking-type, replace them
with lock-nuts, part number 4006926.
Step 17. Check and adjust the engine oil level if necessary.
NOTE: It is recommended that the sealer be allowed to cure for

approxinately one-to-two hours before starting the engine.
DEALER Not affected.

REIMBURSEMENT:
10-83-025
82-14
*
-Engine Electrical-Cooling
No. 1-06-82 Mar. 5, 1982
TECHNICAL BULLETIN
PROBLEM AND The cylinder head cover removal/installation procedures published
APPLICATION: in the 1982 Jeep Technical Service Manual for six-cylinder engines
are incorrect.
CORRECTION: Make a note of this correction on page 18-45 of the 1982 Jeep Tech
nical Service Manual and refer to the procedures in this bulletin
whenever removing, resealing, or replacing the cylinder head cover
on 1982 six-cylinder engines.
COVER, Cylinder Head 1 3237808 1.068

PRIMER 1 8130453 1.068
SEAL, Cylinder Head 2 3237837 1.068
Cover to Attaching
Stud
NUT, Locking 2 4006926 1.068
SEALER, Gasket-In- 1 8993317 15.260
A-Tube
FABRIC CLEANER 1 8990968 15.050

ELIGIBILITY;
SSO INFORMATION:
Operation Description Code Number Model -82- Level
COVER, ENGINE CYLINDER

HEAD - RESEAL 1.072 lOll 6-cyl. 1.4 G
Material allowance
is $2.85
COVER, ENGINE CYLINDER

HEAD - REPLACE 1.068 1012 6-cyl. 1.3 G
Material allowance
is $2.85
PROCEDURE:
Removal
1. Disconnect the battery negative cable.
2. Remove the air cleaner and PCV molded hose.
continued
-2-
3. Disconnect the distributor vacuum advance hose at the distributor.
4. Disconnect the fuel line at the fuel pump. Rotate the line as necessary
to provide cylinder head cover removal/installation clearance.
5. Remove the PCV valve from the cylinder head cover grommet and disconnect
the PCV shut-off valve vacuum hose.
6. Remove the vacuum switch and bracket assembly from the cylinder head
cover.
7. Remove the diverter valve and bracket assembly.
8. Remove all necessary vacuum and air hoses to provide cylinder head
cover removal/installation clearance.
NOTE: Tag the hoses for assembly reference.
9. Remove the cylinder head cover retaining nuts.
10. Detach the cover from the cylinder head by breaking the silicone seat
using a putty knife or razor blade. Do not attempt to pry the cover up
ward until the seal has been completely broken.
11. Rotate the cylinder head cover toward the passenger side and remove the
cover.
Installation
1. If the cover is to be resealed only, remove the old sealer from the cover
flange sealing surface and inspect the cover. Replace the cover if
cracked or damaged in any way with new cover 3237808.
2. Transfer the PCV valve grommet and oil filler cap from the old cover to
the replacement cover.
3. Remove old sealer from the cover sealing surface of the cylinder head and
clean the surface using AMC Fabric Cleaner 8990968, or equivalent.
Remove all residue from the sealing surface using a clean, dry cloth.
4. Apply General Electric SS 4004 primer 8130453, or equivalent, to the

cover sealing surface of the cylinder head. Allow 10 15 minutes for
-
the primer to set-up.
CAUTION: The following step involves the application of Casket-In-A-Tube

silicone sealer. For an effective repair, it is required that the sealer
be no more than twelve months old at time of use. Before using the sealer,
check the date code stamped On the crimped seam at the tube bottom or on
the sealer carton. The two character letter code can be deciphered using
the Sealer Date Code Chart.
5. Apply a 1/8-inch diameter bead of Casket-In-A-Tube, or equivalent,

silicone sealer to the sealing surfaces of the cylinder head and
cylinder head cover. Allow approximately five minutes for the sealer
to set-up.
-3-
First Character Second Character

is Year of is Month of
Manufacture Manufacture
K -1980 A - January
A -1981 B - February
B -1982 C - March
C-1983 D -April
D-1984 E -May
E-1985 F -June
F-1986 G -July
G 1987
- H - August
H -1988 J - September
-1989 K - October
K -1990 M - November
N - December
Sealer Date Code Chart
CAUTION: Avoid any time delay between sealer set-up and cover installa
tion. The sealer can become tack-free in l0-to-15 minutes which will re
duce its adhesive qualities.
6. Install the replacement seals on the cylinder head cover attaching

studs. be sure the studs are clean before installing the seals.
7. Install the cylinder head cover on the cylinder head as soon as the
primer and sealer have set-up. Do not allow the sealer to contact
the valve train or other components to avoid smearing the sealer.
8. Install and tighten the cylinder head cover nuts to 28-inch-pounds

3 Nm torque.
NOTE: If the cover nuts are not the locking-type, replace them with lock-
nuts, part number 4006926.
9. Install the diverter valve and bracket assembly on the cover.
10. Install the vacuum switch and bracket assembly on the cover.
11. Install the PCV valve in the cover grommet and connect the PCV
shutoff valve hose.
12. Install all vacuum and air hoses that were removed for cover removal/
installation clearance.
13. Connect the fuel line and the distributor vacuum advance hose.
14. Install the air cleaner and molded PCV hose.
15. Connect the PCV hose to the PCV valve.
16. Connect the battery negative cable.
17. Check and adjust the engine oil level if necessary.
NOTE: It is recommended that the sealer be allowed to cure for approxi

mately one-to-two hours before starting the engine.
82-036-A/J
82-17
FILE: Engines-Fuel Systems-
No. 1-07-82 March 18, 1982
TECHNICAL BULLE11N
PROBLEM AND The exhaust manifold to front exhaust pipe stud nuts on 1982 Jeep
APPLICATION: four-cylinder engines built prior to February 1982, may loosen
causing an exhaust noise.
CORRECTION: Replace the original exhaust manifold to front exhaust pipe studs
and nuts with the locking-type studs, stud nuts, and hardened
washers used on 1982 six-cylinder engines.
STUD, Exhaust Manifold 2 3242198 4.178

to Front Exhaust Pipe
NuT, Hex 2 4006567 4.178

Std. 3/8-16
WASHER, Hardened 2 4001181 4.178

ELIGIBILITY:
SSO INFORMATION

STUD, EXHAUST PIPE

TO MANIFOLD REPLACE BOTH
- 4.178 4199 4-cyl. 0.9 C
PROCEDURE:
1. Raise and support the vehicle.
2. Disconnect the front exhaust pipe from the exhaust manifold.
3. Remove the studs from the exhaust manifold with vise grip pliers.
NOTE: It may be necessary to apply heat to the exhaust manifold in

order to remove the studs.
4. Install the replacement locking-type studs in the exhaust manifold.
5. Position the front exhaust pipe on the exhaust manifold studs and
install the replacement washers and nuts. Tighten the nuts to 23 foot-
pounds 31 Nm torque.
6. Remove the supports and lower the vehicle.

82-O52-A/J
service Englneerng Department s 14250 Plymouth Road * Detroit, Michigan 48232
Additional copies of this bulletin are available thmugh your zone office.
82-18
POWER PLANT-Engine Elec
trical REVISED
No. 1-04-82 Mar. 4, 1982.:
TECHNICAL BULLETIN
PROBLEM AND Unnecessary replacement of electronic regulator used with 1981-82
APPLICATION: Jeep Cruise Command systems.
CORRECTION: Before replacing an electronic regulator for a suspected malfunc

tion, refer to the additional diagnosis information and improved
regulator adjustment procedure in this bulletin. Also make a note
of this information in the Cruise Command chapter of your 1981-82
Jeep Technical Service Manuals.
PARTS: None required.
WARRANTY Not affected

ELIGIBILITY:
SSO INFORMATION: Mark the following information on page 1-06-1 of the 1982 Jeep SSO
Manual.

REGULATOR, CRUISE
COMMAND ELECTRONIC-
ADJUST 3.823 4311 6-cyl. 0.2 0.2 C
PROCEDURE:
Diagnosis Information
Whenever a Cruise Command malfunction occurs, first verify that the Cruise
Command wire harness is properly connected to the electronic regulator be
fore starting normal diagnosis and repair procedures. A poor connection
can cause a complete or intermittent malfunction and is also the only non-
testable connection in the circuit. This connection is disturbed whenever
Test Tool AN PC-i-p. is used. For this reason, a loose connection may be
misdiagnosed as a regulator malfunction. Also, whenever an electronic reg
ulator is replaced, it will be necessary to-adjust the replacement regula
tor as outlined in this bulletin.
Electronic Regulator Adjustment
1 Remove the regulator attaching screws or tie straps and move the regu-
lator downward for adjustment access.
2 Verify that the wire harness is tightly connected to the regulator.
continued

-2-
3 Drive the vehicle on a level road surface and check Cruise Command
operation.
a If actual engagement speed is 2 or more mph above selected en

gagement speed, stop the vehicle, turn the regulator centering
screw approximately 1/16 of a turn counterclockwise and check the
engagement speed again- Readjust speed as needed.
b If actual engagement speed is 2 or more mph below selected en

gagement speed, stop the vehicle, turn the regulator centering
screw 1716 of a turn clockwise and check engagement speed again.
NOTE: Only a very slight amount of centering screw movement is needed to

adjust engagement speed. Approximately 1/16 of a turn in either direction
should be all that is needed for adjustment.
4 Position the regulator under the instrument panel and install the reg
ulator attaching screws.
82-035-J
FILE: Engines-Fuel
VI Jeep
Systems-Engine Electrical
Cooling
No. 1-05-82 Feb. 12, 1982
TECHNICAL BULLETIN
PROBLEM AND The four-cylinder engine identification code information in the
APPLICATION: 1982 Jeep Technical Service Manual and 1982 Jeep Service Specifica
tions handbook is incorrect.
CORRECTION: Correct the four-cylinder engine identification code information

on page 1B-l of the 1982 Jeep Technical Service Manual and page 36
of the 1982 Jeep Service Specifications handbook tg indicate the
following:
a. The identification code is a three-character code. All 1982

four-cylinder engine codes begin with the letter X, and end
with the code number/letter combination described in the 1982
Jeep Technical Service Manual arid 1982 Jeep Service Specifica
tions handbook.
b- The identification code is located at the front, top left-hand

corner of the block see illustration. Only the Georgia-Ten
nessee identification code is located at the rear of the block.

ELIGIBILITY:
IDENTIFICATION
CODE
LOCATION
PU American Motors Sales Corporation 82-O39-A/J

82-21
3 Secure the regulator to the lower end of the support rod by wrapping
the tie strap around the regulator harness and rod see illustration.
Pull the strap tight to prevent the regulator from rotating.
4 Cut the ends off the tie straps approximately 1/2-inch away from the
strap buckle.
Securing Electronic Regulator
82-017 -J
8223
_________________ ___________________
FILE: Engines-Fuel SysteMs
P1 Jeep
No. 1-02-82 Dec. 18, 1981
TECHNICAL BULLETIN
PROBLEM AND The procedure for replacing the distributor vacuum advance mechan
APPLICATION: ism on 1982 four-cylinder CJ models is incomplete. The procedure
does not indicate that the distributor must be removed in order to
replace the vacuum advance mechanism.
CORRECTION: Remove the distributor before attempting to replace the vacuum

advance mechanism on a 1982 four-cylinder distributor. Also, make
a note of this revision on page 1G-8 in the 1982 Jeep Technical
Service Manual.
WARRAIITY Not affected.

ELIGIBILITY:
550 INFORMATION: Not affected.
PROCEDURE:
Distributor Vacuum Advance Mechanism Removal
1 Remove the distributor from the engine.
2 Remove the rotor.
3 Remove the vacuum advance mechanism attaching screws.
4 Turn the vacuum advance pickup coil assembly clockwise to disengage

the rod-end of the vacuum advance mechanism from the pickup coil
plate.
Digtributor Vacuum Advance Mechanism Installation
1 Engage the rod-end of the vacuum advance mechanism into the pickup
coil plate and turn the pickup coil assembly counter clockwise.
2 Install the vacuum advance mechanism attaching screws.
3 Install the rotor.
4 Install the distributor in the engine.
82-0l3-J
‘U American Motors Sales Corporation
82-2 4
Jeep- Engine Electrical-Cooling
No. 1 01-82 Dec. 17, 1981
TECHNICAL BULLETIN
PROBLEM AND The cylinder head-to-block and damper pulley hub bolt torques for
APPLICATIoN: 1982 four-cylinder engines have been changed.
CORRECTION: The current, correct torque specifications are charted below.

Please mark these changes in the Torque Specifications Charts on
pages lB-27 of the 1982 Jeep Technical Service Manual and on page
44 of the 1982 Jeep Service Specifications handbook.
USA ft-lbs. Metric N.m
Service Service
Set-to Recheck Set-to Recheck
Cylinder Head- 92 81-103 125 110-140

to-Block Bolt
Damper Pulley 162 133-192 220 180-260

Hub Bolt

ELIGIBILITY:
SSO INFORMATIION: Not affected.
82-OlS-A/J
Acidilional copies of this bulletin are available through your zone office.
FILE: Transmission-
Fl Jeep Transfer Case-Clutch-

Drive Shafts
No. 2-10-82
TECHNICAL BULLETiN
Subject: Date: 1-03-33
GEARLUBE Type "5" Campaign: Original
Lubricant Used in T4 and T5 Transmissions
to be Replaced with a New EP Type Lubricant Application: 1982 Jeep
Wagoneer, Cherokee, Truck,
and CJ Models with T4 or
T5 Manual Transmission
Campaign No: 8208
This is a Type "5" Campaign subject to all campaign procedures and involving safety
related elements.
On some 1982 Jeep Wagoneer, Cherokee, Truck, and CJ models with a T4 and T5
manual
transmission and built between the indicated Vehicle Identification Numbers, the
original lubricant used in T4 and T5 transmissions may not provide adequate
lubrication. It is possible the transmission first gear could be damaged to the
degree that the transmission becomes inoperative.
Service correction involves draining the original T4/T5 transmission

lubricant and
replacing it with the following improved lubricant.
PARTS:
Description Quantity Part Number
LUBRICANT, Transmission Gear 2 8983 000 000

per vehicle
PROCEDURE:
1. Remove the transmission fill and drain plugs and allow the original lubricant
to drain completely.
2. Install and tighten the drain plug to 20 foot-pounds 27N.m torque.

3. Fill the transmission to the bottom edge of the fill plug hole with lubricant,
part number 8983 000 000, and install the fill plug. Tighten the plug to 20
continued I
P1 Aniaptean Matape Calae

-2-
CAUTION: The new lubricant, part number 8983 000 000, is for use in T4 and T5
transmissions only. Do not use this lubricant for any other application
especially in axles or other transmissions.
4. Paint the drain plug red to indicate campaign lubricant change completion.
S.R.T. INFORMATION:
Code for
Operation Description Claim S.R.T.
CO. LUBRICANT, T4/T5 A 0.3

TRANSMISSION REPLACE
-
CLAIM HANDLING:
Based on the repair code checked on the recall claim form, the dealer will
automatically be credited on the Mid- or End-of-Month Memorandum of Warranty
Transactions Code 40 referencing the claim number on the form. The single credit
will include labor, parts cost and applicable parts mark-up.
Cempeign 0: 8208
NHTSA $O 329-125
Fl Ameican Macon
SSn CocpotaSn
Ca".’
January 3. 1983
Deer Jeep Vehicle Owner:
This noUc. La sent to you in eccordsnce with the requiresent. of the I.t.ooel
Treffic and Motor Vehicle Safety Act.
Jeep Corporation he. det.r.ined that a detect which relate, to motor vehicle safety
estate in some 1982 model. Jeep vehicle. equipped with either * 4-speed or S-speed
manual transuispion. It is poe.ible that the crØoaeissioa in your vehicle may
becoee deaaged. Such damage could cause your transmission to become ioo?etative
and leeS to a vehicle crash without soy prior werning.
Plea.. contact your Jeep Seater to arrange an appointment to heve the original
lubricant in the trsnsai..ion of your vehicle replaced with an extreae pressure
lubricant. We recoaend that you avoid driving at highway ,peed. and, if your
vehicle is equipped with e 5-speed traneaieaion, that you not ne fifth gear until
your vehicle ie serviced. Tour dealer is now prepered to change the lubricant in
your vehicle. This :ep.ir shauld rake t300rq then cnn.,.,- cod will oe p.rromed
at no charge to you.
Please present the entire encloeed fore to your dealer when you present your
vehicle for campaign eervicing. If you no longer own the vehicle described, or you
have eoved, please complete the change of a4dreea or ownership fore attached to the
back of the eccloeed for, and return it to ue in the encloaed pre’eddreseed postage
paid envelop. co that we may updete our record. accordingly.
If your dealer does not perform thie service on your mutually arranged appointment
date or within five deye thereafter end without charge, pleas. contact the local
Zone Office listed in your Owner’s PIs.iusl or Aaaricaa Motors Sales Corporation,
Owner Relatione, 14230 Plymouth load, Detroit. Nichigen 48232, Telephone 313
4932341. It you are then unable to obtain thie campaign service within a
reasonable time or without cherge, you say wish to contsct the National Highway
Trsfftc Safety Adeinistrstton. 400 Se*enth Street, S.W. , 4eehiogton D.C. 20590 or
csll the toll-free Auto Safety Hotline at 800-424-9393 Washington D.C. area
residents say cslL 426-0113.
We regret any inconvenience this nay cause you; however, we have tekin chi, action
in the interest of your .aafety and contiftuld satisfaction with our products. We
again wish to thank yots for your continued confidence in purchasing our jeep
products and may you have eany happy miles of pleasant motoring.
FILE: Transmission-
Transfer Case-Clutch-
Drive Shafts
No. 2-09-82 Dec, 10, 1982
TECHNICAL BULLETIN
PROBLEM AND Some 1982 -83 Wagoneer, Cherokee and Truck models with a 360 CID
APPLICATION: eight-cylinder engine and automatic transmission may develop a
shudder-type vibration. The condition is often compared to
driving over toll booth speed warning bumps and may also produce a
visible but slight vibration of the instrument panel and steering
column, The condition may be caused by one or a combination of
the following: rough road surface, loose engine-transmission-
-transfer case mounts, incorrect manual or throttle linkage
adjustment, incorrect transmission fluid level, poor engine
performance, wheel/tire imbalance, or damaged transmission
component.
CORRECTION: Perform the diagnosis and repair procedure outlined in this

bulletin.
PARTSt The following parts may be required.
GASKET, Oil Pan 1 8120984 16.315
CONVERTER, Torque 1 8133181 16030
KIT, Transmission 1 8997307 15.211

Oil Cooler
S.R.T.
INFORMATION:
Operation
Operation Descript ion T.I.C. Number S,R.T.
CO, TRANSMISSION, UNDERHOOD, 2-314 2999 0.8

AND DRIVELINE COMPONENTS -
INSPECT
CO. ROAD TEST 2-314 0129 0.3
CO. LOCKUP MODULE-MODIFY 2-314 2999 0,9

Includes Oil Pan R&lt and
Inspection and Valve Body R&R
continued
flanMomnSsCoon
-2-
S.R.T.
INFORMATION: con.t
Operation
Operation Description T.I.CC Number S.R.T.
CO. TRANSMISSION-OVERHAUL 2-314 2999 8.0

Includes Oil Pan R&R and
inspection, transmission
R&R, replace torque
converter and modify
lockup module
CO. OIL COOLER KIT - INSTALL 2-314 2999 1.0

REIMBURSEMENT:
PROCEDURE:
I. Check and adjust the following transmission components if necessary:
* Fluid level
* Throttle linkage
* Shift linkage
2. Check the following underhood items and make any necessary corrections:
* Ignition operation and timing

* Vacuum hose routing and connections
* Wire harness routing and connections
3. Check engine, transmission, and transfer case mountings. Tighten

loose mounts or replace any damaged mounting components.
4. Check wheel/tire condition and tire inflation pressures.

Correct inflation pressures if necessary and note any abnormal tire
wear that might be caused by excessive wheel/tire run-out, damaged
wheels, or an Imbalanre condition. Refer to Chapter 211 in the
1982 Jeep Technical Service Manual for tire pressure specifications
and abnormal tire wear patterns.
S. Road test the vehicle to verify a shudder condition. Drive the

vehicle at least seven miles to warm the tires and driveline
components. If shudder or vibration is not experienced during the
road test, return the vehicle to the owner.
a. If a shudder-type vibration similar to driving over toll booth

speed warning bumps occurs at approximately 40 mph in
third gear, proceed to step 6.
-3-
b. If a shudder-type vibration did not occur but some type of

vibration was experienced, further driveline or wheel/tire
diagnosis is required; especially if abnormal tire wear was
noted in step 4. Refer to Chapters 2E and 2H in the 1982 Jeep
- Technical Service Manual for further diagnosis procedures.
6. Carefully remove and inspect the transmission oil pan for a heavy
accumulation of debris friction material and/or metal particles.
a. If the pan contains little or no debris, proceed to step 8.
b. If the pan contains a heavy accumulation of debris, proceed to

step 7.
7. Remove and disassemble the transmission. Perform the following

operations as outlined in Chapter 2C of the applicable Jeep Technical
Service manual, and proceed to step 8.
* Clean and inspect all components. Replace any parts that are
worn or damaged.
* Flush the oil cooler and cooler lines.
* Replace the torque converter.
* Reassemble and install the transmission but do not install the
valve body at this time.
* Proceed to step 9.
8. Remove the valve body.
9. Remove the lockup module and oil tube from the valve body see
illustration.
10. Remove the end plate from the lockup module. Then remove and discard
the lockup spring see illustration.
11. Assemble a 9/64 to 5/32-inch thick stack of 3/8-inch 0.0. flat washers.
Then install the washers in the lockup module in place of the lockup
12. Install the end plate on the lockup module and tighten the end plate
screws to 35 inch-pounds 4 N.m torque.
CAUTION: Be sure the end plate fits flush against the module. If not,
remove enough material from the washers to show a flush fit.
13. Install the lockup module and oil tube on the valve body. Tighten
the module attaching screws to 35 inch-pounds 4 N.m torque.
14. Install the valve body. Tighten the valve body attaching screws
alternately and evenly to 100 inch-pounds 11 N.m torque.
15. Install the oil pan and replacement gasket on the transmission.
Tighten the pan bolts to 150 inch-pounds 17 N.m torque.
-4-
16. Install transmision auxiliary oil cooler kit, part number 8997307.
Refer to the instruction sheet supplied with the oil cooler
kit and the Auxiliary Cooler Installation procedure in Chapter 2C of
the 1982 Jeep Technical Service Manual.
17. Fill the transmission with AMC/Jeep, flexron II, or an equivalent

automatic transmission fluid.
18. Verify proper transmission operation and return the vehicle to

the owner.
82-08 5-J
FILE: Transmission-
Drive Shafts
No. 2-08-82 Nov. 11, 1982
TECHNICAL BULLETIN
PROBLEM AND This bulletin supercedes the manual transmission and transfer
APPLICATION: case lubricant specifications published in Jeep Technical
Bulletin numbers 2-01-82 and 2-06-82 and in the 1982 Jeep
Technical Service Manual and Service Specifications handbook.
CORRECTION: Discard your copies of bulletin numbers 2-01-82 and 2-06-82

and refer to this bulletin for all transfer case and manual
transmission lubricant specifications. SAL 80W-90 or 85W-90
are the only lubricants to be used in 14/IS transmissions.
These lubricants must be used for service refill purposes and
should also be used to replace the original lubricant in
vehicles not yet sold or in service in dealer stock.
Change the T4/T5 transmission recommended lubricant and

lubricant capacity specifications on pages 2B-18 and 2B-26 of
the service manual to reflect the following lubricant recom
mendations and capacities:
Recommended Lubricants SAL 8OW-9O or

8514-90 A.P.I.
Grade CL-S only
Lubric it Capacity - In-Service Refill
Transmission U.S. Pints Imperial Pints Liters
14 3.5 2.9 1.7

T5 4.0 3.3 1.9
Lubricant Capacity Dry Fill

-
Transmission U.S. Pints Imperial Pints Liters
T4 3.9 3.2 1.8

IS 4.5 3.7 2.1
Please mark the following underlined correction in step 42 at

the top of page 20-21 lii your 1982 Jeep Techntcal Service
Manual:
"Pour 6 pints 2.82 liters of ANC/Jeep Dexron II, or equivalent

automatic transmission fluid into transfer case through fill
plug hole and install and tighten fill plug to 18 foot-pounds
24 N.m torque."
continued

Service Engineering Department * 14250 Plymouth Road * Detroit. MichIgan 48232
Additional cop’es of this buhe tin ate available through your zone office.
-2-
SALT. INFORM&TION:
Operation
peration Description T.I.C. Number S.R.T.
CO. LUBRICANT, T4/T5

TRANSMISSION REPLACE
- 2-170 2999 0.2

REIMBURSEMENT:
82-096--A/J
82-33
FILE: Transmission-
Drive Shafts
No. 2-07-82 Sept. 10. 19W
TECHNICAL BULLETIN
PROBLEM AND Some Model 208 transfer cases built prior to April 5, 1982 may de-
APPLICATION: velop an intermittant clunk noise that only occurs in 4-wheel drive
high or low range and primarily when driving on pavement. The
noise occurs every 1/4 to 1/2 mile and is a result of increasing
front-to-rear wheel torque bias that causes the sliding clutch to
rapidly disengage then reengage with the sprocket carrier.
CoRRECTION: Replace the original sprocket carrier, sliding clutch, clutch

spring, and mode fork with the new and improved parts that were
phased into production on April 5, 1982, as a running change. It
may also be necessary to replace the range fork and anuulus gear if
either of these component-s exhibit excessive wear or damage.
PARTS: Description Quantity Part. Number Group
KIT, Model 1 8130481 1.8.000

208 Clutch
and Carrier
Kit Contents:
Carrier, Sprocket 1 8134541 18.820
Clutch, Sliding 1 8134542 18.850
Spring, Clutch 1 8134543 18.850
Fork, Mode 1 8130851 18.865
FORK, Range 1 8130858 18.865

Includes inserts
GEAR, Annulus 1 8130864 18.848
S.R.T. Not affected.

INFORMATION:

REIMBURSEENT
PROCEDURE:
1. Remove the transfer case as outlined in Chapter 2D of the 1981-82 Jeep

2. Disassemble the transfer case as outlined in the 1981-82 Jeep Technical

Service Manuals but do not remove the planetary assembly, input gear,
range sector, or lockplate.
continued
Service Engineering Departsn*nt * 14250 Plymouth Road * Detroit, Michigan 48232
82-34
-2--
3. Discard the original sprocket carrier, sliding clutch, clutch spring,

and mode fork, then clean and inspect the remaining transfer case com
ponents that were removed.. Pay particular attention to the range fork
inserts and the fork groove in the annulus gear- Replace the fork if
the inserts exhibit wear and the annulus gear if the fork groove sur
face is rough or worn.
4. Obtain the necessary replacement parts and reassemble the transfer case
as outlined in the 1981-82 Jeep Technical Service Manuals. Do not fill
the transfer case with lubricant at this time however.
5. Install the transfer case as outlined in the 1981-82 Jeep Technical

Service Manuals. Then refill the transfer case with 6.0 pints 2.9
liters of Dexron II automatic transnission fluid or equivalent.
82-072-J
82-35
FILE: Transajssion-Trana-
Let Case-Clutch-Drive
Shafts CHASSIS Clutcir
-
Manual Transmission
No. 2-04-82 April 29, 198
TECHNICAL BULLETiN
PROBLEM AND Improper servicing of the reverse gear shift rail on 1981-82 Jeep
APPLICATION: T-176 manual transmissions built after June 29, 1981 beginning
with serial number RCFB-2695.
CORRECTION: When servicing a 1981-82 T-176 transmission built after June 29,
1981, do not discard the spacer, part number 8134403, on the re
verse gear shift rail see illustration. This spacer was added to
prevent reverse gear overtravel and must remain in place on the
shift rail. Make a note of this information on pages 28-22 and
25-23 in the 1981 Jeep Technical Service Manual and pages 23-33 and
2B-34 of the 1982 Jeep Technical Service Manual.
NOTE: When repairing a T-176 transmission built prior to June 29,

1981, if the reverse idler gear front thrust washer exhibits
an unusual amount of wear, reverse gear overtravel is indi
cated and a spacer should be installed on the reverse shift
rail.
PAnS: See note.
WARRARrY Not affected.

ELIGIBILITY:
SSO INP0RM&TION; Not affected.
9
3,
REVERSE
SHIFT
FORK
8 REVERSE GEAR
SHIFT
I RAIL
.- ---- SPACER
DO NOT
DISCARD
Reverse Gear Shift
Rail Spacer Location
82-061-J
Additional copies 0/this bulletin are available through your zone office.
82-38
______________ ___________________
FILE: Transmissions-
Transfer Case Clutch-
-
Drive Shafts CHASSIS -
Transfer Case/Quadra-Trac
No. 2-05-82 April 21, 1982
TECHNICAL BULLETIN
PROBLEM AND Difficulty shifting into and out of four wheel drive on some 1980-
APPLICATION: 82 CJ and Scrambler models with Model 300 transfer case.
CORRECTION: Remove the shift control link assembly and measure the distance
between the rear edge of the shift lever hole and the forward edge
of the guide pin and replace the link assembly if this distance is
other than 1-9/16 inch, see illustration.
LINK ASSEMBLY,
Shift Control 1 5360073 18.182
PIN, Cotter 1 G112726 18.183

ELIGIBILITY:
SSO INFORMATION:
Operation Description Code Number Model -80- -81- -82- level
LINK ASSEMBLY, SHIFT

CONTROL -INSPECT... 18.135 18047 CJ- 0.3 0.3 0.3 G
Scrambler
Replace - Add 0.1 0.1 0.1
PROCEDURE:
2. Remove the shifter shaft nut, slide the shifter shaft out of the trans
fer case shift lever, and move the shift lever aside.
3. Remove the cotter pin that retains the outer shift control link pin and
remove the outer link pin.
4. Remove the shift control link assembly by rotating it outward to disen

gage it from the inner shift link pin.
continued

ServIce Engineering Departmat * 14250 Piymouth Rood e Detroit, Michigan 4fl01Q
82-37
-2-
5. Using an accurate steel scale, measure the distance between the rear
edge of the shift lever hole and the forward edge of the guide pin on
the shift control link assembly see illustration. The correct dis
tance is approximately 1-9/16-inches.
a. If the distance measured is approximately 1-9/16-inches. and some

type of shift problem occurred, further diagnosis is necessary.
Refer to Chapter 2D in the appropriate Jeep Technical Service
Manual for procedures.
If the distance measured is other than 1-9/16-inches, the link

assembly is out of tolerance and must be replaced. Proceed to next
step.
NOTE: Link assemblies that are out of tolerance will be from 1/16
to 1/8 inch over the correct distance.
6. Install the replacement shift control link assembly by rotating the as

sembly inward and engaging it with the inner shift link pin. Be sure
the link guide pin is also engaged in the shift lever link.
7. Install the outer shift control link pin and secure the link pin with a
replacement cotter pin.
8. Seat the transfer case shift lever in the shift control link assembly.
Insert the shifter shaft into the shift lever and install and tighten
the shifter shaft nut.
GUIDE
PIN
LEVER
HOLE
Checking Shift Control

Link Assembly Dimension
32-054-J
82-38
FILE: Transmission-
Transfer Case-Clutch-Drive
Shafts CHASSIS - Automa
tic Transmission
No. 2-03-82 Mar. 17, 1982
TECHNICAL BULLETIN
PROBLEM AND The clutch plate clearance specification for model 727 automatic
APPLICATION: transmissions with 4 disc front clutches, is incorrE in the 1980-
81-82 Jeep Technical Service Manuals and 1980-81-82 Jeep Service
Specification’s handbooks.
CORRECTION: Change the 4-disc clutch plate clearance specification for Model
727 automatic ttansmissions to: "4-Disc 0.082 O.!51 inch."
-
Please note the correct specification on the following Jeep Tech

nical Service Manual and Service Specification handbook pages.
Page 2C-ÔO of the 1980 Jeep Technical Service Manual and page
183 of the 1980 Jeep Service Specification’s handbook-
- Page 2C-68 of the 1981 Jeep Technical Service Manual and page
129 of the 1981 Jeep Service Specification’s handbook.
Page 2C-66 of the 1982 Jeep Technical Service Manual and page
137 of the 1982 JeepS Service Specificationts handbook.

ELIGIBILITY:
SSO INFORMATION: Not affected
82-055-J
- -. .. - . -
.___
FILE: Axles-Suspension-’
Brakes-Steering CHASSIS
Jeep Transfer Case/QuadraTra
No. 3-04-82 Mar. 8, 19
TECHNICAL BULLETIN
Transfer case shift lever rattles or makes a buzzing noise in some

PROBLEM AND
Install a flat washer and rubber bumper on the transfer ease shift
CORRECTION:
lever ball-end see illustration
WASHER, Flat 1 G131016 17.814
BUMPER, Rubber 1 637936 35.300

ELIGIBILITY:
SSO INFORMATION:


SHIFT MODIFY
- 18.135 18019 CJ 0.2 0.2 0.2 G
PROCEDURE:
1. Raise the vehicleb
shift lever.
3. Lift the shift lever upward and out of the shift control link,
the shoulder at the ball-end of the shift lever.
continued
-2-
CASE SHIFT
LEVER
FLAT
WASHER
RUBBER
BUMPER
SHIFT LEVER
BALL-ENO -

82-057-J
________________ _________________
FILE: Transmission-Tram
fer Case-Clutch-Drive -
Shafts CHASSIS-Transfer
Case/Quadra-Trac
No. 2-02-82 Dec 18, 11
TECHNICAL BULLETIN
PROBLEM AND Model 208 and 219 transfer cases in 1980-81-82 Jeeps are being un
APPLICATION: necessarily disassembled when only the input gear oil seal is re
placed.
CORRECTION: Whenever it is necessary to service only the input gear oil

seal, the seal can be removed easily with a sharp punch and hammer
after the transfer case is out of the vehicle. Disassembly of the
transfer case is not required. Make a note of this information in
Chapter 2D of the 1980-81-82 Jeep Technical Service Manuals.
PARTS: As required.

ELIGIBILITY
SSO INFORMATION: Mark the following 550 information on page 2-03-3 of the 1982 Jeep
SSO Manual.

pçration Description Code Number Model -80- -81- -82- Level
TRANSFER CASE R&R - 18500 6-Cyl. 1.3 1.3 1.3 C
Model 208, 219 8-Cyl. 0.9 0.9 0.9
Input gear
oil seal Replace
- 18.216 G 6-Cyl. 0.1 0.1 0.1 C
8-Cyl. 0.2 0.2 0-2
PROCEDURE:
1 Remove the transfer case as outlined in the appropriate Jeep Technical

Service Manual.
2 Remove the seal using a sharp punch and hammer. Tap the punch into
the metal outer shoulder of the seal, place a wood block between the
punch and transfer case, and carefully pry the seal out of the transfer
case.
p-I American Motors Sales Corporation

CAUTION: Do not attempt to remove the seal by prying directly against
the transfer case. A wood block or similar item must be placed
between the punch and case to avoid damaging the aluminum case.
3 Clean the seal bore in the transfer case thoroughly.
4 Apply a coating of Jeep Gasket-In-A-Tube or equivalent sealer to outer

the outer edge of the replacement seal and install the seal in the
tnnsfer case.
5 Install the transfer case as outlined in the appropriate Jeep Technical

Service Manual.
______________
PILE: Axles-Suspension-
F’I Jeep
Brakes-Steering
No. 3-03-82 Feb. 19, 1982
TECHNICAL BULLETiN
PROBLEM AND Occasional suspension spring squeaks and a hard or stiff ride on a
APPLI CATION: 1982 CJ Limited model may be caused by improperly installed suspen
sion spring retainers. On some models, the retainer tabs were
clinched flat against the spring instead of allowing the required
spring-to-tab clearance.
CORRECTION: Inspect the retainer tabs on each leaf spring and bend any tabs up
ward to provide the required clearance if necessary see illustra-
tion.

ELIGIBILITY:
SSO INFORMATION:
Cost Operation Year and Time
Qperation Description Skill
Code Number Model -80- -81- -82- Level
SUSPENSION
SPRING RETAINERS -
ADJUST 11.084 11165 CJ 0.2 C

PROCEDURE:
Inspect the spring retainers and bend the retainer tabs
upward as
necessary to provide the required 0.100 0.250 inch 3
- 6mm clear -
ance as shown in the illustration.
CAUTION: Do not use an acetylene or propane
torch to heat and bend the
the retainer tabs as this could damage the
spring. Use a pry bar
only to bend the tabs.
CLEARANCE BETWEEN
TABS AND SPRING
RETAINER MUST BE 0.100 0.250
-
TAB INCH.
SPRING___
LEAVES
£I___aX____/ ‘N,
S!R!NG
vu Jeep
PILE: Axles-Suspension-
Brakes-Steering CHASSIS-
Brakes-Wheels
No- 3-02-82 Feb. 12, 1982
TECHNICAL BULLETIN
PROBLEM AND Disc brake caliper pistons in some 1976-82 Jeep vehicles may devel-
APPLICATION: op a light coating of rust on the suface under the dust seal out
board of the piston seal. This coating could cause the piston to
not fully retract.
CORRECTION: When overhauling disc brake calipers on a 1976-82 CJ or Scrambler

model, apply a coating of Dielectric Compound, 8126688, to the
caliper piston bore area indicated in the illustration before in
stalling the caliper piston. Also make a note of this procedure in
NOTE: Caliper overhaul kits for 1976-81 models ordered after Jan
uary 1982, will contain a 1.5 gram package of silicone lub
ricant for piston bore area lubrication.
COMPOUND, Dielectric AR 8126688 3.038

ELIGIBILITY;
550 INFORMATION: Make a note of this information on pages 2-05-1 and 2-05-4 of the
1982 Jeep SSO Manual.

CALIPER ASSEMBLY R&R

- 8064 C
One 0.3 0.3 0.3
Both 0.4 0.4 0.4
Caliper assembly-Overhaul 8.155 A G
One 0.3 0.3 0.3
Both 0.6 0.6 0.6
Material allowance for
piston bore lubricant
is 0.l2
BRAXESHOES -REPLACE
FOUR WHEELS 8.009 8050 1.2 1.2 1.2 C
Includes adjust
parking brake
Caliper assembly-Overhaul 8.155 F C
One 0.3 0.3 0.3
Both 0.6 0.6 0.6
Material allowance for
piston bore lubricant
is $0.12 continued
Michigan 48232
Service Engineering Department * 14250 Plymouth Road * Detroit,
Additional copies of this bulletin am available through your zone oThce.
82-45
-2-
PROcEDURE:
1- Remove, disassemble, clean and inspect the caliper assembly as out

lined in the appropriate Jeep Technical Service Manual. Pay particu
lar attention to caliper piston condition. Replace the piston if
scored, pitted, or corroded, or if the plating has worn through.
2. Lubricate the caliper piston bore and replacement piston seal with
brake fluid and install the seal in the piston bore groove.
3. Apply a light coating of Dielectric Compound or silicone lubricant to the

entire circumference of the caliper piston bore area between the dust
boot and piston seal see illustration.
4. Install the dust boot as outlined in the appropriate Jeep Technical

Service Manual.
5. Install the caliper piston as outlined in the appropriate Jeep Techni

cal Service Manual. Take care to avoid wiping the Dielectric Compound or
silicone lubricant from the caliper bore during piston installation.
6. Clean excess lubricant and brake fluid from the end of the caliper piston
or dust boot after seating the piston in the bore.
7. Complete caliper assembly and installation as outlined in the appro

BOOT
NflON
SEAL
Caliper Piston Bore Lubrication
R2 -027 -J
82-46
vu Jeer FILE: Axles-Suspension-
No. 3-01-82 Jan. 22, 1982
TECHNICAL BULLETIN
PROBLEM AND Service procedures and 550 times for air adjustable shock absorbers
APPLICATION: on 1982 Jeep Wagoneer, Cherokee, and J-lO Truck models.
CORRECTION: When servicing air adjustable shock absorbers, refer to the infla-
flation, test, and service procedures outlined in this bulletin.
Make a note of these procedures in Chapter 2N of the 1982 Jeep
PARTS: As required.

ELIGIBILITY:
SS0 INFORMATION: Make a note of these times on page 2-07-3 of the 1982 Jeep SS0 Man-
ua 1.

SHOCK ABSORBER,
AIR ADJUSTABLE -
REPLACE 11.220 11150 Wag-Cke-Trk C

One 0.4
Both 0.5
TUBE ASSEMBLY, AIR

SHOCK-TO-AIR
SHOCK REPLACE
- 11.235 9144 Wag-Cke-Trk 0.2 C
TUBE ASSEMBLY, AIR

SHOCK-TO-FILL VALVE -
REPLACE 11.235 9146 Wag-Cke-Trk 0.2 C
VALVE, AIR SHOCK

FILL - REPLACE 11.233 9148 Wag-Cke-Trk 0.2 C
PROCEDURES:
GENERAL
Air adjustable rear shock absorbers for 1982 Jeep Wagoneer, Cherokee, and
J-10 Truck models are manually inflated units with a minimum inflation
pressure of 20 psi 138 kPa and a maximum pressure of 120 psi 827 kPa.
The complete air shock system consists of the two shock absorbers plus
interconnecting air lines and an inflation valve located at the rear of the
vehicle see illustration.
continued
Addq,onal copies of this bullet,,, are available through your zone office
82-47
-2-
AIR S AIR
INFLATION S FILL
VALVE * HOSE
HOSE
cup
INTERCONNECTING
AIR HOSE
Air Shock Absorber Assembly
AIR SHOCK INFLATION PROCEDURES
With Unloaded Vehicle
For normal unloaded operation, the air shocks should be maintained at an

inflation pressure of 20 psi 138 kPa for best ride characteristics.
Pressures higher than this are not recommended for unloaded vehicles.
With Loaded Vehicles
Caution: Do not inflate the air shocks until after the vehicle is loaded
or had a trailer attached. If the £hocks are inflated before loading, the
combined force of initial inflation plus load weight could exceed the air
shock maximum pressure limit of 120 psi 827 kPa and damage the shock ab
sorbers.
Inflation
1 Release all air from the shock absorbers.
2 Place the load in, or attach the trailer to the vehicle.
3 Connect an air supply hose to the inflation valve.
4 Add air to the shock absorbers until the vehicle is at the desired
ride height or until the maximum pressure limit of 120 psi 827 kPa is
reached; then disconnect the air supply hose.
Deflation
1 Detach the trailet or remove the load from the vehicle.
2 Press the inflation valve core inward uncil the desired amount of air
is released from the shock absorbers.
3 Adjust the air shocks to the recommended unloaded pressure ot ZU psi

138 kPa.
82-48
-3-
AIR SHOCK LEAK TEST
If the air shocks do not maintain desired ride height or are slow to in
flate, it will be necessary to test the entire system for leaks as follows.
1 Prepare a solution of soapy water.
2 Inflate the air shocks to 120 psi 827 kra.
3 Apply the soapy water solution to the shock absorbers, hoses, hose
connections, and inflation valve and check for leaks. Leaks will
cause bubbles in the soapy water solution at or near the leak area.
4 If leaks are detected, repair or replace the leaking components as

necessary.
AIR SHOCK REMOVAL/INSTALLATION
Removal
1 Release all air from the shock absorbers.
2 Raise and support the rear of the vehicle.
3 Position the hydraulic jack under the rear axle housing and raise the
axle slightly to relieve the springs of axle weight.
4 Disconnect the air lines at the shock absorbers. Tag the lines for
assembly reference.
5 Remove the nut and washer that attach the shock absorber to the upper
mounting pin.
6 Remove the bolt and locknut that attach the shock absorber to the
lower mounting bracket.
7 Remove the shock absorber.
Installation
1 Position the shock absorber on the upper mounting pin and in the lower
mounting bracket.
2 Install and tighten the shock absorber lower bolt and nut and upper
washer and locknut to 43 foot-pounds 58 Nm torque.
3 Connect the air lines to the shock absorbers.
NOTE: The driver side shock absorber has two line connectors. The
passenger side shock absorber has only one
4 Inflate and deflate the air shocks to verify proper operation.
5 Remove the hydraulic jack from under the axle, remove supports and
lower the vehicle.
6 Adjust the air shocks to 20 psi 138 kPa.
82-018-llJ
FILE: Windshield-Windows-
Jeep Body Hardware BODY-Body

General
No. 5-03-82 Oct. 8, 1982
TECHNICAL BULLETIN
PROBLEM AND Revisions made to certain part has improved the operation
APPLICATION: of the lock button and latch on CJ models with metal doors and
remote door handles. If the door handle or lock button in the
metal doors of 1981-82 CJ models require service or become
difficult to operate, use the following procedure to determine
proper servicing.
CORRECTIONS Inspect and repair the door lock button and latch mechanism as
outlined in the Procedure portion of this bulletin.
PARTS: The following parts may be required.
LATCH ASSEMBLY, i. 23.050

Front Door
Left 5758177
Right 5158176
ROD AND BUSHING ASSEMBLY, 1 per door 5758179 23.074

Outside Door Handle
CLIP, Lock Button 1 per door 4007207 23.055

Pivot Pin Retaining
S.R.T. INFORMATION:
Operation
Operation Description T.I.C. Number S.R-T.
CO. FRONT DOOR LATCH AND 5-224 5999

ROD AND BUSHING ASSEMBLIES -
INSPECT
One door 0.1
Both doors 0.2
SO. FRONT DOOR LATCH - 5-121 5999

REPLACE
One door 0.3
Both doors 0.5
continued

Service Engineering Department * 14250 Plymouth Road . - Detroit, Michigan 48232
-2-
Operation
SO. ROD AND BUSHING 5-130 5999

ASSEMBLY, OUTSIDE
DOOR HANDLE -REPLACE
One door 0.1
Both doors 0.2
CO. CLIP, LOCK BUTTON 5-130 5999

PIVOT PIN RETAINING -
INSTALL
One door 0.2
Both doors 0.3

REIMBURSEMENT:
PROCEDURE:
1. Remove the front door window regulator handle, door pull

strap, and lower trim panel.
2. Inspect the latch assembly and control rods, and the .1-shaped
outside door handle rod and bushing.
a. Replace the latch assembly if damaged or if the nylon

spacer between the lock and release levers, as
shown in Figure 1, is damaged or missing.
b. If the latch control rod is bent or binding, it must

be replaced. Do not attempt to straighten it.
c. Inspect the J-shaped outside door handle rod and bushing

assembly. If it is bent or dautaged, it must also be
replaced. The rod must be equipped with a solid-type
bushing as shown in Figure 2.
LATCH
ASSEMBLY
Fig. 1 - Latch Assembly Inspection
82.51
-3-
3. Install any necessary replacement components as indicated in
the previous inspection step. Refer to the appropriate Jeep
Technical Service Manual for procedures.
4. Lubricate the latch mechanism and the outside door handle

rod and bushing with Lubriplate or an equivalent lubricant.
5. Roll the front door window down.
6. Remove the remote control handle attaching screw and rock the
handle out of the door.
SOLID-TYPE
BUSHING
OUTSIDE
DOOR
HANDLE
ROD
Fig. 2 - Outside Door Handle Rod and

Bushing inspection
7. Install retaining clip, part number 4007207, over the remote

control handle lock button pivot pin and pin boss Fig. 3.
Be sure the clip irtch is fully seated on the plastic pin and
pin boss.
8. Install the remote control handle in the door and install the
handle retaining screw.
9. Install the door lower trim panel, door pull strap, and window
regulator handle if not already installed.
RETAINING
CLIP
PIVOT
PIN
Fig. 3 - Lock Button Pivot Pin Retaining 82-091 -J

Clip installation
82-52
r Jeep FILE: Windshield-
Windows-Body Hardware
BODY - Body General
No. 5-02-82 Sept. 10.1982
TECHNICAL BULLETIN
PROBLEM AND Discoloration or peeling of the finish coat on wood side rails in-
APPLICATION: stalled on some 1981-82 Scrambler and Sportside Truck models.
CORRECTION: Strip and refinish both wood side rails as outlined in this bul
letin.
PARTS: Not affected.
S.R.T. INFORMATION:
Operation
Operation Description t.I.C. Number S.R.T.
Co. WOOD SIDE RAILS -
REFINISU BOTH 9-350 5999 5.1

Material allowance
for paint, sandpaper,
stripping agents, sealer
and bleach is $2C.O0 for
both sides
DEALER Reimbursable within tie provisions of the applicable warranty.

REMIBLJRSEMENT:
PROCEDURE:
1. Remove the side rails from the vehicle.
2. Strip the original finish from the rails using a quality chemical
stripping agent such as Savogran, BIX, Zip-Strip, or an
equivalent varnish remover.
the
3. Sand the side rail surfaces with medium grit sandpaper to smooth
surfaces and remove all traces of the old finish.
bleach and water

4. Wash the side rails with a 50/50 solution of household
Allow the rails to dry
to remove and prevent mildew formation.
thoroughly after washing.
to the side rails and allow the

5. Apply one or two coats of wood sealer
seater to dry thoroughly.
air drtype
6. Repaint the decorative grooves in the side rails with an
enamel. Have the owner select paint color if necessary.
polyurethane or
1. Apply a minimum of two coats of an exterior grade
marine spar varnish to the side rails. Be sure to follow the man
ufacturer’s instructions for vanish application.
8. Install the side rails when the varnish coats have dried thoroughly.
82-079-3
‘I Amerkari Motors Sales Corporation
48232
Service Engineering Department * 14250 Plymouth Road * Detroit, MichIgan
your zone office
Additional copies of this bulletin are available through
82-53
FILE Windshield-Windows
VU Jeep -Body Hardware BODY -
Body General
No. 5-01-82 Feb. 15, 1982
TECHNICAL BULLETIN
PROBLEM MW Power windows on some 1980-82 Wagoneer, Cherokee, and Truck models
cogREaIoN Install a polypropylene wedge at each end of the door glass bottom
PARTS:
Part Description Quantity Part Number Group
WEDGE, Door AR 5762644 25.030

Glass Bottom
Channel

ELIGIBILITY:
550 INFORMATION:


DOOR GLASS BOflOM
INSTALL WEDGES.... 25045 Wag-Cke-Trk
One door 0.8 0.8 0.8
Each additional
door Add
- 0.7 0.7 0.7
Replace bottom
channel Add....
- 0.2 0.2 0.2
Front 25.030
Rear 25.032
PROCEDURE:


the wedges to the bottom of the channel as shown in the illustration.
continued
Additional conies of thtc fm/latin am ni,ailahM th,nnnh LgnJJr .nna nifiro
-2-
4. Install the door glass and bottom channel as outlined in chapter 3J of

DOOR GLASS
N BOTTOM CHANNEL
SEAL
POLYPROPYLENE
WEDGE
8 2-031-J
82-55
VU Jeep
PILE: Body/Chassis
Electrical BODY Body -
Electrical
Np. R-03-R2 Sent. 10 ics:
TECHNICAL BULLETIN
C0RRECnON: Install the improved gauge that was phased into production on
PAKF S: Description Quantity Part Number Group
GAUGE, Oil 1 5750279 3.605

Pressure
S.R.T. INFORMATION:
Operation
Qperatiou Description T.I.C. Number S .R.T.

REPLACE 8-352 8999 0.3

REIMBURSEMENT:
PROCEDURE:
1. Remove the original oil pressure gauge as outlined in Chapter lL of the appro
stallation to be sure it is one of the improved gauges. The code must be B201
2-01-82 or later.
D foi April. The first number indicates the year, which in this case is
code C2l7 would represent March 17, 1982 and code D2O8 would represent
3. Install the replacement oil pressure gauge as outlined in Chapter 1L of the appro
82-064-U

Additional cies of tins bulletin are available through your zone office.
82-56
FILE: Body/Chassis -
Electrical
No. 8-04-82 Sept. 10. 1982
TECHNICAL BULLETIN
PROBLEM AND The trailer tow harness wires may be improperly connected to the
APPLICATION: receptacle on 1982 Wagoneer and Cherokee models equipped with a
Class III trailer tow package and built prior to May 3, 1982. The
improper connections could cause inoperative trailer signal lights
and full time electric brake application.
CORRECTION: Reconnect the receptacle wires, if necessary, as outlined in the

procedure portion of this bulletin.
S.R.T. INFORMATION:
Operation
CO. WIRES, TRAILER TOWING

HARNESS RECEPTACLE
- RECONNECT 8-960 8999 0.2

REIMBURSEMENT:
PROCEDURE:
tow harness receptacle to the

1. Remove the screws that attach the trailer
housing.
2. Trim the sealant away from the harness wires at the rear of the recep
tacle and remove the wires and receptacle from the housing.
3. Inspect the wires connected to terminals 1 and 3 of the receptacle.

Black wire should be connected to terminal 1 and white wire to terminal
3 see illustration. If these wires are reversed, loosen the terminal
screws and reconnect the wires properly.
4. Inspect wires connected to terminals 2 and 4 of the receptacle. Blue

tracer wire to ter
wire should be connected to terminal 2 and red with
If these wires are reversed, loosen the
minal 4 see illustration.
terminal screws and reconnect the wires properly.
continued

Service Engineerina Department * 14250 Plymouth Road * Detroit. Michiaan 4P232
-2-
5. Install the receptacle and wires in the housing and seal the harness
wires-to-receptacle connection with silicone sealant.
6. Verify correct harness operation.
LIGHT GREEN
WITH TRACER
WHITE WITH
TRACER
WHITE
BLACK
RED WITH BLUE

TRACER
LIGHT GREEN
Trailer Tow Wire Harness Receptacle Connections
82-081-3
82-58
______________
______________________ _________________
FILE: Body/Chassis
VU Jeep Electrical BODY - Body

Electrical
No. 8-03-82 June 9, 1962
TECHNICAL BULLETIN
PROBLEM AND The center horn button cap on some 1981-82 Jeep vehicles with a
APPLICATION: sport steering wheel may rattle when driving over bumps. In add
ition, although the horn operates when the cap is pressed at other
points, it may not operate if the outer edge of the cap is pressed
directly over one of the steering wheel spokes.
CORRECTION: Check horn operation and inspect the cap for looseness as outlined
in the following procedure and, if necessary, deepen the spoke re
cesses in the cap see illustration and replace the center horn
button cap receiver if damaged.
RECEIVER, Center
Horn Button Cap 1 3242217 3.400

ELIGIBILITY:
SSO INFORMATION:

Operation Description Code Number Model -81- -82- Level
CAP, CENTER HORN

BUTTON INSPECT
- 3.400 3229 0.1 0.1 C
Includes modify
spoke recesses
if necessary
Receiver, center
horn button cap -
Replace 3.400 A 0.2 0.2 C
PROCEDURE:
1. Check horn operation by pressing the outer edge of the horn button cap
directly over each steering wheel spoke and check the cap for looseness
also.
2. If the center horn button cap is loose or if the horn did not operate
at one or more of the spoke positions, mark the positions on the cap
and proceed to the next step.
continued

Service Engineeflng Department * 14250 Plymouth Road * Detroit, Michigan 48232
82-59
-2-
3. Remove the center horn button cap.
a. If the horn did not operate at one or more of the spoke positions,
deepen the spoke recess areas in the cap using a file or knife see
illustration. Trim the recess area down to the cap inner support
only.
b. Inspect the horn button cap receiver for being bent or warped, es
pecially around the retaining lip. If the receiver is damaged or
if the cap was loose, replace the receiver as outlined in the fol
lowing steps. If the receiver is not damaged and the cap was
tight, proceed to step 7.
4. Disconnect the battery negative cable.
5. Remove the three screws that attach the center horn button receiver to the
steering wheel hub and remove the receiver bushing and receiver.
6. Position replacement receiver 3242217 in the steering wheel hub and install
the bushing and receiver attaching screws.
NOTE: Before installing the receiver attaching screws, be sure the re

ceiver and contact plate are centered around the steering shaft and
that the concave side of the contact plate is facing upward.
7. Install the center horn button cap.
8. Connect the battery negative cable.
TRIM
THIS AREA OF
RECESS AWAY
Center Horn Button Cap Spoke

Recess Modification
82-067-A/J
on an
__________ _________
FILE: Body/Chassis Elec-
P1 Jeep No. 8-02-82 Jan. 28, 1982
TECHNICAL BULLETIN
PROBLEM AND Incorrect radio speakers may have been installed on some 1982
APPLICATION: Wagoneer, Cherokee, and Truck models with the optional electron
ically tuned cassette stereo radio ErR. Models built prior to
VIN 1JCNA15N1CTO15217 may have been equipped with standard 3.2 ohm
speakers instead of the required 8-ohm coaxial speakers. This
could result in poor fidelity or a buzzing noise from the speakers.
CORRECTION: Inspect the radio speakers using a flashlight beam directed through
the speaker grille to view each speaker and replace any speaker
that is not a coaxial type see illustration.
SPEAKER, Radio AR 5756851 15.320

coaxial

ELICIBILITY:
SSO INFORMATION:

SPEAKERS, RADIO - 3605 Wag-Cke-Trk 0.1 C

INSPECT
SPEAKER, RADIO FRONT

DOOR MOUNT REPLACE
- 15.321 3648 Wag-Cke-Trk C
One side 0.4
Both sides 0.6
SPEAKER, REAR MOUNT-

REPLACE 15.321 3600 wag-eke C
One side 0.2
Both sides 0.3
continued

Service Engineering Department * 14250 Plymouth Road * Detroit Michigan 48232
Additional copies of this bullet’n are available through your zone ofhce
82-61
PROCEDURE
1 Inspect the radio speakers by directing a flashlight beam through each

speaker grille to view the speaker.
NOTE: Wagoneer and Cherokee models have speakers mounted in the

front doors and rear quarter panels. Truck models have speakers
noun ted in the front doors only.
2 Replace any speaker that does not have a tweeter support bar mounted
across the top of the speaker see illustration - Coaxial speakers
have a support bar, standard speakers do not.
3 Verify proper radio opera t ion a I ter speaker replacement.
TWEETER
SUPPORT
BAR
Coaxial Speaker Identification
82-020-A/J
82.62
____________
FILE: Body/Chassis Elec
P1 Jeep trical BODY-Body Elec

trical
-
No. 8-01-82 Dec. 18, 1981
TECHNICAL BULLETIN
PROBLEM AND The Cherokee, Wagoneer, and Truck windshield wiper linkage removal/
APPLICATION: installation procedures in the 1981-82 Jeep Technical Service Man-
are incorrect.
CORRECTION: The connecting link is permanently attached to the right pivot

shaft body and must be removed with the linkage as an assembly
see illustration. Make a note of this change on page 3T-5 of the
the 1981-82 Jeep Technical Service Manuals. The new procedures
apply to models with or without air conditioning.
WARRANTY
ELICIBILITY: Not affected.
550 INFORMATION:

Operation Description Code Number Model -81- -82- level
LINKACE, WINDSHIELD
WIPER R&R - 22.047 20001 Cke-Wag-Trk 1.6 1.6 G
PROCEDURE:
Windshield Wiper Linkage Removal
1 Disconnect the battery negative cable.
2 Remove the right and left wiper arms, pivot nuts, washers, escutche
ons, and gaskets from the pivot shaft bodies see illustration.
3 Remove the instrument cluster and the left defroster duct.
4 Disconnect the crank arm from the wiper motor.
5 Remove the glove box and the ash tray and slide assembly.
6 Remove the radio.
7 Remove the attaching screws from both pivot shaft bodies and remove
the wiper linkage and both pivot shaft bodies as an assembly.
Vi American Motors Sales Corporation

82-63
Windshield Wiper Linkage Installation:
1 Install the wiper linkage and pivot shaft bodies as an assembly and
install the left and right pivot shaft body attaching screws.
2 Attach the crank arm to the wiper motor.
3 Install the left defroster duct.
4 Install the radio, the ash tray and slide assembly, and the glove
box.
5 Install the instrument cluster
6 Install the gaskets, escutcheons, washers, and nuts on the pivot

shaft bodies and install the wiper arms.
7 Connect the battery negative cable.

BLADE
ARM
BLADE
_ARTICULATING
ARM ESCUTCHEON
AUX.
ARM RIGHT PIVOT
SHAFT BODY
ESCUTCHEON
PIVOT
NUT
GASKET POINT WHERE

MOTOR DRIVE CONNECTING
ARM LINK IS NOW
RIVETED TO
LEFT PIVOT PIVOT SHAFT
SHAFT BODY BODY
.1
WAVE WASHER
CLIP
BOLT
WINDSHIELD WIPER LINKAGE - 82-009-BSJ

WACONEER, CHEROKEE, AND TRUCK MODELS
82-64
--
Jeep Protection-Decals-
Iiscel1aneous
To. 9-04-82 Nov. 11, 1982
TECHNICAL BULLETIN
PROBLEM AND Paint codes and intermix formulas for 1983 Jeep vehicles.
APPLICATION
CORRECTION: Refer to this bulletin for the paint codes and intermix
formulas for lacquer or enamel paints available from Dupont,
Ditzler, and Rinshed Mason.
S.R.T. Not affected.

INFORMATION:

R]&L’IBURSEMENT:
Sterling Metallic Sterling Metallic Sterling Metallic

Clear Coat Clear Coat Clear Coat
Lacquer Lacquer Lac quer
Dupont Ditzler Rinshed Mason
88375 3594 13329
Mixing 1 Quart Mixing 1 Quart Mixing L Quart
447 L 816.5 DMA 321 2 PNT-90 100
475 L 907.5 DMA 346 20 AT-ll6E 795
DMA 312 380 AT-l14 980
DMA 323 850 AT-i42 990
DMA 310 990 AT-178 1,000
Clear Coat Clear Coat
Olympic White Olympic White Olympic White

Lacquer 9B Lacquer 98 Lacquer 98
45701 3107 9867
PNT 90 100
AT 190 980
N/A N/A AT 184 992
AT 141 996
AT 174 1,000
continued

82-65
-2-
Mist Silver Metallic Mist Silver Metallic Mist Silver Metallic

Labquer 2A Lacquer 2A Lacquer 2A
3466 12840
DMA 311 10 PNT-90 100
DMA 346 20 AT-ill 360
DMA 321 30 AT-114 460
N/A DMA 312 120 AT-l92 488
DMA 323 300 AT-l42 306
DMA 310 980 AT-127 519
AT-154 531
AT-100 1,000
Sherwood Green Sherwood Creen Sherwood Creen

Lacquer 2A Lacquer 2A Lacquer 2A
8192 12840
442 L 14.25 PNT-90 100
457 L 33.25 AT-176 480
455 L 65.5 AT-l33 690
406 L 106.6 N/A AT-143 790
443 L 163.1 AT-ISO 855
465 L 375.5 AT-112 880
485 L 875.8 AT-lOU 1,000
Sebring Red Sebring Red Sebring Red

Lacquer 38 Lacquer 38 Lacquer 38
88372 DDL 3592 13327
Mixing 1 Quart Mixing 1 Qaurt Mixing 1 Quart
401 L 20 DMA 311 6 PNT-90 100
305 L 67.5 DMA 333 74 AT-l70 397
436 L 225.5 DMA 360 314 AT-153 674
440 L 379 DMA 336 614 AT-iSO 823
229 L 439.5 DMA 361 1,064 AT-176 938
465 L 931.5 AT-l87 970
AT-l43 995
AT-190 1,000
continued
82-66
-3-.
Deep Night Blue Deep Night Blue Deep Night Blue

Lacquer 2D Lacquer 2D Lacquer 2D
8827 9 3469 13326
DMA 401 36 PNT-90 100
DMA 490 166 AT-l21 644
N/A DMA 450 380 AT-143 944
DMA 495 20 AT-151 983
DMA 415 420 AT-190 1,000
Deep Maroon Deep Maroon Deep Maroon

Metallic Lacquer 1K Metallic Lacquer 1K Metallic Lacquer 1K
8197 12458F
MIxing 1 Quart Mixing 1 Quart Mixing 1 Quart
PNT-90 100
AT-163 558
AT-176 867
AT-143 954
N/A N/A AT-153 976
AT-ill 994
AT-l14 997
AT-187 1,000
Jamaican Beige Jamaican Beige Jamaican Beige

Lacquer 2J Lacquer 2J Lacquer 2J
DDL 3472
DMA 392 15 PNT-90 100
DMA 346 69 AT-l90 525
DMA 393 289 AT-176 574
N/A DMA 311 1,049 AT-184 612
DMA 310 1,099 AT-127 625
AT-138 634
AT-l80 641
AT-lOU iI_000
continued
82-67
-4-
Topaz Gold Metallic Topaz Gold Metallic Topaz Gold Metallic

Lacquer 211 Lacquer 211 Lacquer 211
DDL 3471 128450
DMA 311 4 PNT-90 100
DMA 386 18 AT-lll 364
DMA 383 124 AT-176 615
N/A DMA 312 318 AT-l92 678
DMA 384 720 AT-114 726
DMA 310 980 AT-186 741
AT-143 751
AT-iO0 1,000
Copper Brown Metallic Copper Brown Metallic Copper Brown Metallic
Lacquer 1E Lacquer 18 Lacquer 18
88194 124550
PNT-90 180
AT-176 583
AT-179 667
AT-114 735
N/A N/A AT-180 785
AT-192 830
AT-143 859
AT-l87 869
AT-100 1,000
Slate Blue Metallic Slate Blue Metallic Slate Blue Metallic

Lacquer 2C Lacquer 2C Lacquer 2C
DDL 3468 12842
MIxing 1 Quart Mixing 1 Quart Mixing 1 Quart
DMA 357 4 PNT-90 [00
DMA 375 27 AT-ill 227
DMA 311 66 AT-143 295
N/A DMA 358 140 AT-124 360
DMA 321 292 AT-114 374
DMA 386 820 AT-129 387
DMA 310 990 AT-190 399
AT-100 1,000
continued
-5-
Chestnut Brown Chestnut Brown Chestnut Brown

Metallic Lacquer 111 Metallic Lacquer lEt Metallic Lacquer 111
Dupont Ditzler Rlnshed Mason
DDL 3371 12456F
442 L 4.0 DMA 320 26 PNT-90 100
412 L 14.0 DMA 309 34 AT-176 498
406 L 36.5 DMA 312 62 AT-lbS 195
433 L 72.0 DMA 360 122 AT-143 953
434 L 118.0 DMA 307 982 AT-liZ 1,000
455 L 356.5
465 L 828.0
485 L 895.0
82-094-A/J
FILE: Paint-Corrosion-
Protection-Decal s-Misc.
BODY Headlining
- Ext.
-
Decals and Overlays

No. 9-03-82 June 16, 1982
TECHNICAL BULLETIN
PROBLEM AND Hardtop inner panel headliner touches hardtop outer panel on
APPLICATION: some 1981-82 Scrambler models causing a buzz or flutter noise.
CORRECTION: Drill four 1/4-inch diameter holes in the hardtop inner panel see
illustration, spray an expandable foam, part number 8130438, be
tween the two panels to prevent touching, and install button plugs
in the drilled holes afterward.
TOUCH-N-FOMi 1 8130438 30.051
PLUGS, Button 4 8134258 28.608
WARRANfl Not affected.

ELIGIBILITY:

Operation Description Code Number Model -80- -81- -82 Level
HARDTOP -REPAIR 28.412 28167 88 0.2 0.2 C

Material allowance
for foam is $2.40
PROCEDURE:
1. Locate, mark, and drill four 1/4-inch diameter holes in the hardtop
inner panel headliner. Refer to the illustration for hole locations.
CAUTION: Be very careful to avoid drilling through the outer panel

when drilling holes in the inner panel.
82-063-J
S_. a
__
-2-
2. Attach a three inch long section of 1/4 inch O.D. hose to the hose on
the Touch-N--Foam can.
3. Insert the 1/4-inch 0.D. hose into each hole drilled in the inner
panel and spray foam into each hole for 45 seconds.
4. Install the button plugs in the drilled holes.
5. Allow the foam to cure 12 hours.
WINDSHIELD
,_,/‘HEADER
FRONT
VV
‘
‘t
9"
‘:
I
i
I I
2".I*v’
+
I WHOLE
I 4 REaD.
22"
II
I HARDTOP
" CENTER INNER
I RIB OF PANEL
HEADLINER
I INNER
PANEL
I I
+:
2"
4 I
ii
I
I
2"
REAR
Spray Foam Hole Locations in Hardtop Inner Panel

Headliner Viewed From Passenger
-
Compartment
82-7 1
Protection-Decals-Mise.
BODY Instrument Panels-
-
Seat Assemblies
No. 9-02-82 Mar. 16, 1982
TECHNICAL BULLETIN
PROBLEM AND The odometer on some 1981-82 Wagoneer, Cherokee, and Truck models
APPLICATION: may generate a high-pitched squeaking noise that occurs only occa
sionally and at any speed.
CORRECTION: Remove the speedometer/odometer assembly and lubricate the forward

pivot bearing area of the odometer drive gear with Dielectric Com
pound, 8126688 see illustration,
DIELECTRIC AR 8126688 3.038

COMPOUND

ELIGIBILITY:
SSO INFORMATION:

Code Number Model -80- -81- -82- Level
Description
GEAR, ODOMETER
DRIVE-LUBRICATE 3.505 3493 Wag-Cke-Trk 0.6 0.6 C
PROCEDURE:
1. Remove the speedometer/odometer assembly as outlined in Chapter 3C of

2. Apply Dielectric Compound to the forward pivot bearing area of the

odometer drive gear as follows: Rotate the odometer driven gear rear
ward slightly, lift the drive gear upward in its retaining slot, and
work the compound into the pivot bearing area see illustration
NOTE: The odometer drive gear forward pivot bearing area should also
be lubricated on a replacement speedometer/odometer assembly
before it is installed.
continued

MichIgan 48232
ServIce Engineering Department * 14250 Plymouth Road * Detroit,
Additional copies of this bulletin are available thwugh your zone office.
82-72
-2-
3. Clean the odometer numeral wheels and speedometer face plate of any
traces of compound.
4. Install the speedometer/odometer assembly as outlined in Chapter 3C of

APPLY DIELECTRIC
COMPOUND TO
FORWARD PIVOT
BEARING AREA
OF DRIVE GEAR
Odometer Drive Gear Lubrication
82-056-A/J
82-73
FILE: Paint-Corrosion-Pro-
Jeep tection-Decals-Miscella-
neoüs
No. 9-01-82 Dec. 14, 1981
TECHNICAL BULLETIN
PROBLEM AND 1982 Jeep paint color names and code numbers - Dupont.
APPLICATION
CORRECTION: Attached is the 1982 Dupont paint color chart for 1982 Jeep vehi
cles. The 1982 color names and corresponding code numbers are in
cluded in each chart. These charts are being sent to all dealers
in limited quantities only. If additional quantities are needed,
please contact your District Service Manager or Field Service Man
ager.

ELIGIBILITY
82-O12-BSA/J

1977 Jeep Technical Service Bulletin (TSB)

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TECHNICAL

MARCH 1984 U.S.AJCANADA EDITION

Copyright © 1984, American Motors Sales Corporation. All Rights Reserved.

Improving Performance of 1982 Jeep Vehicles Being Operated at 1-08-82 82-11

The Cylinder Head Cover Removaillnstallation Procedures Published in 1-08-82

1982 ENGINES-FUEL SYSTEMS-ENGINE ELECTRICAL-COOLING

1982 TRANSMISSION-TRANSFER CASE-CLUTCH-DRIVE SHAFTS

Transmissions with 4 Disc Front Clutches, is incorrect in the 1980-81-82

Subject Problem and Application BulletIn Number Page

of the Piston Seal.

1982 WINDSHIELD-WINDOWS-BODY HARDWARE

1982 BODY!CHASSIS ELECTRICAL

1982 PAINT-CORROSION PROTECTION-DECALS-MISC.

Hardtop Inner Panel Headliner Touches HardtopOuter Panel on 9-03-82 82-70

Revision to 1981 Six-Cylinder PCV Valve Specifications - Service 81-14 81-15

1981 ENGINE ELECTRICAL

Unnecessary replacement of Electronic Regulator used with 1981-82 1-04.82 82-19

New Voltage Regulator Tester - 1975-81 Jeep Vehicles 81-1 81-12

1981 FUEL AND EXHAUST SYSTEMS

Catalytic Converter Heat Shield - 1981 California Six-Cylinder 81-3 81-13

1981 CLUTCH-MANUAL TRANSMISSION

SR4 Four-Speed Manual.Transmisslon Vent - 1980-81 CJ and 81-1 81-17

1981 AUTOMATIC TRANSMISSION

1981 TRANSFER CASE!QUATRA-TRAC

1981 BODY GENERAL

1981-82 CJ Metal Door Lock and Latch Service. 5-03-82 81-30

1981 BODY ELECTRICAL

1981 HEATER-AIR CONDITIONING

Delco Air Conditioning Compressor Mainshaft Rotating Torque 81-16 81-73

Refer to Service General.

1981 INSTRUMENT PANELS-SEAT ASSEMBLIES

1981 METAL REPAIR-PAINTING-WATER LEAKIWIND NOISE

1981 Phase-Out11982 Phase-in Program Paint information - 1981 81-4 81-59

Paint Information - Au 1981 Jeep Vehicles. 81-1 81-64

1981 SERVICE GENERAL

Plastic Front Frame Crossmember Cover Attachment - 1981 81-16 81-73

New Model Information - 1981 Jeep Scrambler. 81-13 81-76

Correction to Automatic Transmission Stall Speed Specifications Chart 81-11 81-86

Correction to Carburetor Numbers and Usage - 1981 Jeep CJ Models

1981 Six-Cylinder Main Bearing Capscrew Torque Revision. 81-4 81-94

Fuei Feedback Modules Damaged By Incorrect Battery Cable 81-4 81-94

Camshaft Spring Pin Correction - Six-Cylinder Camshaft Pin 80-7 80-109

1980 COOLING SYSTEM

and Truck Modeis With Six-Cyilnder Engine.

1980 ENGINE ELECTRICAL

New Voltage Regulator Tester - 1975-81 Jeep Vehicles. 81-1 81-12

Revised Exhaust Pipe-to-Manifold Fastener Torque Specifications - 80-11 80-105

1980 FUEL AND EXHAUST SYSTEMS

Altitude Performance Adjustments - 1968-80 Jeep Vehicles. 80-7 80-11

Running Change to Four-Cylinder Engine Choke System - 1980 CJ 80-5 80-15

1980 CLUTCH-MANUAL TRANSMISSION

SR4 Four-Speed Manual Transmission Vent - 1980-81 CJ and 81-1 81-11

T-176 Four-Speed Manual Transmission Used in 1980 Four-Cylinder CJ 80-4 80-23

1980 AUTOMATIC TRANSMISSION

1980 TRANSFER CASEIQUADRA-TRAC

Correction to in-Vehicle Torque Bias Check - 1980 Cherokee, 80-4 80-112

1980 AXLES-PROPELLER SHAFT

Service Technical Letter- Refer to Service General.

1980 STEERING AND SUSPENSION

Correction to Camber Specifications - 1980 Cherokee, Wagoneer, and 80-4 80-112

1980 BODY GENERAL

1980 BODY ELECTRICAL

WIndshield Wipers inoperative on Low and Intermittent Speeds - 81-8 80-93

1980 HEATER-AIR CONDITIONING