Jeep CJ '49'86 (Haynes Repair Manual)

Citation preview

JeepCJ Automotive Repair Manual by Larry Warren

and John H Haynes

Member of the Guild of Motoring Writers

Models covered CJ-2A, CJ-3A, CJ-38, CJ-S, CJ-SA, CJ-6, CJ-7 Scrambler, Renegade , Laredo and Golden Eagle Automatic and manual transmissions

ISBN 1 56392 221 5

©

Haynes North America, Inc. 1996 Willi I*T'I'IIIOI'IIrom J H

~ ...

10 Co lid

All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic: or mechanical, h:Iuding photocopying, IlKXlI'ding or by any information storage or retrieval system, -Mthout pemVssion in .....ntJng from the copyright holder.

Printed in the USA

i9Z2 - 50020) (412)

Haynes Publishing Group

Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc. BS1 Lawrence Drive Newbury Park California 91320 USA

97-70336

Acknowledgments Special thanks are due 10 American Motors Corporation for their supply of technical information BOO certain illustrations.

About this manual Its purpose The purpose of this manual is to help you get the besl value from your vehicle. It can do so in several ways. It can help you decide what work must be dona, even If you choose to have it done by a dealer ser-

vice department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it oHers diagnostic and repair procedures to follow when trouble occurs. It Is hoped that you will use the manuel to tackle the work yourself. For many simpler jobs, doing it yourself may be quicker than ,manging an appointment to get the vehicle into a shop and making the trips to lallve it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must pass on to you to cover its labor and overhead costs. An added benefit is the sense of sstisfaction and accomplishment that you feel after having done the job yourself.

Using the manual ' The msnual is divided into Chspters. Esch Chspter is divided into numbered Sections, which are headed in bold type between horizontsllines. Each Section consists of consecutively numbered paragraphs.

The two types of illustrations used (figures and photographsl. sre referenCed by a number preceding their caption. Figure reference numbers denote Chapter and numerical sequence within the Chspter; U.e. Fig. 3.4 means Chapter 3, figure number 4). Figure csptions are followed by a Section number which ties the figure to a specific portion of the text. All photogrephs apply to the Chapter in which they appear and the reference number pinpOints the pertinent Section and paragraph; i.l.l., 3.2 means Section 3, paragraph 2 . Procedures, once described in the text, are not normally repeated . When it is necessary to refer to another Chapter, the reference will be given ss Chapter and Section number i.e. Chapter 1/16). Cross references given without use of the word ' Chapter' apply to Sections and/or paragraphs in the same Chapter. For example, ' see Section B' means in the same Chapter. Reference to the left or right side of the vehicle is based on the assumption that one is sitting in the driver's seat. facing forward . Evan though extreme care has been taken during the preparation of this manual, neither the publisher nor the author can accept respon · sibility for any errors in, or omissions from. the information given.

Introduction to the Jeep CJ The Jeep CJ is available in an open utility body style with a folding windshield. Later models feature removable, folding tops or hsrdtops in both conventional and pick-up styles. Power from the engine is passed through the trsnsmission to a trsnsfar casa and then to tha front snd resr allies by driveshatts. Both msnual and sutomatic trsnsmissions ara available on these vehicles.

Esrly models used a csm snd lever type staering gear while later models featured a recirculating ball type steering gear with power assist as an option. Suspension is by semi-elliptic springs with tubular shock absorbers. Both four-wheel drum and front disC/rear drum brakes are used on these vehicles. with power assist as an option.

Contents

Page

Acknowledgements

0-2

About this manuel

0-2

Introduction to the Jeep CJ

0-2

General dimensions

0-6

Vehicle identification numbers

0-7

Buying perts

0-8

Maintenance techniques, tools end working facilities

0-9

Booster battery (jump) starting

0-15

Jacking end towing

0-15

Automotive chemicals and lubricants

0-16

Safety firstl

0-17

Troubleshooting

0-18

Chapter 1 Tune-up and routine maintenance

1-1

1

Chapter 2 Pert A General engine overhaul procedures

2A-l

2A

Chapter 2 Part B 151 cu in four-cylinder engine

26-'

28

Chapter 2 Part C 150 cu in four-cylinder and aJi in-line six-cylinder engines

2C-1

2C

Chepter 2 Part 0 VB engine

20-1

20

va engine

2E-l

2E

2F-O

2F

Chapter 2 Part E

Chapter 2 Part F L-and F-head four-Klnents is stamped on the tag located on the 'ight bank rocker arm cover. The oversize/undersize code is located adjacent to the engine build date code on the tag.

rr--

Fig . 2.42 Thll lIogloe build date and oversize/underslza codes are loceted on the right sida rockar arm cover (Sec 131

2D

20-4

Chapter 2 Part 0 t21 ~'6 INCH · 12 Nun

V8 engine

... .

~

LJII'ItEA TAUNNIOH

IE ... 'UNG

"VOTOA SLEEVE

•

'~H

D •• HD"

N.

~

"""'......

..O"~

I .

''''N'

MOUNTING BRACKETS

FRAME SUI'PORT

~~ "

2 X 2XIINCH

HARDWOOD

0···,c~': Y~:::~~DN , (. ~ 1

2 I( 2 It'" INCH HARDWOOD BLOCK

121 liZ INCH HOLE S

Fig . 2.43 Typical Inginl Wfting'lupponing fixture which can be fabn.c.tad and v.,d when r,placlng engine mount cu5hlon. (See 74)

74

Engine mount. -

r.pl.c.~nt

Rubber engine mounts SUPPOIt the engine 81 three points. These mounts should be inspected periOdically to make sure they haven't become hard, split or separated from the metel backing. 2 The mount cushions can be replaced after supporting the engine/transmission weight with 8 jack, hoist or holding , jxture.

75

Engine - removal

Not.: The foNowing sequence of operatIOns d~s not necessarily nHd to be Pflrformed in the order given. It is, rather, e chlJCklist of everything th., must be disconnected or remo...cJ befol'8 the engine can be lifted out of the vehicle. If \'Our vehicle is equipped with an aUlomeric tmnsmission, the engine removal procedure will be slightly different from the procedure for vehicles equipped with e manual trensmission. It is very important that aI/linkages. electric.' wiring, hoses and cables be removed or disconnected before attempting to lift the engine clear of the vehicle, so double·check eVflrything thoroughly. 1 Open the hood and tilt it completely back. 2 Remo\le the air cleaner assembly. 3 Drain the coolant into a suitable container. then remove the heater hoses and radiator hoses. 4 On automatic transmission equipped models. disconnect and plug the transmission fluid cooler lines. S Remo\le the radiator and engine cooling fan. 6 Disconnect and plug the pOW1lr steering hoses and remove the power steering pump assembly. 7 If the \lehicle is equipped with air conditioning, ha\le the system discharged by a dealer ser\lice department or properly trained teChnicien. Caution: Do not ettempt to disconnlJCt the air conditioning system components until the system h8s been s. f./y discharged, as serious in;ury could result. 8 Remove the air conditioning compreasor. 9 If equipped with cruise con trol, remove the se,...,o bellows end mounting bracket as an assembly. 10 Disconnect the negati\le battery cable from the battery. 11 Disconnect the fuel supply and ,eturn lines et the chassis connactlons. 12 Olsconnect the engine wiring herness and move it out of the way. 13 Disconnect the vacuum line hom tha pOW1lr brake unit. 14 Disconnect the heater damper door vacu um line at the intake menifold. 15 On automatic transmission equipped models. disconnect Ibut do

Fig . 2.44 T,!,plcal engine mount component Ia'!'out - uploded view (Sec 74)

not remO\le) the filler tube at the light cylinder head. 16 Remove the nuts from the liOn! engine mount support cushIOns.. 17 Connect a suitable lilting device to the engine and raise il suffi ciently to support the englne's weight 18 Remove the left front engine support cushion and bracke t. 19 On four wheel drive models equipped with a manual transmission, remO\le the transfer case shift le\lar boot, 11001 mat and transmission access covar. 20 On automatic transmiSSion eqUipped vehicles. remove the upper torque converter·to·engine bolts. 21 On manual transmission eqUipped models. remolle the upper clutch houslng-to-engine 601ts. 22 Unbolt and disconnect the exhaust pipes Irom the manifolds and support bracket. 23 Remove the SlaMel motOI. 24 Support the transmiSSion wllh a jack. 25 On eutomotic transmission equippad models, remove the inspec· tion cover and mark the relati\le position of the con\lerter and dllveplate. 26 Remo\le the convertel ·to·dri\leplal8 bolts by rotating the crankshaft pulle,!, nut with a wrench to prOVide access to each bolt. 27 Remo\le an,!, remaining boilS retaining the engine to the transmis· sion. On manual transmission equIpped models. remove the clutCh houS' Ing lower cover for access to the remaining bolts. 28 Withdraw the engine forward and tift it up at an angle to ramove the engine from the vehicle.

76 Engine - dlsessembly .nd , ••ssembl,!, sequence To completely disassemble the engine. remove the follOWing Items in the order given: Oil pan Intake manifold Cylinder head/valve train components Timing chain cover Timing chain end sprock~ts Camshaft PiSlonJconnecting rod assemblies Crankshaft Oil pump 2 Engine reassembl,!, is bUlcaU'!' the ,everse of disassembl,!,. InSll1l tha following components In the order gl\lon: Oil pump Crankshaft PiSlon/connecting rod assemblies

Chapter 2 Part 0

va engine

20·5

IENOI~E ACCESSOAY OAIVE I'VlllEY

~.~ .",,,,;000 DAMPEA COVIE" Oil SEAL

Fig. 2.46

I Fig. 2.45

)

nmlng chein cove r components 15K 80)

•

Rocur arm assembly components (Sac 791

elCploded view

Timing cham and sprockets Camshaft Timing chain COYer Cylinder head/Va/ve train components Intake mamfold 011 pan Fig . 2.47 77

011 p.n -

80

Remove the carburetor and linkage (Chapter 41. Remove the retaining bolts and lilt the manifold Irom the engine. Remove the metal gasket and the end seals.

81

79

ChKking timing ch.n

_.t

2D (deflection) (Sec 81)

removal

Remove the bolts attaching the oil pan to the engine block. 2 Tap on the pan with a solt-Iaced hammer. to break the gasket seal. and 1,lt the 011 pan off the engint 3 Remove the oil pan neoprene seals. 4 USing a gasket scraper. remove all traces 01 gasket Itom the oil pan and engine block gasket surfaces. 5 Clean the oil pan with solvent and dry it thoroughly. Check the gasket sealing surfaces for distortion.

1 2 3

e:llploded view

Cylinder head -

removal

Remove the rocker arm covers. The cover. are installed with a formed · in-pl.ca ATV· type gasket and it m.y be necassary 10 tap Ihem sharply With a soft -faced hammer 10 breek Ihe le.1. 2 Remove the intake manifold. 3 Remove the rocker arm assembly bolts/nuts. 4 Remove the rocker arm assemblies .nd pushrods, keeping them in order so they c.n be reinstalled in thel' oligin.1 locations. 5 Loosen the cylinder head bolts 1I4-tu,n at • time. working Irom the inside out. Remove the boilS, then lift all the cylinder head and gasket. It may be nacassary to tap the head sharply with a soft-faced hammer around Its circumference to bra.k the gaskel seal.

nmlng chain cover -

removel

1 Remove the vibration damper bolt. 2 Using a suitable puller, remova the vibration damper. 3 Remove the timing COvel mounting bolts. Since these bolts are of varying lengths. mark the location of each one at tha time of removal so Ihey can be reinstalled in the sama locations. 4 Ramova the cover by pulling it atraight out. off the locating dowels. 5 Pry the oil seal out and cle.n the bC/fe. Cle.n the gasket surfaces of the timing cover and engille block.

Timing chain _ar ct..tk

1 Remove the timing chain CoYer. 2 Rotete either the cranksheft or c.msh.ft sprocket until there Is no sl.ck in the right side of the ch.ln. 3 To determine. reference point for deflection measurement, move 314 01 an Inch up from the dowel on the right side of the engine .nd make. mark at this location. PI.ce • streightedge across the timing chain from. point at the lowest root 01 the c.mshaft sprocket to the marked position. Grasp the ch.in at this point to use as • reference. move the chain in tow.rd the centerline of the engine and mark the point 01 m.ximum deflection. Move the ch.in out to the point of m'lIimum deflection .nd make .nother mark. 4 Me.sure the distance between the two merk. to determine the total deflection (as shown in the .cCompenying illustration). 5 If the deflection Is beyond the malClmum .1I0wed in the Specifications. replace the chain with a new one. If the chain is replaced, new .prockets probably 8hould be used as well.

20-6

Fig. 2 .49

Fig. 2 .48 Thil ml,k, on the Iprocket' mUlt be Illgned belo,.. removing the eh"'" end sprockets 15K 821

17'

F:;:.:fJ (~

IOLIER I!iAFT

Fig. 2 .51 Checlllng oR pump g"r end elelr.nc. with PIa.tlgeg. (Sec 85)

t-' ~I

~iJ

'O"'G"'~

OIL !'''lAURIE IULIEf VALVE ....1. . Ly

A

~~

~

Cam, haft componenta - Ixploded view (Sec 831

Fig. 2 .52

Checking oU pump gear end

cle.r.nce with • I..ler gauge and Itralghtedge (Se''''0' BEARING CUP PtNION BEAFIING

SUl

J" "~ I RE~INER

BEARING RETAINER RING

GASKET AXLE SHAFT

/

Fig. 8.14 Da na flanged 8xlishaft semi· flo8ling reB r IXla assemb ly com ponen ts - 8)1ploded vie w (Sec 10 t hrough 14)

10

Raaf 811leshah - removal and installation

Most of these vehicles were equipped with semi-floating reafaxles, although early models of Ihe CJ-2 ithrough serial number 15453) used full-floating type axles. Two types of semi-floating ax' leshefts were used: tapered and flanged . Early models used Spicer/Dana tapered axles, while later models lafter 19761 were equipped with 8X les manufactured by AMC/Jeep. Vehicles using flanged 8xleshafts were equipped with Dana 44 rear 8)(les.

Full-ffoating axles 2 It is not necessary to raise the vehicle when removing a full -floating axleshaft. Remove the screws which retain the axle flange to the hub and Ihen screw Iwo of these screws Inlo the threaded holes in the flange 10 loosen Ihe shaft. Withdraw Ihe axleshefl from the housing. 3 To remove a broken axleshaft, firsl remove the ouler piece and Ihen loop a piece of sliff wire around Ihe broken piece. Use the wire 10 pull the broken section 01 axleshah from Ihe housing. As an alternetive, remove the other axle and use a rod or pieca of pipe to push the broken section 01 axle out of the housing.

Spicer/Dana tapered axles 4 Raise Ihe rear of Ihe vehicle, support it securely on jackstllnds lind remove Ihe wheel. 5 Remove the axleshaft colter piri, nUl and washer. 6 Back Ihe brake adjuster off sufficiently 10 allow Ihe drum to be removed. 7 Remove the hub ISection 12). 8 Remove the screws retaining the brake dust protector, grellsellnd Dearing relainers, brake and shim 10 Ihe axle housing. 9 DisconneCI and plug Ihe brake line. 10 Remove the dust and oil shields. 11 Use a slide hammer puller to remove the axleshaft, bearing cone,. roller and cup as shown in Ihe accompanying lliuslration. 12 Inspect Ihe oil selll 10 see if it is twisled, damaged or leaking. Replace it if necessary ISection 101. 13 A special puller is required 10 remove the bearing from the axle so this job should be left 10 a dealer or repair shop. 14 Installation of the axleshaft is the reverse of removal, taking care to install Ihe original shims and lighten Ihe axle nut 10 the specified torque.

Fig. 8 .15

Removing e l apered axleshaft w ith a alide hammer Cone end roller 2 Axlesha'l

3 Slide nammer

A M C/Jeep tapered axles 15 Remove Ihe axleshalt dust cap. nut and washer. 16 Raise the vehicle, support it securely and remove Ihe wheel. 17 Remove Ihe rear axle hub (Section 12). 18 Disconnect and plug the broke hose al the wheel cylinder and remove the brake support plate assembly, oil seal and shims from the axlesha ft . 19 Use a puller to remove the axleshaft and bearing from the housing as shown in the accompanying illustration. 20 An arbor press is required 10 remove the bearing Irom the axle so this job should be left to a dealer or repair shop. 2 1 Install a new oil seal ISection 11). 22 Insert Ihe axleshaft carafully into the housing, aligning the shaft splines with the differential gears. 23 Install I he bearing cup. 24 Apply a coat of sealant to the axle tube flange to prevent the en· Iry of dust and water into the housmg. 25 Inslall the o'i~inel shims. oil seal assembly, brake backing plale and

8-11

Chapter 8 Oriveline

FLANGE ADAPTER J.ZlilS,

.1/

~a:).'" -

.~~

AXLE

PULLER J.26 1e

Fig. 8.16 Removing the AMC/Jeep tapered aKlnhaft Ind bearing asaembly with I Ipeclal puUer ISec 10 through 131

Fig. 8 .17

Removing a flangad alliashaft with a pullar and adapter (Sec 10 through 13)

replacement on these models is beyond the scope of the home mechanic and the job should be left to a dealer or repair shop.

Spicer/Dana tapered axles 3 Remove the hub ISection 12) and exleshaft (Section 10). 4 Carefully pry the old seal tram the axle housing, noting Ihe direc· tion in which it is installed. Clean the seal seat in the axle housing with a clean, linl·free cloth. 5 Insert the new oil seal into Ihe housing. making sure Ihal it faces in the same direction as the original. Use a large socket to seat the seal in Ihe housing. tapping It into place with a hammer. 6 Install the axleshaft and hub.

AMC/Jeep tapered axles

Fig. 8 .18

Removing the hub using a puller ISpicer/Olnl tapered allieshlft) ISec 121

mounting bolts. Tighten the bolts to the specified torque. 26 Install the hub. brake drum and axle nut. 27 Install the wheel and hub cap and lower the vehicle.

Dana 44 flanged axles 28 Raise the vehicle. suPPOrt is securely on jackstands and remove the rear wheels. 29 Remove the brake drum. 30 Use a sharp tool to pierce the center of the axleshalt cup plug and pry the plug out. 31 Remove the nuts retaining the backing plate and retainer to the axle tube Ilange. working through the access hole in the shaft lIange. 32 Remova the axleshaft using a puller and lIange adapter such as AMC tools J·2619 and J·25156 lor equivalent) as shown in the ac· companying illustration. 33 Remove the old bearing cup and oil seel from the axle housing tube. 34 Carefully insert the axleshalt into the housing making sure not to contact the oil seal. Apply a thin coat of wheel bearing grease to the outside circumference of the bearing cup prior to installation in the hous· ing bearing bore. 35 Use a soft·laced hammer to tap the axleshaft flange and seat the bearing in the beering bore. 36 Inslall the axleshalt retainer and brake backing plate on the axle housing anti install a new cup plug in Ihe axleshaft flange hole. 37 Install the brake drum and wheel and lower the vehicle.

11

Rear axle seals - replacement

Raise the rear 01 the vehicle. support it securely on jackstands and remove the rear wheels.

7 Remove the hub ISection 12) and axleshaft ~Section 101. 8 Carefully pry the old seat from Ihe axle housing and wipe the seal cavity with a clean. lint·frae cloth. 9 Coat the outer circumference of the seal with light oil and insert it into the housing. Use a large socket and hammer to carefully tap the seal squarely inlO place until it is aeated completely. 10 Lightly coat the seal retainer with non·hardening sealant and in· stall the axleshaft and hub.

Dana 44 flanged axles 11 Remove the axleshaft (Section 10). 12 Remove Ihe otd oil seat Irom the axle housing using a slide ham· mer puller such as AMC tool C·637. 13 Wipe the seal bore out with a clean, linl-free cloth. 14 Install the new seal squarely in the housing using AMC tool W·186 o. a large sockeL Make sure it is completely seated. 15 Install the axleshaft.

12

Rellr hub - removal end Inltllilation

Raise the rear of the vehicle. suppon it securely on jackstands and remove the rear wheels.

Full-floating axles 2 Remove the axleshaft (Section 101. 3 Bend the lip of the lock washer away from the locknul and remove the locknut, washer and bearing adjusting nut and washer. Grasp the hub and rock it back and forth to dislodge the outer bearing. Remove the bearing and withdraw the hub from the axte. 4 Installalion is the reverse of removal. Be sure to adjust the bear· ings ~Chapter 11\.

Spicer/Dana tapered axles 5 Remove the axleshalt nut and use a puller to remove Ihe hub as shown in the accompanying illustration. 6 Place the hub and drum on the tapered portion of the axleshaft and insert the key Into the keyway. Install the axles haft nut and lighten it to the specified torque.

Full-floating axles 2 The seals on these axles are located at the dillarential and replace· ment requires disassembly of the axle assembly. Consequently, seal

AMC/Jeep tapered axles 7

Remove the axleshah dust. cap. cotter key, nul and washer.

8

8-12

Chapter 8

8 Remove the brake drum and mounting screws. 9 Remove the hub uSing a puller such as AMC tool J-25109-01 lor equivalentl as shown in the accompanying Illustration. 10 To install the original hub. align the key In the hub with tha keyway In the axleshaft, slide the hub onto the a)(leshah as lar as it will go and install the washer and nut. Tighten the nut to the specified torque after the vehicle has been lowered onto the wheels. If the cotter key hole is not aligned. tighten the nut sufficiently to allow Insertion of the key. Do not loosen the nut to align the cotter key hole. 11 To install a replacement hub. align the key in the hub with the a)(le· shah keyway and slide the hub onto the shaft. Install two well oiled washers, the a)(leshalt nut, the braka drum and screws end the whael. 12 lower the vehicle and tightan the axleshatt nut until the specified distance lrom the end at the a)(leshah to the hub outer face (1-5116-inchl is obtained as shown in the accompanying illustration. 13 Remove the axlashah nut and one washer. Install the nut end tighten It to the specified torque. To align the cotter key hole so the key can be inserted, tighten (never loosenl the nut.

13

Pinion all seal - replacement

1 Raise the vehicle and support it securely on jackstands. 2 On models equipped with semi· floating rear axles with tapered a)(leshafts, remove the wheels and brake drums. 3 Mark the relative positions of the driveshaft 8nd axle pinion yoke to simplify installation, then disconnect the driveshaft.

Driveline 4

On semi·lloating lesr axles with flanged sJ(leshaits, attach an in-

Ib torotJEI wrench snd socket to the pinion nut, rotate the pinion through ~Il\feral

revolutions ana record the torque reqUired to turn the nUl.

5 On ell models, remove the pinion nul using II yoke holding tool such as AMC tool J·8614·01 as shown in the accompanying illustration. S Mark the reilltive positions of the yoke and pinion for alignment reference during reinstallation. 7 Remove the yoke using a puller such as AMC tool J-8614·2 as shown in the accompanying illustration. S Inspect the yoke seal surface. If it is dllrnaged, burred or scored. replace the yoke with a new one. 9 Use AMC tool J-9233 to drew the pinion seal out 01 the housing. 10 Coat the lip of the new seal with a)(le lubricant prior to installation, Insert the seal into position and tap it squarely into the housing with a hammer and a large socket or 8n installation tool such as AMC tool J-22661. 11 Install the yoke using the alignment marks made during removal . 12 On seml·floating a)(les with taperad a)(leshafts, install a new pin· ion nut and tighten it only sufficiently to remove the pinion bearing end play. Attach the in-Ib torque wrench and rotate the pinion several times to determine an accurate reading of the torque required to initially turn it. Compare this reading with the one taken in Step 4 and add five (51 in-Ib to determine the proper preload torque. If the reading is less than this, tighten the nut slightly and reCheck the torque. Repeat this procedure and gradually tighten the nut until the proper torque is reached. Caution: 00 not over tighten the nut, as it will collapse the pinion spacer sleeve. The differentiel will then heve to be disassembled and II new specer installed.

f.---.., Fig. 8.19 Removing the AMC/Jeep tapered axlesheft hub using a puller ISec 121

1-61111

INCHES

Fig . 8 .20 The AMC/Jeep reer axle replacement hub mUlit be Instelled with tha specified dl.tance between the axle end and hub fece (Sec 12)

o 'd Fig. 8.21

Removing the a)(le pinion nut ISec 13)

Fig. 8.22

Removing the axle pinion flange (Sec 131

Chapter 8 13 On all other axles, Il'1stall the pinion nut and tighten it to the specilied torque. 14 Connect the driveshaft, Install the brake drums and wheels (il removed) and lower the vehicle.

14

8-13

Driveline 15

Front wheel drive hub - removal and installation

Raise the vehicle and sur-port it securely on jackstands, Remove the front wheels, if necessary. 2 Place the hub in the 2WO position. Remove the bolts and tabbed lockwashers retaining the hub body to the axle hUb. Remove the hub body and discard the gasket. 3 Using snap-ring pliers, remove the retaining ring from Ihe axleshaft and slide the hub clutch and bearing assembly from the axle shaft. Caution: Do no rotate the hub control dial with the hub removed or damage to the hub may occur. 4 Clean the hub components with solvent and dry them thoroughly. Make sure all dirt, water and old lubricant has been completely removed. Apply a light coat 01 EP-type waterproollithlum-based grease to 5 the hub internal components. Note: Do not apply an excessive amount of lubricant; apply B light coat only. 6 Place the hub clutch and bearing assembly on the axleshaft and install the retaining ring. 7 Using a new gasket, inslallthe hub body. 8 Align the bolt holes and install the tabbed washers and bolts Tighten the bolts to the specified torque. Inslall the Iront wheel. 9 Turn the hub control dial 10 the 4WD position and rotate the front wheel. The front axleshaft should be engaged with the hub. Turn the dial to the 2WD position, the wheel should rotate freely. If operation is not as described, make sure lhe control dial is fully engaged and the hub is properly assembled.

Rear axle assembly - removal and installation

Raise the rear of the vehicle, support it on jackstands and remove the rear wheels. 2 Disconnect the driveshaft from the axle and fasten it out of the

way. 3 Disconnect the shock absorbers from the axle, 4 Disconnect and plug the brake hose at the T-fitting. 5 Disconnect the parking brake cable (if equipped), Support the axle wIth a lack. 6 7 Remove the U-bolts and nuts. 8 Disconnect the rear shackles, slide the axle to the rear and remove it from the vehicle. 9 To instalilhe axle, raise it into position, align Ihe springs with the axel spring pads and inslall the U-bolts. Position the spring on Ihe shackles and Inslall the bolts finger tight. 10 Attach the brake line to the T-fitting and connect the parking brake cables. 11 Connect the drives haft and shock absorbers to the axle 12 Bleed and adjust Ihe brakes (Chapter 9). . 13 Install the wheels and lower the vehicle. TIghten the spring bolts 10 the specifIed torque.

4

;

2

/ 7

-

8,23 Front wheel drive hub exploded view I 2 3 4

5 6 7 B

9 10

"

12 13 14 15 I.

Retaining ring Bearing hub Wear washer Hub shaft Retaining ring Spring Ring clutch Retaining ring Clutch nut Dial screw O-ring Clutch cup Spring Hub body Control dial Screw

8

11

13

15

I.

9-0

Chapter 9

Brakes

Cootents Brake caliper - removal and installation 8 Brake caliper (1977 through 1979 models) - overhaul 9 Brake caliper j19aO through 1986 models) - overhaul 10 Brake check .•. _ • . • . . • . • . . • . . .. . . .. . . . Chapter 1 Brake disc - in~pection, removal and installation . . . . 7 Brake drum - removal, inspection and installation .. . 11 Brake system bleeding procedure .....•..•.•..•. 3 Brake vacuum booster - check . .. . .....•.•. 4 Brake vacuum booster - removal and installation 5 Disc brake pads - replacement . . •.• . .. . . . 8 Drum brake shoes - removal, installation and adjustment 12

Dual piston master cylinder - overhaul .. . 18 Fluid level check . . Chapter 1 General information 1 Hoses and brake lines - inspection end replacement .. . 2 Master cylinder - removal and installation . ....•..•. 18 Parking brake - adjustment ... .....•..... Single piston master cylinder - overhaul . 17 Transfer case mounted drum·type parking brake - shoe replacement . . .•..•.. 15 Wheel cylinder - removal , overhaul and Installation ...•.... 13

"

SpecHlcatlonl

Disc brakes Brake disc minimum thickness 1977 and 1978 .. . .. . . . 1979 through 1986 .. Brake disc thickness variation limit Brake disc runout limit

1.120in(28.5mmf 0 .815 in (20.7 mmf 0 .001 in (0.02 mm) 0.005 in (0. 12 mm)

Torque specifications

Ft-Ib

Brake booster-to -dash .••..••......•.••.•.••• . .. Master cylinder-to-booster •.•.•......•.•........... _ Brake pedal push rod nut _ . _.. .

18t025 20 to 30 25 to 40

34 to 54

20 to 30 151019

2710 41 201024

100 30 301035 4105

40 41 1047 5106

35 to 55 10 to 15 4 to 5 35 to 55

47 to 74 14 to 23 5 to 6 47 to 74

Nm 24 to 34 27 to 41

Front disc brakes Brake line-Ie-caliper fitting bolt •..•..•.•..• . . _.. Caliper support key retaining screw _ . Caliper anchor bracket-Io-steering knuckle Caliper mounting pins •• . .••.•..•..•..• . . Brake support plate mounting nuts and bolts ..•..• . BIee(!9f" screw . __ . _ . . ...•..•..•.••.

136

Front drum brakes Backing pllte bolts. _ . . . .. . ..•..•. __ . •.. Brake line-to-wh&el cylinder fitting nut ..•.•••.. • .• _ ...• Bleeder scrlw ....•.•..•.•........•.••...•......• Rear backing plate bolts/nuts .......... . . . 1

Ganlrat Information

These vehicles are equipped with four-wheel hydraulic brakes. later have separate systems for tha front and rear brakes. The parking brake is connected mechanicelly to a drum-type brake located on the driveshaft at the rear of the transfer case on early models and to the rear-wheel brakes on later models. Models manufactured through 1976 had drum brakes on all lour wh&els while later models had disc brakes at the front and drum brakes model~

at the reaf. Later model drum brakes are self -adjusting. A vacuum operated brake booster was available on later models. On 1974 and laler models, a combination valve is used. The combination valve serves as a front junction block for the brake hydraulic system and contains a brake pressure differential warning section and a brake proportioning section. A failure in either brake system will cause the piston to move and contact a switch pin, completing an electrical circuit and providing power to the warning light on the dash. The proportioner section provides balanced front-to-rear pressure during hard braking, reducing the rear line pressure so the wheels don't lock up.

Chapter 9 Brakes 2 Hoses and brake linel -

inlpection and replacament

The brake hvdraulic system has a series of flexible rubber hoses connecting the wheel cylinders or the calipers and the rear axle fitting to metal lines running the length 01 the frame. If an inspection IChapter 1) revaals a problem with either a rubber hose or a metal line. the component must be replaced immediately fOf continuad safe use of the vehicle. 2 Before replacing a line or hose. determine the cause of failure and remedy it or the hose or line will fail again. Often componants such as axhaust pipes have come loose end are rubbing tha lina, causing the braak Of tear. 3 Replacement steel and flexibla brake linas ale commonlv evailable from dealer parts departments and auto parts stores. Cauti on: Do nor, vnder any circumstances, use anything other then genuine steel or approved flexible brake hoses as replacement items. 4 Whan removing a brake line or flare-nut hose fitting. always use the proper flara-nut wrenches when loosening and tightening the connections. 5 At the junctIOn where a brake line meets a bracket supporting it and its connection, remove the spring clip with pliers or a vise grip after loosening the connection. 6 Steal brake lines are usually retained along their span with clips. Always remove thasa clips completely before removing any brake line that they are supporting. Always replace these clips when replecing a metel brake line. as they provida support and keep the lines from vibrating. which will fatigue and aventually braak the line. 7 Once a lina has been replaced. the hydraulic system must be bled \0 rid the system of any air bubbles. Refer to Section 3.

3 Brake 8Y8tem bleeding procedure If the brake system has air in it. operation of the brake pedal will be spongy and imprecise. Also, on later models with combination valves (1974 and later! tha warning Ught on the dash will go on if there is air in the velve. Air can enter the braka system whenever any part of the system is dismantl.uf or ilthe fluid 19Vil1 in the master cylinder reser-

A

B

voir runs low. Air can also leak into the system through a hole too small to allow fluid to leak out. In this case, it indicates that a generel overhaul of the brake system is required. Note: Inspect all brake line flexible hoses, steel lines lind connections. See Chepter , for visuel inspections before bleeding the system. By doing this, you will save a lot of rime and prevent fluid loss. 2 On models equipped with a combination valve. it will be necessary to bypass the valve. On 1974 through 1976 models with four-wheel df1Jm brakes. this is accomplished by removing the brake warning switch wire. switch terminal, plunger and spring from the combination valve. On models wirh front disc brakes, hold the metering velve section of the combination valve with AMC tool J-26869 {or equivelentles shown in the accompanying illustration. 3 To blead the brakes. you will need an assistant to pump the brake pedal. a supply of new brake fluid, an empty plastic container, a clear plastic or vinyl tube which will fit over the bleeder screw nipple and a wrench for the bleeder screw. 4 There are five locations at which tha brake system is bled: the master cylinder, each front brake wheel cylinder and each rear brake wheel cylinder. 5 Check the fluid level at the master cylinder reservoi r. Add fluid, if necessary. to bring the level up to the Full marlc.. Use only the recommended brake fluid, and do not mix different types. Never use fluid from a container that has bean standing uncapped. You will have to check the fluid level in the master cylinder reservoir often during the bleeding procedure. If the level drops too far, air will enter the system through the master cylinder. 6 Raise the vehicle and set it securely on jackstands lrefer to the J8Cking end towing procedures at the front of this manuall. 7 Remove the bleeder screw cap from the wheel cylinder or caliper assembly that is being bled. If more than one wheel must ba bled, start with the one farthest from the master cylinder. 8 Anech one end of tha clear plastic or vinyl tube to the bleeder screw nipple and place the other end .submerged in a smell amount of claan brake fluid! In the container. 9 loosen the bleeder screw slightly. then l ighten it to the point where it is snug yet easily loosened. 10 Have an assistant pump the brake pedal several times and hold it in tha fully depressed position. 11 With pressure on the brake pedal. open the bleeder screw approximately one-half turn. As the brake fluid is flowing through the tube and into the container. tighten the bleeder screw. Again, pump the brake pedal, hold it in the fully depressed position and loosen the bleeder screw momentarily. Do not allow the brake pedal to be released with the bleeder screw in the open position. 12 Rapeat Ihe procedure until no air bubbles are visible in the brake fluid flowing through the tube. Be sure to check the brake fluid level in the master cylinder reservoir while performing the bleeding operation. 13 Tighten the bleeder screw. remove the plestic or vinyl tube end install the bleeder screw cap. 14 Follow the same procedure to bleed the other wheel cylinder or celiper alsamblies. 15 To blaed the master cylinder. have an assistant pump and hold the brake pedal. Momentarily loosen the brake line littings, one at e lime. where they attach 10 the master cylinder. Any air in the master cylinder will escape when the fittings are loosened. Bnlke fluid will damage painted surfaces, so use paper lowals or rags 10 cover and protect the areas eround the mas ter cylinder. 16 Inslall the brake warning swilch wi re. terminal, plunger and spring or remove the metering tool on combinetion valve'aquipped vehicles. 17 Check the brake fluid level in the master cylinder to make sure it is adequate. then test drive the vehicle end check for proper brake operation.

4

Fig. 9.1

Combinetion valve metering val ve tool Inllallation ISec 3)

A

B

1977 and 1978 models 1979 through 1985 models

9-1

Brake vecuum bo08ter - ·check

Tha most common symptom of e fauh in the brake vacuum booster is lack of vacuu m assist when the brakes ere IIpplied, so thaI excessive pedal effort is requi red. 2 To check t he brake booster. tum the engine off and place the transmission in Neutral (manual transmission! or Park {automatic transmission!. Apply tha brakes several times to deplete the vecuum from the system and then. with light pressure, hold the pedal all the way down. Start the engine and verify thet the pedal tends to fall away

9

9-2

Chapter 9 Brakes

CALIPER

BLEEDER SCREW

SUPPORT SPRIHG RETAINING SCREW

~~

PISTON UAL OUTIIOARO

'RAKE SHOE

\

DUST BOOT

~

SUPPORT

'"

AHTI·RATTLE sPRING

'"0' FIg . 9 .2

1977 through 1981 disc brake caUper components - exploded view (Sec 6 through 10)

under toot pressure and require lass pressure for brake application, in· dicating thel the booster is working properlv. 3 If the vacuum booster presure is not felt, the system is not functioning. Inspect the vacuum hose for damage end IElClks. 4 If the vacuum booster operates properlv bullhe brake pedal returns slowlV or the brakes grab or drag. check the pedal mechanism and baoller unit be"erank and pivot pin •. lubricate the pedal pivot points and lemOVtl, clean, lubricate and install the bellcrank pivot pins. S If replacing the vacuum hose and cleaning and lubrication of the pedal mechanism and bellcrenk pivot pins does not correct the problem.. the booster is dafective and must be replaced with e new one ISeclion 5).

5

&ake vacuum booster - removel end Instellatlon

D,sconnect the booster pushrod at the brake pedal and discard the nut and bolt. 2 Disconnect the vacuum hose from the booster. 3 Remove the nuts and washers retaining the master cylinder to the booster and move the master cylinder out of the way. 4 Remove the mounting nuts and bolts and lift tha vacuum booster and bellcrenk assembly from the engIne compartment. 5 To install the booster, place the booster and bellcrank assembly ,n pOlltion on the engine compartment dash panel, install the mounting nuts and bolts end tighten them to the specified torque. 6 Connect the vacuum hose. 7 Attach the master cylinder to tha booster and tighten the nuts to tha spaclflad torque. 8 Align the pushrod with tha brake pedal, Install a new bolt and nut and l ighten them to the specified torque.

6

Dllc brag padl - replacement

1 Reier to Chapter 1 for a genera' inspectIon 01 the disc brake pads.. 2 Balore replacing the brake padl, siphOn 011 end discard two-thirds of Iha fluid in tha brake master cylindar reservoir. 3 Remova tha Ironl hub caps and loosen the wheel nuts. Raise the front 01 Ihe vehicle, support il on jack.stands and remove the wheels. Perform tha disc braka pad raplacemant on ona braka assembly at a time, using Iha assembled brake lor reference if necessary. 4 Use a C-clamp or large acrewdriver 10 bottom Ihe piSlon in ils bore

(photo). 5 Dn 1977 through 1981 models. remove the caliper support key screw with a 1/4-inch Allan wranch, use a hammer and punch toddv, the kev nl" and lift the callDer UP and out of the anchor platelphotoll. 6 On 1982 and later models, remove the two seven (7) millimeter hal( head mounllng pins located on the back of the caliper and then lilt the caliper off the anchor plate and rotor. 7 Fasten Ihe cali per out of the way, taking care not to Itretch or damage the brake hOle. 8 On 1977 through 1981 models. remove the 'nboard brake pad Irom the anchor plate. noting the location ollhe anti-rattle spring to sImplify Installation. Remove the outboard pad from the caliper. 9 On 1982 and 7983 models.. remove the outboard pad whIle holdl~ the anti-rattle clip. lollowad bV the Inboard pad and anti-rallie clip as shown in the accompanying illustrations. 10 On all models, carelully clean tha sliding surfaces of the callpar and anchor plate with a stiff brush or fine sandpaper to remove dirt end rust. Note: Make 8n effort not to inhale any dust raised by this operation, 8S if m8Y contain asbestos, which IS h8rmful to your health. Apply a thin coat of moly-based or h,gh-temperature grease to the caliper and enchor plate sliding lurfaces Iphoto). liOn 1977 through 1981 models. Instatlthe antl-raute spring on the reaf flange 01 the inboard pad so the looped end is facing away Irom the brake disc. Instatl the pad and spring in the anchor plete. laki~ care not to distodge the spring. Install the outboard pad in th e anchor ptate. Place the caliper in position over the anchor plata and braka diac:.. being careful not to tear or damage the pISton boot. Align the caliper and anchor plate, insert the support kay and spring and inllall the ratalnlnt! scraw, tightening it to the soecified tOfOU8. 12 un 1982 and later models, Install the anti-rattle clip on the tralli~ edge of the anchor plate WIth Ihe split end facing away from the disc. Hold the cl ip in the plate while Installing the inboard pad. Install tha outboard pad in the plate while holding the anti-rattle clip In place. Install the caliper over the anchor plate and brake disc, takIng care not to damage the piston boot. Align the caliper and anchor plate. then install the mounting pins and hohten them to Ihe spel':iliP.d torqUf' U On all mooels, 1111 tne master cylinder reservoIr 10 within 114-lOch of the ,im and depress the brake pedal several tImes to seat tha new pads. 14 Install the wheels. lower the vehiclfland check the master cylinder lIuid level. 15 Belore driving Ihe vehicle but with the engine running. chack lor a lirm brake pedal (if equipped with a vacuum booster) and bleed tha brakes (Section 3) if n&Cassary.

9-3

Chapter 9 Brakes

......,.

,.

6.4 Using a screwdriver to push the piston back into its bore

-

6.5A Removing the 1977 through 1981 caliper key retaining bolt with an Alten wrench

6.5B Drive the caliper key out with hammer and punch

8

auro'A sen .... AND

.,

'NIIDAAD

Fig. 9.3 1982 and later disc brake ca liper com ponents· exploded vie w (Sec 6)

Fig. 9.4 Remove the outboard disc brake pad (1 982 and leI te r m odel s) (Sec 6)

7

Fig. 9,5 1982 and later model inboard brake pad r emoval (Sec 6)

Brake di,c - Inapectlon. removel and in st allation

Inspection , Raise the front of the vehicle, support il securely on jackstands and remove the front wheels. 2 Remove the caliper and brake pads as described in Section 6. 3 Inspect the surface of the brake disc for sevilre score marks, cracks. chipped areas. excessive wear and alternate shiny/dark colored areas indicating hard spots. Moderate damage can be remedied by heving the disc resurfaced on a brake lathe. 4 Check the thickness of the disc at the center of the lining contact area with a micromatar. The disc must be replaced with a new one if the measurement is less than shown in the Specifications. 5 Mount a dial indicator on a support stand or the spindle and place the stylus in contact with the center of the pad contact affle on the disc. Zero the indicator, rotate the disc through one revolution and note the indicator reading. Compere this reading with the runout limit in the Specifications. If the nmool is excessive. the rotor should either be fflsurfaced on 8 brake lathe 01 replaced with a new one. 6. 10 Use your finger to lubricate the caliper and anchor plate sliding surfaces (arrows I with moly-based, hightemperature brake grease

Removal 6 To remove the disc on 1977 through 1979 models. remove the hub cap and hub cover assembly. Remove the drive flange snap-ring and flange. Straighten the lip of the outar locknut retaining washer and

9

9-4 SUPPORT

SPR'NG~ETAINING , ..... flEW

SUPPO'"

,ev ANCHOR

_

\

\

~ ~

PLAT\IE

J;J

INBOARO ANTI RATTLE SPRING

PAD

I

fJ \~

f

OUTBOARD

'AD

~~ ;~~ I ~@/ ~/'~t v,r';'~HUB 'NN'R LOCKNUT

' " , " '"

SPLASH SHIELD

1'-

HUB

'NBDARD

SPRING

SCRE\W

AN" RATTLE cu,

~~~

"ATE\

;t;;

r

~

.. o

•

0\:r.. . . . . .

DR'V'

fLANGE

t

CAe

SNAP RING

A'oded view IS&

Typical early model

Hlf-edJu.tlng rear brake components - •• ploded view

(See 12) I AnChor block FIlii _ 9 .13

Typical .arly model ...' ·

IdJu.tlng fronl wh.. , drum brake componentl - exploded view (Sec 12)

I Prim/IfY shoe 2 Wheel cylinder 3 SecondlJfy shoe

•

Lev"r pl8 re

7 Uppef linkllge rod

8 Screw Ad;ustlng screw assembly 9 Lower linkege rod 5 Sleeve 10 Adjuster lever

•

2 Anchor plere 3 Pilricing br.ke Isver 8nd pin

•5

ShOB r.lurn spring

8rIJIt,e shoe C-wlIsh"f 7 Parking bfllk" strut 8 AnChor lind link

•

9 Actuator link

10 Lev., shoe tldjusting spring /I

Lev", lind sleeve screw

12 Srake adjUsting

$C~W

(lefr-hIJnd thft/edl

13 8,.k8 adjusting screw

" 17 "18

(dghr-hIJnd rhre6d1 Adjusting screw spring

15 Strut :spring Hold-down spring Backing p/lft8 Hold-down pin /9 Adjusting holtl plug

9

9-8

Chapter 9 Brakes

•

12.8A Inlert I screwdriver into the hold-down .pring used on some letor model brake shoes to disengage it

12.88 The hold-down spring used on some later model ael f-adjusting drum brake shoes

12.9A Removing the reer brake pllfking brake Ilrut

12.98 Oisengage the parking brake cable (arrow) from Ihe $1'108 lever .a the rellf brake ,hoe is removed

12.18 The adjuster screw muSI be installed in the lully retracted position

12.24 Whh the plug removed from the backing plate, the adjuster star whul (arrowl is accessible

cup (usmg a brake tool or pliers) and .epallile the shoes from the backIng plate. SeIf-adjul1lng brakes 5 Gnp the automatic adjuster lever with 8 pllors and remove the pivot hook from the hole in the secondary shoe. 6 Detach the shoe return springs. 7 Remove the adjuster cable. guide. lellef and spring. S Remolle the shoe hold-down springs. On some later models. this is accomplished by inserting a screwdriver and twisting the springs from Ihen enChor pletes Iphotos). 9 Remove the breke shoes. adjuster screw assemblv and. in the cese of the rear brakes. the parking brake strut (photo!. Detach the parking brake cable from the lever as the shoe assemblv is removed (130010). All modals 10 Placa a wide rubber band or pIece of wire around the wheel cVlinders to retain them while the shoe. are removed . 11 While all the brake parts are removed . carelully brush away any accumulations of dirt and dust from the backing plate and wheel cvlinder. Nota: MlJklJ sure thet no 9rease comes in contact with the bflJke shoes at any time. If it does. cfflen tham thoroughly with denatUlwd alcohol. 12 Prior to Installation. applv a small amount 01 high·temperature braka grease to the backing plate surfaces which come in contact with the side. ollhe brake shoes. Note: Make sure that no gl'8ase comes in contact with the brake shoes et any tima If it does. cwn them thoroughly With denatured alcohol. 13 Applv a small amount of high-temperature grease to the conlact paiOls of the brake shoes. parking brake and adjuster levers. struts and springs.

Installation Non self-adjusting brakes 14 Install tha brake shoes on the backing plete and remove the rubber band or wire from the wheel cvlinder.

15 Install the adjuster eccent"cs end brake shoe retelning spflngs. Sett-edJu.tlng brake. 16 PIece the brake shoes ,n position on the backing plate, remove the rubber band or wire from the wheel cylinder and ins ten the hold-down springs. 17 Install the primary shoe return spring and than place the adjuster cable eyele t on the enchor pin. position Ihe cable guide and install the secondary retu rn spring. 16 Install the adjuster screw. alter making sure that (on the rear brakesl the parking brake strut is correctly positioned and allached. Meke sure the adjuSler screw is threaded all the way iOlo the sleeve to the minimum adjustment (photol. 19 Place the small hookad end of the adjustar spring in tha large hole in the primary shoe and then place the large hooked end 01 the spring in the adjuster lever. 20 Engage the hooked end of the adtusler cable in the adjuster leyer and locate the adjuster cable oyer tha gu,de. 21 Pry the adjuster lever until the pivot hook engages in the large hole at the bottom of the secondary shoe. All modal. 22 Make sure the shoes are correctly centered and instell the brek. drum ISection 11).

Adjustment Non .elf-. dJulting brake. 23 Raler to Chapter 1 lor the adjustment procedure lor non saltadjulting brtkes. Selt -adJu.ting brake. 24 R.move the access plug from Ihe backing plate, insen a brake adjousting tool and, after depressing Ihe adjusting lever, rotate the Stlllr wheel until the brake shoes are lockad against the drum and the wheel won't turn (phot o). 25 Back off the star wheel unt,l the drum fotates freely and InstaM the access plug.

Chapter 9

9-9

Brakes ~

BLEE D ER SCREW

~ ~j)~

~

6Y~

-- t

LI NK

' ;P: 'J

dv-"""

OOM,.ES"ON SP RING AND

" "ON

WHEEl mAND'"

CUP

CYLINDER

PI ST ON

DUST

'00' Fig. 9 .16

Fig. 9 .15 Moving the brake adjus ter ster wh eel with a tool inserted through the hole in the backing plate while unseating the adjU5ter lever wit h a screwdriver iSec 121

Exploded view of a typical wh eel cylinder i Sec 13)

Fig. 9 .17 Earl y model t ransfer case mounted drum·type panting brake iSec 14)

,.

I

" "

• 5 6 7

8 9 10 /I

" AH models 26 Install the wheels and lower the vehicle. 27 On self·adjusting brake'equippad models, drive the vehicle in for· ward and reversa while applying the brakes 10 or 15 times to complete adjustment. 13

Wheel cy linder - removal. overhaul and installation

If the wheel cylinder is leaking fluid around the piston. it should be removed and overhauled to restore braking performanca. Befora disassembling it. read through this entire procedure and make SUfa you hava the corract rebuild kit. Also, you will nead some ne w, clean bra ka fluid of the recommended type and some clean rags. Nota: Disassembly, overhaul and reassembly of the wheel cylinder mus t be done in a spotlessly clean work erea to avoid contamination end possible failure of the brake hydraulic system components. If such a work area is not tIIIai/able, have it rebuilt by a dealer service department or a service station. 2 Refer to Section 12 fo r the brake shoa removal procedure. 3 Although It is possible to overhaul a wheel cylinder while it is still attached to the backing plate, it is recommended that it be re· moved. To do this, disconnect the brake line from the cylinder and either plug the line or seal the master cylinde r reservoir with a sheet of thin plastic to prevent loss of fluid and to keep conteminants from enter· ing the brake system. 4 Remove the two small bolts on the back side of the backing plate which hold the cylinder to the plate, Remove the cylinder. S Next, cerefully remove the rubber dust boot with your finoer!!

Cable and conduit

2 Hand brake clip 3 Hand brake bracket

12 13 I.

Hand brake handle assembly Rear cap Drive gear bushing Driven gear Driven gear sleeve Backing plate Brake shoe Lever end return spring Brake drum Bolt Rear companion flange

15 Washer Nu, 17 Driveshaft flange yoke 18 Rear driveshaft 19 Adjusting end spring 20 Adjusting screw bracket 21 Operating lever 22 Clevis 23 Retracting spring clip 24 Retractmg spring link

"

6 You can now remove all the remaining parts within the cylinder housing; both pistons, the cups and the compression spring and ex· panders. An easy w ay to remove thase parts is by tepping the cylinder on a piece of wood. 7 EJC amine the mating surfaces of the pistons and the cylinder walls. If thera is scoring, evidence of metal-to-metal contact Of bright wear ereas, replece the complete cylinder assembly with a new one. 8 If the metal components are in good condition, discard the rubber boots and the cylinder cups and replace them with the new parts from the rebuild kit. 9 Thoroughly clean all the parts with new brake fluid. When cleaning the brake cylinder walls, wrap a clean white cloth around a stick and soak it in new brake fluid. Insert the stick, fi rst in one side of the cylinde r and then the other, end rotate it several times. 00 not use a push·pull movement. 10 Jf tha bleeder screw is stripped or damaged, raplace it with a new one. Jf it is in good condition, use compressed lIir and blowout any foreign material that might block it and hinder the flow of brake flu id when bleeding the system. 11 You can now prepare the parts for reassembly. If your rebuild kit comes w ith a package of special grease, coat the piston cups, pistons and inside wells of the cylinder with it. If not, then coat these same parts with new, clean brake fluid . 12 Insert the spring first. Then, from either end of the cylinder, insert the piston cups, followed by the pistons. Note: Milke sure these p8rrs are inserted correctly. 13 Install the boots on the brake cylinder, then attach the cylinder to the backing plate and hook up the line. 14 Refer to Section 12 for the brake shoe installation procedure..

9

9-10 14

Chapter 9 Brakes

Parking brake - adjustment

Two types of parking brskes Bfe used on these models.. Early models used 8 drum brake located 8t the rear of the transfer case which locked the driveshaft and resr wheels when applied. On laler models, the rear brake shoes are actueted by a s~tem allevars and cables when the parking brake lever or foot pedal Is applied. 2 Before adjusting either type of parking brake, first inspect Iha cables, connections end mechanism for damage, binding and corro· sian. Replace any damaged components with new ones.

8 Tighten the equalizer nut until there is a slight drag when (ha rear wheels are turned. 9 Loosen the nut sufficiently to allow the rear wheels to turn freely and tighten the locknut. 10 Lower the vehicle.

Transfer case mounted drum-type parking brake 3 Make sure the brake handle is completely released and rotate the drum until one pair of the three sets of holes is over the adjusting screw star wheels in the brake. 4 Use the edge of the holes as a fulcrum for an adjusting (001 or screwdriver and rotate each star wheel by moving the tool away from the center of the driveshaft until the shoes are locked against the drum. S Back the star wheels off seven (7) notches to achieve the proper running clearance. The operating lever-to·backing plate clearance should be 3/32-inch as shown in the accompanying illustration.

Cable-operated rear brake shoe parking brake 6 Block the front wheels securelv. Raise the rear of the vehicle and suppa" it on jackstands. 7 Make sure the parking brake is released and loosen the parking brake cable equalizer locknut.

hi;T ...

.~~ '. ,

r

CLIP

Early model drum·type parking brake adjustment (Sec 14)

HANDLE

CLIP

•

Fig. 9 .18

CLIP

\

RELEASE CA8 L E

AND HANDLE

".

BRACKET

EQUALIZER

~

~ /-

PARKING BRAKE ASSEM8LV

/'

...

(!)

RIGHT REAR

FRONT CABLE

LEFT REAR CA8LE CLAMP

Fig. 9. 19

Typical hue model parking brake cable layout (Sec 14)

9·11

Chapter 9 Brakes

7 Instal! the master cylindel and, on non-vacuum booster·equlpped models. connect the pushlod to the brake pedal. B Connect the brake lines to the mailer cylinder. 9 Bleed the brake system (Section 31.

15

Tr.n.f.r cau mounted drum-type parlling brake - .hoe replacement Rllse tha rear of the vehicle and support it securely on jackslands. Remove the four mounting nulS and lower Ihe driveshafl OUI of the way. 3 Remove the retracting spring clevis pin and spring pin. followed by the locknut. nUl and washer from Ihe uansfar case output shalt. Use II puller to remove the universal joint companion Ilange and brake drum. 4 Remove thaletlacting springs and sepalale the blake shoes from the backing plate. 5 Carefully blush away any accumulations of din and dust flom the backing pla'e and adjusting screw mechanism. Nota: Make an effort not to inhale this dust; it conrains esbesto$, which is harmful to your health. 6 aefole Installing new shoes, back off Ihe adjusting star wheels 10 the fully off pOSition and lubricate Ihe contact surfaces ollhe backing plele. blake shoes and adjusler mechanism with a small amount 01 hightemperature grease. 7 Install Ihe blake shoes and IIltum springs. The yellow spring fits ne)(t to the notched adjusting wheel screw and the black spling next to the cam. Install the brake dlum and universal joint flal'lQ8 and adjust the brtIke (Section 14). 9 Install Ihe dliveshaft and lowel the vehicle.

1 2

17 Single piston master cyllnde, - overhaul Early models were equipped with alngla brake systems. which re ' quired only a single piston in the master cylinder. 2 Before the master cylinder is removed (Section 161. obtain the propel rebuild kit and read through the following procedure to make sure you have the correct kit. You will elso need .ome new brake fluid of the recommended type and some clean rags. Note: Disassembly, OVtJrhau/and rellssembly of the mIIster cylinder must be dOM in a spotlessly clean work llrea to llvold contllminetion and possible failure of the brake hydreulic system components. "such II work llree is not available, have It rebuilt by II dfHJler service depllrtment or e properly equipped shop. 3 Drain the fluid from Ihe reservoir into a container and wash the master cylinder with denatured eleohol or clean brake lIuid. 4 Dismantle the master cylinder by referring to the accompanying illustration. Wash the components with denal\Jred alcohol or clean brake flUid . 5 Inspect the cylinder bore for heavy sCOfing. scratches and corro'IOn. Make sure the passages between the reservoir and piston bore ale open lind free 01 foreign material. Clean them with a wire if necessary. light scratches or roughness in the bore can be removed by honing but a new unit should be obtained if the scoring or demage is extensive. The rebuild kit should contain a new piston. primary cup. valve and valve seat. 6 Install the valve seat in the end of the piston bore with the flat surlace facing the valve. 7 Install the valve assembly. lollowed by the return spring and primary cup with Ihe flat side of the cup toward the piSlon. InSlall the piston. stop plate and lock. wire retainer spring. 9 Install the fitting connection. using a new gaskel. 10 Fill the reservoir haff full 01 new. clean brake lIuid and bleed the master cylinder as described in Section 16.

a

16

M ester cylinder - removal and Installation

1 Place rags or newspapers under the master cylinder to catch and lOek up eny bleke fluid that might spill dutlng remOval . Note : Be careful not to spilf any fluid on rhe painred surfacfls of 'hI! vehicle as it will demage the p8inr. Wipe up any spilled fluid immediately. 2 On vehicles without a vacuum booster system, disconnect the blake ptJshrod flam the brake pedal. 3 Disconnect and plug the brake IlI'Ies at the master cylinder. 4 Unbolt the mastel cylindel and lift it from the engine compartment. S Check lor Iluid leakage around Ihe lIange area at the base 01 the piston. If thele is evidence of leakage, the master cylinder should be overhauled !Section 1701 IS) or replaced with a new or rebuilt unit. S PriOr to installation. the master cylinder should be bled. Connect two lengths of tubing and actuate the piston(s! until the unit is primed with clean fluid and all air is bled out as shown in the accompanying illustration. IIlhe master cylinder is not bled before Installation. it can be done later when the brakes are bled (Section 31. It is recommend · ed, however. that the unit be primed first .

e

IS

Dual pilton mastlt cyRnd.., - ovemaul

If the cylinder is leaking fluid around the piston, 1\ should be removed and overhauled to restore braking performance. Before disassembling il. lead through this procedure and make sure you have the correct rebuild kit. When you Durehase the rebuild kit Irom vour dealer, be sure

9 SUEO

TueES

Fig. 9.20

Sleeding air from the malter cylinder (Sec 16)

Fig . 9.21

Typlcalaingle piston mlStlt cylnder -

1 2 3 4 5 6 7

Pusflrod Boot Piston stop lock wire Stop pia,. Piston M8Stflf cylinder cup Return spring

exploded ...lew (Sec 17)

8 Piston VMve seet 9 Reservoir '0 Fil,., cap g8sker , 1 F,I,., CliP '2 Outlet fitting gasket '3 Outlet fitting 14 Outlet fItting bolt gasket

9-12

Ch apter 9 Brak es

to get two spare brake line l itting nuts elsa. You will need them to instell the new tube seats. Also, you will need some new, clean brake fluid of the recommended type end some clean fags. Note: Disassembly, overhaul end reassembly o( the master cylindllf must be done in 8 spotlessly clean work 8,8a to avoid contamination Bnd possible fll/lure of the brake hydfBulic system components. If such II work area is not available, heve it rebuilt by II dealer service department or 8 properly equipped shop.

2 On models built through 1975, unscrew Bnd remove the primary piSlOn stop bolt located on the bottom of the master cylinder. 3 On models with manulJl bruka$, slide the pushrad boot back and remove the retainer clip or snap-ring. pushrod and boot. 4 Press the primary spring in. using the pushrod or tool. Remove the snap-ring from the groove in the piston. 5 Remove and discard the primary piston assembly. A complete piston assembly is supplied with the rebuild kit. 6 Remove the secondery piston assembly by applying air pressure through the compensator port in the front reservoir. 7 On some models the residual check valves must be removed. To gain access to the check valves, the outlet tube sealS must be removed with the self-tapping screws supplied in the rebuild kit. Thread the self-tapping screws into the tube seats and place two screwdriver tips under the screw head. Carefully pry the screw up and remove the tube seat. Wash all metal parIS with clean brake fluid or brake cleaning solvent. Use air pressure to remova dirt and cleaning solvent from the recesses and internal passages. 9 On '976 and later models there are no check valves and the lube

a

seats rarely need replacement. If the seats are cracked, scored, loosa or cocked in the fluid outlet pOrt, they should be replaced. It might be preferable to buy a rebuilt master cylinder. Read through the entire procedure below be fore attempting to replace the tube seats on later modal master cylinders. a) Enlarge the holes in the tube seats using a 13164-inch drill bit. b) Place a flat washer on each tube seat and thread a '/4 -20 x 3/4 -inch screw into the seat. c) Tighten the screw until the tube seat is loose and remove the seet, screw and washer. d) Remove all chips using compressed air and alcohol or brake cleaning solvent. e) Install the tuba fitting seats using the spare brake line fitting nuts to press the seats into place_ Do not allow the seats to become cockad during installation and be sure the seats are completely bottomed. II Remove the brake line litting nuts, remove all chips or bUfrs and rinse the master cylinder with alcohol or brake cleaning solvent. Blowout all passages using fillered compressed air. 10 Inspect the master cylinder bore for severe scoring, corrosion, pitting and damage. Replace the master cylinde r wi th a new one if the imperfections in the bore cannot be removed by honing. 11 Before reassembly, dip each compon ent in clean brake fluid. 12 On models built through 1975, install the piston washer, rear seal. protector and return spring on the secondary piston. Install the O-ring and front seal on the secondary Piston. Be sure tha flat faces of both seals lace each other.

RE AR BFlA KE

MAS TER CYL· INDER ACTUATING U N'

FRONT BflAKE

.'

.'

o-RING

.'

OlJTLET

PISTON STOP

PISTON

Fig.9.22

Typical dual piston master cyl inder co mponents - explodad view (Sec ' S)

Ch apter 9 Brakes

Fig . 9.23

Tube seet reffiOvallSec 1S)

9-13

13 On 1975Ihrough 1986 models, ioslalllOO piS10ll cups on lhe secondary piston. The cup installed in the groove al the end 01 the piston should have its lip lacing away from Ihe piston and the ne)(t cup lip should face toward Ihe pislon. Install the seal protector. piston seal. spring relalner and spring on the secondary Piston. The piston seal lip should face the interior of Ihe cylinder bore when the assembly Is Installed. 14 Lubricate the piston bore and piston !l550mblie:> with cloan brake fluid. 15 Install the secondary piston assembly. spring end first, in tho piston bore. Press the primary piston in using tho push rod Of a 1001 Secure Ihe pistons in the bore wllh the snap-ring. 16 00 models so equipped. install the pilton stop, using a new O-nng. 17 On check valve-equipped models. place the new check valves over the check valve springs and install them in the fluid outlet holes. spring end lirst. 18 InstIll the lube seats iii removed) and press them into place with Ihe brake line litting nuts. 19 On vtJhicl8s without power brakes. Install the pushrod and boot assembly. 20 8elore tho master cylindor is inStllllod on the vehicle, the unit should be bled. Refer to Section 16 lor the master cylinder bleedlllg procedure.

9

10-0

Chapter 10

Chassis electrical system

Contents Batterv check and maintenance . . ...... • ... Bulb replacement ........ . . . . Directional switch - check end replacement . . . Electrical troubleshooting - general information Fuses and fusible links - general information General infannelion ......••.• . .. . .......... . Headlight dimmer switch - check, removal tlnd instililation ... .. . .. . . . .... . . . . . . Headlight switch - removal and installation

Chapter 1

Headlight feplacament ... . . . . . . .. . .... . . . Horn - check and replacement ....... . .. . . Ignition switch - ramoval and installation. Instrument cluster - removal and installation Neutral sa fety switch - check. adjustment and repl;lcemenl Speedometer - removal and installation Speedometer cable - check. removal and installation Windshield wiper motor - removal and installation

5 12 2

, , 7

Specifications

Bul b application F- and l ·head four·cvlinder engine (6-volt system) Headlight . . . ........ . Perking light Perk and directional signal light .. . . . .... . Stop, tail and directional signal light . • _ ... . Instrument cluster lights .. . ... .... . .. .. . . InSHument light . . . . . . . . . . . . . . . .. . .. . Flesher and directional signal lights .............. . F-head four-cvlinder and V6 engines 11 2-voh system) Headlight .. . .. .. .. .. .. . . .... . . ... . . . . Parking and directional signal lights Ucense plate light .. . Side marker light ... . Instrument cluster light Backup light indicator Hazilrd flasher light .. Brake warning light .. All others (1972 and 1973) Headlight ........ . Parking and directional SIgnal lights Side marker lights . Backup light . .. .. .. .. . . . . .. . . license plate light . . . . . . . . . . . . . .... . . . ... .. .. . Stop, tail and diractional signal light Brake failure light Charge. directionel signal and high beam lights Directional lignal flasher . . . . . .. .. Glove box light Hazard warning. heater controls. instrument cluster and oil pressure gauge lights ........ . All others (1974 through 1986) Headlight Parking and directional signal lights Side marker lights ...... . . . . .. . . ... .. . . . . Backup light . . .. . . . . . Stop, tail and directional signal light Instrument cluster lights ....••.•.... Indicator lights .. . .. .. .. . ... . .. . . ...... . Clock light ...... .. . . ... . .. . . .. . . . . . . Automatic transmission column light . ••.•.... Tachometer light . . . .. .. . .. . . . . •. . . ........ . Radio light

Bulb type 5040·5 or 6006

"

1158 1158 51

55 P229D 6012 1157NA 1155

194 57 " 56

57 57

6012 1157NA

19. 1156 1155 1157

57

"

Tvpe 144

170

57 6014 1157

19. 1156 1157

""

1892 1892 1895 1893

•

13 6 14

Chapter 76

10 11 9

Chapter 10 Chassis electrical system

10-1

Fuse app lication F- and l-head four-cylinder engine (6-volt system! Heater Directional signal F and L-head four-cylinder and V6 engines Healer . Backup light Windshield Wiper Directional signal 4-way flasher Brake warning light All others (1972 through 1914) Directional Signal Backup lights Brake warning light Cigar lighter Air-conditioner Heater 4-way flasher Headlight Circuit breaker Control panel circuit breaker All others n975 through 1977) Directional Signal Backup lights 1975 1976 and 1911 Brake warrllng light 1975 1976 and 1977 Cigar lighter All-conditioner Healer Headlight clrcun breaker Instrument cluster Windshield washer/Wiper Tall and stop lights RadiO Panel IiQhl~ All others (19781hrough 1986)

Amperage

14 14 9

14 14 9

14 9 9 9 9

14 25 15

14 25 25 10

9 15 9 3 15 25 25 24 3 10

20 10 (5 amp ill-line)

3 Refer to fuse panel

1 Genllr.1 Information This Chapter covers the repair and s9fvice procedures for the various electrical components nOt associated With the engine. as well as general inlormation coocermng troubleshooting the electrical circuits. loforma· tion about the battery, generetor or elternator, distributor end starter motor cen be found in Chapter 5. Thlt electrICal system IS a 6·volt (early models! or 12-volt, negetive ground type with power supplied by a generator (eady models! or alternator_ It should be noted thet whenever portions 01 the electrical system are worked on, the negetlve battltry cable should be disconnected to prevent electrical shOll!! endfOl fires.

2

Electrlcel tro ubleshooting - general Info rmation

A typical electrical cirCUit consists of all electrical component, elly .witches. relays, mOIOrs, etc. related 10 that component and the wlr· Ing and connectors that conllect the component 10 both the battery and the chassis. To aid 10 locating a problem in any electrical circuit, winng diagrams for each model are Included at the end o f this Chapter. Before tackling allY troublesome electrical circuit, first study the ap· proprlate diagrams to get a complete understanding 01 what makes up that IndiVidual Circuit. Trouble spots. for instance, can often be nar· rowed dowll by noting il other components related to that circuit are operating properly or not. If several componltnts or circuitslail at one time, chalices are the problem lies in the fuse Of ground connectioll, as several CIICU,IS often are routed through thlt same fuse and groulld connections. Electrical problems oftltn stem from Simple causes. such as loose or corroded connections. a blown fuse or meltad fusible link. Prior to

any electrical troubleshooting, always visually check the condition of the fuse. wires and connections In the problem circuit. If testlllg instrumellts are goillg to be utili:ted, use the diagrams to plao ahead of lime where you will make Ihe Ilecessary connections in order to accurately pillpoint the trouble spot. The basic tooll needed lor electrical troubleshooting include a cir· cuit tester or voltmeter Ie 12-volt bulb with a set of test leads can also be usedl. a continuity tester (which includes a bulb, battery and set of telt leads) alld a jumper wire. preferably with a circuit breaker incorporated, which can be used to bypass electrical components. Voltage checks should be perlormltd if a circuit is not fUllctioning properly. Connect olle lead of a circuit tester to either the negative bat· tery terminal or a known good ground. Connect the other lead to a Call· nectar in the circuit being tested, prelerebly nearest to the battery 01 fuse. II the bulb 01 the tester goet on, vohage it reaching that POlOt {which means the part of the circuit between that connector and the banery is problem free l. Continue checking along the entire circuit in the .ame fashion. When you reach I point where no voltage Is pres ent. the problem lies between there and the last good test point. Most of the time the problem is due to a loose connection. Keep In mmd thet .Omll circuits receive voltege only when the ignition kay is in the

Accl!t'$ory or Run position. A me thod of finding shorts in e circuit is to remove the fuse lind COIlnect a lest light or voltmeter in its place to the luse lerminals. There should be no load in the cirCUit. Move the wiring harness from side-toside while watching the test light. If the bulb goel on, there II a short to ground somewhere in that area. probably where Insulation has rubbed all of a wi re. The .ame test can be performed on other components of the circuit, including the switch. A ground check .hould be done to see if a component is groullded properly Disconnect the banery and COl1nect one lead of a sell-powered test light such 81 a continuity teSter to a known good ground. Connect the othltr lead to the wire or ground coonection being tested. It the bulb goes on. the groulld is good. If the bulb does nOI go on. the

10

10-2

Chapter 10 Chassis electrical syst em

ground IS not good. A continuity check is performed to see if a circuit, section of circuit or individual component is passing electricity through il properly. Disconnect the battery and connect one lead of II self-powered hIS! !tghl such as II continuity tester to one end 01 the circuit. II the bulb goes on, there is continuity. which means the circuit is passing electricity through it properly. Switches can be checked in Ihe same way. Remember Ihat all electrical circuits life composed basically of elec-

tricity running from the battery, through the wires, switches, relays, etc. 10 the electrical component (light bulb, motor, etc. I. From there it is run to the body Iground) where it is passed beck to the battery. Any electrical problem is basically lin interruption in the flow of electricity to and from the battery.

3

Fuses Ind fusible links

~

ganerll Information

The electrical circuits of the vehicle are protected by e combination of fuses lind fusible links. The fuse panel is located under the dash in the main electrical harness. Later models also incorporete circuit breakers for certain circuits and components. Elch of the fuses is designed to protect a specific circuit as identified on the fuse panel. If an electricel component has failed, your first check shold be the fuse. A fuse which has "blown" can be readily identified by inspecting the metal element inside the housing. If the element is broken, the fuse is inoperable end should be repleced with a new one. Circuit breakers reset automatically when the circuit is turned off. Fuses can be replaced by pulling out the old one and pushing in the new one. It is important that the correct fuse be installed. The different electrical circuits naed varying amounts of protection, indicated by the amperage rating on the fuse. A fuse with too Iowa rating will blow prematurely, while a fuse with too high 8 rating may not blow soon enough to avoid serious damage to other components or the wiring. Never bypess the fuse with metal or foil. Serious damage to the electrical system could result. If the repillcement fuse immediately fails, do not replace it with another until the cause of the problem is isolated and corrected. In most

Fig. 10.2

cases it will be II short cirCUli In the wiring caused by a broken or deteriorated wire. In addition to fuses, the electrical system incorporates fusible links for overload protection. These links are used in circuits which are not ordinarily fused. The fusible links are located in the engine compartment and are replaced by unsoldering the ends lind then soldering a 'eplacement in place. The link must be wrapped with electrical tape. If an electrical failure occurs in one of the circuits protected by a fusi· ble link, check the link first. If the link is melted, replace it with a new one, but only after checking snd correcting the electrical fault that cllused the failure.

Fig. 10.1

Typical late model f use psnel (Sec 3)

Typical later model headlight and perkingldlrectionel light components - elCploded view (Sec 41

Chapter 10 Chassis electrical system 4

Id

Headlight replacement

1 Remove the headlight door attaching screw. 2 Pull the headUght door out slightly at the bottom, push up to disengage the upper retaining tab and lift the door off. 3 Loosen the headlight retaining ring screws, rotete the ring to disengage it and lift it away. 4 Puilihe headlight out of the shell, unplug Ihe connector and remove the headlighl. 5 Plug Ihe connector securely into the new headlight. 6 Placa the headlight in the shell and instalilhe retaining ring and door.

Fig. 10.3 Early model parking light components - allploded view {Sec 51

3 tiUlO 4 Gasket

, Bezel 2 Lens

10-3

5 Housing 6 Screw

5

Bulb replacement

Parking/directional signa/light 1 Remova the retaining screws, bezel, lens and gasket. Remove Ihe bulb from Ihe housing. 2 Install the new bulb. followed by the gasket, lans and bezel.

Side marker light 3 4 5

Remova the retaining screws and lift off Ihe side marker light lens. Grasp the bulb firmly and pull it from the socket. Insert the naw bulb and install the lens and screws.

Tail, stop, license and backup light Fig. 10.4

Early model tail, stop and directional light compone nts {Sec 51 _

1 Screw 2 Lens 3 Gasket

4 Bulb

5 Housing and wire assembly

6 Nut and washer

6 Remove the taillight lens, screws and gasket. 7 On laler models, the backup light bulb is located in the taillight housing and the stop light bulb on the left side also illuminates the license plate. S On early models, the backup light is contained in 8 separate housing. Remove the snap·rlng, lens and gasket to gain access t o the bulb. 9 Replacement is the reverse of removal.

HOUSING

SIDE MARKER· RIGHT SIOIE !WITHSIDIE·MOUNTEO SPARE TIRE ONL YI SIDE MARIIlER lIGHT BUla

, MARKER LlGHTLEH SlOE

10 TAILSTOP. DIRECTIONAl lIGHT aula

ALSO illUMINATES lICENSE PlATE ON lEFT SIDE OF VEHIClE

Fig. 10.5

Typical latar model taillight allsembly component, (Sec 51

10-4 6

Chapter 10 Chassis electrical system

Ignition switch -

9 Remove the key end push on the switch body so the notched be~el can be easily installed with the notches aligned with the nOlch pins. 10 Rotate the bezel clockwise to lock it in position with the word

removal and installation

1953 through 1975 models

"Starter" at the lOp.

, The ignition switch on these models is localed in the instrument panel adjacent to the steering column. 2 The switch is held in place by 8 threaded bezel nut and, on leter models, e tension spring. To remove the switch, press the body 01 the switch toward the instrument penel until the bezel cen be turned counterclockwise and released from the notch pins. 3 Remove the bezel Bnd pull the switch body back to release the spring tension. 4 lower the switch from the dash and unplug it from the wiring harness. 5 To remove the cylinder from the switch, turn the switch to the On position and insert a piece of heavy wire through the cylinder release hole. Depress the spring loaded brass retainer ring until it clears the retaining ridge, allowing the cylinder to be withdrawn. 6 To Install the cylinder, align Ihe tang with the slot in the case. depress Ihe retainer and insert the cylinder until the retainer snaps into place. 7 To install Iha switch, place the main compression spring on the switch body and then install the body in the instrument panel from the rear. 8 Insert the ignition key in the Off position end turn the switch body unTil the key Is streight up end down.

1976 through 1986 models 11 The ignition switch on these models is located on the lower sec· tion of the steering column and is connected to the key lock assembly by a remote lock rod. Two types of ignition switches are used: one for standard steering columns and another for tilt columns. Removal 12 To remove either type of switch, place tha key in the Off/lack position and remove the two switch mounting screws. Disconnect the switch from tha remote rod, unplug the harness connector and remove the switch from the column. Installation Istandard column) 13 Position the switch as shown in the accompanying illustration, with the actuator rod disconnected. 14 Move the slider to the extreme left. or Accessory position, position the actuator rod in the slider hole and attach the switch to the steering column taking care not to move the slider out of the detent. The right side of the switch must be toward the steering wheel. 15 Hold the key in the Accessory position and then push the SWitch down the column slightly to remove the slack from the actuator rod. 16 Tighten the mounting screws securely and install the white connector, followed by the black connector.

BEZEL RETAINING TABS TENSION SPRING

-4')~~~\

BEZEL

FIg . l0.6 Early model backup light components - exploded viaw (Sec 5) , Snap-ring

2 Lens

3 Gasket 4 Bulb

5 Housing

LOCK ROLE,. .O HOLE Fig. 10.7

Typical dash mounted Ignition switch (Sec 61

and wire

STURING _ I l l

¢ TllTCOl~

STANOARD COLUMN

Fig.l0.8

1976 through 1983 modal Ignition switch actuator rod Installation datails - standard column (Sec 6)

Flg. 10.9

1976 through 1983 model Ignition switch actuator rod installation deleils -lill column (Sec 6)

Chapter 10 Chassis electrical system (tilt column) 17 With the actuator rod disconnected. place the SWitch in positIon as shown in the accompanying illustration. 18 Move the slider to the extreme right or Accessory position. the right side of the switch must lace down. eway Irom the steering column. 19 Position the actuator fod in the slider hole and attach the switch to the steering column wIth the screws finger tight. 20 Push the switch down lightly to remove the play from the actuator rod while holding the key in the Accessory position and taking care not to move the slider out 01 the detent. 21 Tighten the screws securely and plug in the white connector. fOllow· ed by the black connector. Inltll~lIjon

7 Headlight .wltch -

removal lind In.tllilation

1 2 3

Disconnect the negative bettery cable from the battery. Pull the light switch knob out to the On position. Remove the switch knob. On some models the knob is retained by a setscrew or locknut while on others the entire knob and stem essembly can be withdrawn from the switch aher pressing the release button on the switch. 4 Remove the switch retaining nut and bezel. 5 Lower the switch from the dllsh panel. disconnect it from the wir· ing harness and remove it. 6 To install the switch. connect the wi ring harness. place the switch

10-5

in position in the dash end install the nut and bezel. Install t he control knob. 7 Connect the battery cable.

8

Headlight dimmer switch - check. removil end lnltilletion

The switch operation can be checked with a test light. Connect one test light lead to the switch input terminel end probe each output terminal with the other lead as the switch is operated. The current flow should alternate from one output terminel to the other as the switch is operated. Replece a faulty switch with II new one as follows: 2 Disconnect the negative battery csble from the battery. 3 In the engine compsrtment, disconnect the wiring hsrness, remove the retsining screws and separate the dimmer switch from the flOOf~ board. 4 To install the switch. place it in position. install the retsining screws and connect the wiring harness. 5 Connect the battery cable to the battery. 9

Windshield wiper motor - removal and in.tallation

1953 through 1970 models 1 Disconnect the vscuum hose, remove the mounting screws and lift the motor away. Installation is the reverse of removal.

Fig. 10.10 Early model headlight switch termin als (Sec 7) 1 88rrery 2 Resr fights 3 Headlights

4 Parking fights 5 Au){ifisry

Fig. 10.11

late model headlight switch !Sec 71

I'1VOT SHAn '-NO ARM

10

Fig. 10.12

Headlight dimmer switch terminals (Sec 81

Flg.1 0.1 3 Windshield wlpar motor component layout {1970 through 1976 modalsl (Sac 9)

10-6

Chapter 10 Chassis electrical system

I'IVOT I""""

A N D ANM

C""NK M .. O MOTDII

Fig. 10.14 1977 through 1986 model windshield wiper components (Sec 9)

Fig. 10.15 Removing th e steering co lumn lock plate (Sec 121

Fig. 10.16 Directional signal assembly installation details [Sec 121

10

1971 through 1975 models Remove the desh crash pad iii equippedL J Remove the plastic hole plug from the extreme lefl side of the bottom of the windshield frame air duct. 4 Disconnect the drive link from the motor crank. 5 Mark their locations and disconnect the wires from the switch. 6 Remove the cover and mOlor 7 Prior to installation, apply 8 beed of waterproof sealant around the contact surface of the motor cover. Install the motor, followed by the 2

cover. 8

Speedometer - removal and installation

1 Remove the instrument cluster (Section 14). 2 Carefully uncrimp the bezel outer lip and remove the outer bezel. glass and retaining bezel 3 Remove the mountmg screws and separate the speedometer from the housing. 4 Install the speedometer in the housing. ChOCk the inSide of the glass to make sure it is clean and free of fingerprints and install it along With the bezels. Carefully crimp the outer bezel In place in four places. 5 Inslall the instumen! cluster.

Connect the wires to the switch and the drive link to t he motor

crank . 9 Install the plastic hole plug and !if equipped 1 the crash pad.

1976 through 1986 models 10 Remove the crash pad (if equippedl and wiper motor cover. 11 Remove the hold-down knobs and fold the windshield down. '2 Remove the left access hole cover and disconnect Ihe drive link from the left wiper pivot. 13 Unplug the wiring harness from the switch. 14 Remove the mounting screws and lift the motor from the vehicle. 15 Place the wipe r motor in position, install the screws and connect the wiring harness to the switch. 16 Install the access hole cover and raise the windShield. 17 Install the crash pad !if equipped) and motor cover.

11

Speedometer cable - check. removal and Installation

A damaged or kinked speedometer cable is indicated if the speedometer is noisy or the needle action is jerky. A lack of lubrication can also cause these symptoms and can be corrected by disconnecting the cable at the speedometer head and squirting powdarad graphite lubricant into the cable end and head contact surfaces. 2 To remove the speedometer. disconnect the cable at the speedome ter head and transmission. remove the grommet and pull the cable into the engine compartment. 3 To check the cable. place it in an inverted "U" shape on a flat surface and cross the ends. Hold one end of the cable core lightly while turning the other end. The turning action should be smooth: if the core jerks or jumps. the ceble should be replac ed with a new one. 4 Installalion is the reverse 01 removal. Be sure to lubricate the cable and speedometer head With graphite.

10-7

Chapter 10 Chassis electrical system

~A'D"fl

Fig. 10.18 1916 through 1986 relay equipped horn system tenninals !Sec 13) JUliN SIGNAL HARNESS Fig. 10.17 Typical non-relay equipped horn system leyout ISec 131

12

Directional .whch - check and replacement

Burned 01,11 bulbs and loose connections are the most common causes 01 problems in the directional Signal system. If the flashing fate is about tWice the normal rate, a shorted out bulb is Indicated. If there il no ,Ignal et any bulb, check the fuse. If the fu.e is good, install a Il8W flesher UnJ! 1I0cated in the luse panel on most modelsl. If the bulbs, fuse. flasher and wiring check out correctly, replace Ihe directional swilCh. 2 Disconnect the negative battery cable from the battery. 3 On models built through 1975, the directional SWitch Is clemped 10 the left Side of the steering column by two Allen head screws. Replecement is accomplished by unplugging the electrical connector, removing the screws and lifting the SWitch away Irom the steering colurnn. InStalialion is the reverse 01 removal. -4 On 1976 fhrough 1986 models, the switCh IS Iocaled in Ihe steering column. Remove the horn button by pulling straight oul. Remove the screws. bushing. receiver, spring and sleellng wheel and nut (Chapler HI. 5 Lilt the IClCk plate cover and use a comprassor 1001 (AMC J-23653) to depress the lock plate as shown In the Illustration. 6 Pry the round wire snap-ring from the steering shaft groove and remove the tool. snap·rlng. lock plate, directional signal canceling cam, upper bearing preload spring and thrust wesher hom the steering shalt. 7 Dapress the ha~ard warning light switch on the right side of the column and turn II in a counterclockwise dlrreclion to remove it. 8 Remove Ihe directional switch wire harnell connector block from the mounting bracket on Ihe right side ollhe column. On models equipped with aflauto~tic trlmsmisslofl. lr'IS8rt a stiff wire such as a paper clip Into the lock tab retaining the shift quadrant light wire In the conneclor block. 9 Remove the screws and separata the dlreclional SWitch and wirIng harness Irom the column. 10 To install the switch, guide the wiring hame6li inlO pOSition and align the SWitch assembly with the actuating lever pivot seated in the upper housing pivot boss and install the screws. 11 Inltall the switch laver and actuate the sWllch to meke sure Ihe assembly is properly instelled. 12 Piace the thrust washer, spring end directional signa! canceling cam in place on the upper end of the steeling she\t_ 13 Align the lOCk plale sp~rres with lhe steering shah splines and place the lock plate in pOSilion so the directional signal canceling cam shah protrudes through the dogleg opening in the lockplate. 14 Inllall Ihe snap-ring, lock plate cover and steering wheel. 15 Inllalilha steering wheel washer and nUl, followed by the spring wilh the raised side up 16 'nstall tha receivel and bushing, making sure Ihe receiver movas lreely aher Ihe bushing screws are tightened. 17 Align Ihe nOlch on the raceivar with Ihe nib on Iha horn bunon and push the bunon in unlil it snaps intO place.

Fig. 10.19 Instrument clustar IIsambly components (Sec 13) 13

Horn - ch9(:k and repla cement

All models a18 equIpped with a horn system consisting of • Single horn mounted on the left inner lender well. Battery power aClivates the horn when the horn button is deprassed. completing tha circuit. 2 If the horn does nOI sound. use a test Ilghl or voltmeter 10 chack the red (battery feed) wire. 3 A lack of vollage indicalas 8 shon circuit or, on later models laltel 19751, a burned out lusible link. 4 InspeCI the wiring between the horn. relay (on models after 1976\ end battery for loose connections, corroded terminals and Irayed wires. The horn assembly is attached to the lender well with cadmium platad Icorrosion resistant) scraws. Maka sure they hava not been repleced wilh non-plated scraws which may not ground the horn properly. 5 On relay equipped systems !'976 through 1986), ground the number 2 lermmal 01 the relay with a jumper wire. If the hom sounds. the relay and hom are operating properly. If the hom does not souod. ground the number 2 terminal and connect a jumper wire between lhe number I and number 3 terminals. If the horn sounds. the relay is faulty. The relay is encased in plastic aod is located in the w,ring harness under the leh side of the instrumenl panel. If the relay is good, connect a jumper wire from the horn base to a good ground and repeat the lesls. If the hom does not operate, it Is faulty aod must be replaced With a new one 6 On non-relay equipped models, if battery power is reaching the horn, ground the black wire with the yellow tracer. If the horn does nol sound, Ihe horn 8ssembly is faulty and should be replaced with a new one. If Ihe horn operates, there is a fault in the Iteering column wiring. 7 To check the steering column wiring on all models, disconnect the negative banery cable, remova the horn button and inspect the hom conlaCI and spring lor damege and corrosion. S To replace the horn, disconnect Ihe wiring harness plug. ramove the screws and lilt the assembly Irom the inner fender well. Installation is the revarse of removal.

14

Instrument cluster - removal and InstaUallon

I Olsconn.ect the negative bauery cabla from the battary. 2 Disconnect the speedometer cable ISection 11). 3 Remove Ihe cluster mounting screws or nuts aod lower the cluster assembly. On some models it will be necessary to remove twO Icrew. and lower Ihe healer control bracket, 4 Mark their locations and remove Ihe wires Bnd the light bulbi. 5 Separate the cluster from the da,h. 6 To InSlaH the cluster, connect the bulbs and wires. place the cluster assembly in position and instal! Ihe mount,ng screws or nuts. Connect Ihe speedometer cable. 7 Connect Ihe negative battery cable.

10

10-8

Chapter 10 Chassis electrical system

Fig. 10.20 Left headlIght

74

Left parking light RIghI parking 'Ight RIghi headlight

75 7.

5

Generatof

7'

6

Dlstnbulor Voltage regulator

•• 20

NegatIve ground cable Bartery PositIVe cable

Fuel gauge sending unil Tal/and Slop lIght

Starting SWitch

27 22 23 2' 25

Hom

26

JunctlOt1 bJocIc

7 2 3

• 7

••

7O

"

72 73

StartIng motor

Fig _ 10.21

CJ·2A wiring diagram

77

IgmtlOn COIl IgmllOfl sWItch

Ammeter Dash light rell-tale light Fue/gauge Ughl SWlreh

LIght SWItch CircUlI breaker DImmer SWItch

Stop light SWitch

Early model CJ-38 wiring diag,.m

7 Lelt headlight 2 Left parking fIght 3 Right pafking /lgM

•5 Generator

Right headlight

6 Valtage regula/or

73 Dash light 7' Indlcatof light 75 Fuel gauge 7' Igm tion SWitch 77 Ught switch

78 Fuel gauge sending

7 Negative grOlJnd

••

cBbl.

Distributor Igmtion call

7O Battery

""

Stafte, molor

Ammeter

7' 20 27 22 23

unit Tail and stop lIght

Dimmer SWitch Stop light switch Horn

Junction block

10-9

Chapter 10 Chassis electrical system

c;: .?

•

3,

-.'

w iri ng diagram I

2 3 4 5

• 7 8

•

/0 /I

12 13 14 15 /6

Utfr hetldlight /..iIft parking fight Right parking light Right headlight NegatlWJ ground cable Generator DlstributOf Battary PDs/flWJ c8ble Vol/8ge regula tor Starter motor Ignition coil Signal flasher Starter switch Ammeter Dash light

17 Indicator fight 18 Fuel gauge Ignition switch 20 Fuel gauge sending unit 21 Horn button 22 Directional signal sWitch 23 Light switch 24 Right ta;1 and stop light 25 Lef t tail and stop light 2. Dimmer switch 27 Stop light switch 28 Horn 2. Junction block

"

I

uft headlIght signal ligh t

3 Righ t parking and

• 7 8

•

10 /I

12 13 14 15 /6 17

18 79

c::::::- ----€

-

late r modlll CJ-3B (I her I lIrllll number 355 22) wiring diag ram

2 uft parking and

4 5

~~ = .ali

Fig . 10.23

l l t l ' model CJ-3 B (up t o .erlal numbe r 3552 2 1

0 ~

,"

,-'

~

Fig . 10.22

1

"'I . "

signal light Right headlight Bat/ery ground strap Gemuator Ignition coif Junction block Horn Dlstfibutor Battery Voltage regulatof Starter motor Oil pressure sending unit COO/8n! temperature sanding Unit Solftnoid switch Foot dimmer switch Stop fight sWitch Direc tion81 signal flaSher

20 Fusa 21 Light switch 22 Directional SJgnal switch

23 Horn button 24 Ignition and startar switch

25 Instrumen' cluster A Upper baam indica tor 8 Turn signal indicator C Instrument lights 0 Oil pressure indica/()I" E Ch8rg;ng indicetOf F Templlreture g8uge G Fuel gauge H Instrument voltage regulator 2' Fuel g8uge (8nk unit 27 Lsft tail and stop light 28 Right tall and stop light

10

10-10

Chapter 10 Chassis electrical system

"

Ag . 10.24 CJ· 5 )bafor, • • rlll number 49248) and CJ· 6 )befor' •• rlal number 1257711whh F-h •• d four-cylinder Inglnl' wiring diagram

,

lIIfr hetldlight 2 lIItr parking light

17 Ignition switch

3 Right perking light

19 Directional signal switch 20 Right tllif and stop light 2' aft tsil snd stop light 22 Fuel glJUge sending unit 23 Light switch 2' S top light switch 25 Dimmer switch 26 OJ( pressure sending unit 27 Horn 28 Junction block

•5

Right hHdfight N~.tiWJ ground cab/II

6 GaMr.tor 7 Distributor 8 EMttsry

•

'0

" '2

,.

'3 '5 '6

Positive csble Ignition coil Cool8nt tempfJlllturrt sending unit St8rter motor \IoIt8ge r8gu~tor 5t8rte, switch Fuse Instrument cluster

'8 Horn button

Fig. 10.25 CJ-5 tafte' ,erial number 49248) and CJ-6 )afta, •• tlal number 1257711wlth F-head four-cylinder angina) wiring diagram

,

Left hetldfighr

2 Left p"rk,ing (md 3

•5

dif6Criona/l,ght Right perking lind dlrtleriana/light Right headlight Battery ground cable Geneflltof

6 7 Disrributor 8 Ignition coil

•

'0

" A

B

C 0 E F G H

Stsrting motor \IoIts~ regul8tor Instrument cluster Upper bum Indicetor Turn sign81 indicator Instrument lights Oil pressure indicator Cherging indicetof TemperlJture gauge Fuel glJUge Instrument voltage regulator

12 RIght rail ana stop fight

'3 Left tai/and stop light

14 Fuel gauge tank unit

'5 Ignition and starter SWitch

'6 Horn button

17 Directional signsl switch '8 Light SWitch Stop light switch 20 Foot dimmer switch 2' Directional signal flasher 22 Fuse 23 Solenoid switch 2' Temperature sending unit 25 Oil pressure signel switch 26 Horn 27 Junction block

,.

10-11

Chapter 10 Chassis electrical system

~

~J; Fig. 10.26

, 2 3

•5

• 7

8

• '0 " '2 ,.'3

,. '5

17

'8

19 A

8 C 0

CJ· 5 and CJ·6 iwith later model F·head four cylinder englnel wiring diagram

Left headlight Left parking and Signal light Righ t parking and signal light RIght heedllght GenelatOf Ignition distfibutol Oil pressure sending unit Junction block Hom Foot dimmel switch St op ligh t switch - f ront Coolant tempelawre sending unit Ignition coil Staffer motOl Battery ground cable Battery ImItege regulator Fuse Instrument cluster Hi-beam Indicatol Auxiliary Instlument lights Oil pteSSUle indicalOl

E Charging indica t or F Tempera ture indicator G Fuel gauge H Inst rument voltage reguletol 20 IgnitIOn I!Jnd stl!Jlter swit ch 2' F~sher (direction81 signalJ 22 Horn burton 23 Directional signal SWitch 2' 4 -way f/ashel s w itch 25 Flasher /4-way) 2. Fuse 27 M ain light switch 28 St op light switch - reel 2' Fuel gauge tenk unit 30 BlICk·up light swit ch 3' Right tall and stop fight 32 Right back·up light 33 Lef t back-up light 3' Left tail and slop ligh t

Fig. 10.27

,

Earlv model with V6 engina wiring diagram

Lef t headligh t

2 Left plJfking and signal light

3 Right palking end

•5

•

7 8

•

10

"

,.,. '2 '3 '5

17

'8 19

20 A

8

signal light Right headlight ImIt age IBgU1atOl Alt erna tor Oil pffJssule sender Cooolant t empera/ule sendel Ignition dis tribu/ol Junct ion block Hom Igni tion coil Steffel mo tOl Battery ground ceblt! Foo t dimmer switch Stop ligh t sw i tch - front Balfast resis tor Flashel (directional signal) Fusa Inst rument cluster Hi-b eam indicator Auxiliary

Instrument lights Oil pressure indicator Charging indica tor Temperl!Jtute indicl!Jtor Fuel gauge H Instlument voltage regulatOf 2' Ignition and starter switch 22 Hom burton 23 Directional signal switch 2. 4 -way flasher switch 25 Flashal (4 -wey) 2. Fuse 27 M ain light switch 28 Stop light switch - lfIar 2' Fuel gllUge tenk unit 3D Back-up light SWitch 3 ' Right t all and stop light 32 Right bllCk-vp light 33 Le ft beck-up light 3' Left tall and Slap ligh t

C 0 E F G

10

10-12

Chapter 10 Chassis electrical system

Fig. 10.28

Typlcal leter

model with F·head fourcylinder englna wiring diagram

I Left headlight 2 LBft parking and signal light 3 Right parking end signa/light

4 5 6 7 8

Right headlight M8rlcer light - 8mbe' Generator Distributor Ignition coil

9 Starter motor 10 Ba1/ery ground cable " 12-volt battery 12 Flasher (directional signal)

13 Instrument cluster A Hi-beam indicator B Aul(iliary

C Instrument lights D Oif pressure indicator E Ch8f9m9 indicator

F Temperature indicator

G Fuel gauge indicator

H Instrument voltage indicator 14 Ignition and starter switch 15 Horn button 16 Directional signal switch 17 4-way flasher switch 18 Flesher (4-wayl 19 Windshield wiper motor switch

20 21 22 23 24 25 26 27 28 29 30

Main light switch Fuel gauge tank unit 8ack·up light switch Marker light - red Right tsil end stop light Right beck-up light Left back-up light Right tail and stop light Marker light - red Stop light switch Foot dimmer switch

31 Windshield wiper motor assembly 32 Voltage regulator 33 Coolant temperature sendmg umt 34 Oil pressure sending umt 35 Spark plugs and cables 36 Horn 37 Junction block 38 Marker light - amber

22 23 24 25 26 27 28 29 30

Marker light - amber Right tail and stop light Right back-up light Lsfr back·up light Left tail and stop light Marker light - red Stop light signal Foot dimmer switch Windshield wiper motor assembly

31 32 33 34

Fig. 10.29 later model with V6 engine wiring diagram ,

Left headlight

2 Left parking rmd signa/ light 3 Right parking and signal

light 4 RighI headlight 5

6 7 8 9 to 11

12 A 8 C D E F G

H 13

Merker light -

amber

Alternator Volrage regulator Starter motor Bllttery ground cable t2-volt battery Flasher (directional signal} Instrument cluster Hi-beam indicator Auxiliary Instrument lights Oil pressure indicator Charging indicator Temparature Indicator Fuel gauge indicator Instrument voltage regulator Ignition and starter switch

.~ 14 Horn button 15 Directional signal switch 16 4·way flasher switch 17 Flasher (4-wayJ 18 Windshield wiper motor switch 19 MaIn /fght SWitch 20 Fuel gauge tank unit 21 8ack·up light switch

35 36 37 38

8allast resistor Igmtion coil Spark plugs and cables Coolant temperature sending unit Oil pressure sending unit Horn Junction block Merker light - amber

10-13

Chapter 10 Chassis electrical syst em

, , 1>11 BEAMI TO I"STR CLUSTER IHI!!IE .. M INO I 1>11 BEAMI TO HE .. OL ...... P CONN 11'11 If"""l I IG'I SWITCH IIG'I HRM ITO INSTR.CLUSTER VOLT REGUL .. lOR CONN ~~~~:~~GHT TO ~~~~~~G SW TO ~II;~~~ SW 10 CLUSTER L.. MP RIGHT TURN CONN I.. LTERN .. TOR "'UII. lUIM.! TO INSTil CH ... RGE IND. TO INSTR VOLT REG. CONN lOlL PIIESS SENO ER ITOOIL PIIESS.INO TO IN5TII _ VOLT IIEG CONN

~~G~:~;fT

TO

~~~~~~G 5W

TO

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TOCLutTlII

LAM'~m

TURN

IOIlOUNO I fl"'~MTG TO LIGHT SW . WI'fIl' H.. ZAIIO LIOHT' CONN (FII .. ME H ... IIN G"'S G'" TANIe UNIT, TO INSTR CLutTlII G"S GA. INDICA TOil LIGHT S'rOITCH "I" TEIIM TO INSTR CLUSTER LIGHTS TO HE"'UR L...... ' LT SWlTCH iTEAM II 10 l ...... "SLIOHH::.i.~~ER TO INSTR ClUSHIIL",M' SPLICE TO CON ... IST ... IIT SOLENOID lI... n . lEIIM .! IGNITION SWITCH IIG1\I TEIIM.I TO CONN. COIL 101 HIIM IGNITION SWITCH IST ... RT HilMI 10 CONN IST,,"TMOTOR SOLENOID START TEIIM I fOOT DIMMER SWITCH ··B·· HRM TO LIGHT SWITCH "H'" TEIIM LIGHT SWITCH IAn II 21 TOCONN ISlO' LITE SW_I LIGHT SWITCH '" A" nllM TO CONN (f ll .. ME H.. RNESS·T... l l LIOHTSI LIGHT SWHCH ··R" TEIIM TO CONN. (P"'"Ie . TERM,

CONN"~~:~~~F"'T"N

TO HAZARD WARN SW TO DIRECT SIG SW ILEFT TURNI

CONN -FRAME HARN AE... A IIIGHT TO HAZAAD WAAN SW TO

~1';E5c..:- ·IAIOHT1U AN )

SPLICE TO CON'I IIGN SWIICH B" TT ) CIGAA llGHTEA SPLICE TO CONN IliGHT SW II 1 FOOT DIMMf.A SW ILO If ... M) TO .. fAOL .. MP CONN 1l00If ... M) HOAN TERM '0 CONN (HO AN IUTTON) lIGHT SW III 11 ~USlO TOCOfIN IH .. uo,AO FlASt-lEll1 FEED CONN UGN SWITCH ACC TEAM) 10 CONN IDIRECT SIGN"L FL ... ~(RI WfSWIPER SWITCH 10 Wf$ W"'~EA MOlOII WIS WIPEA S'" ·1· TO IGN (ACC lERM_1 CONN IBACK·UP LIGHT SW.I TO COfIN (fRAME KARN BACIe U, L TS ,J T_C SWITCH TO IGN. O~ IGN SW nGN TEAM.! T C. SW TO l ,C V"'CUUM SOLENOID HAuo,AO FlASHEA 10 H"Z .. RD SWllCH CONN (HOAN TERM .I TO SPlICE IGN !OwnCH (lGN TEIIM.I fUSED TO CONN IIiAC Ie UP LIGHT S"',I CONN (TUIIN I CONN HURN I

~US(O

CONN IHlliEAMl lO CON1\I ( HEAOLAMP HI BEAM_LT) TO CONN CONN iTURNSIGN"'~SW RT TURNI TO CONN 10lR SIGN ... L CONN (TURN SIGN"'l $W l T TURN) TO CONN (OlR SIGN"'L ~AM' LEn TURN) CONN (, ... RI( TER ... ) TO CONN. (' ... RI( L........ LT( TO CONN (' ... RI(. L........ RIGHl! CONN ILO Bl ...... ' TO CONN ( >lE ... OL ... M'

~O BEAM Ln

TOCONN

: ~~~~~!:':."Tt

CONN ISTEER COLUMN HORN BunONI TO >lORN TERM

~J~=~=~~~~~~~==~=l'!O~'~'~'!"~'~~~"~';"~'!O!'~'I'!'~M

~

CON1II

,

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C·ll

C-.l

1 ..

GII"'V ~APL[

'"

lT IIlUE BlACK OA"NGE

,

TO CONN . IH MP OVERRIDE $W I

~=====

C01ll1ll ICLUSTER "H" TERM 1 TO "LTER1IIATOR I"UI( I TO "'LTERN .. TOR R[OUL"TOR (H RM .! I"'UX. TERM I CO'lN lOlL 'RUSURE INOIC" TORI TO OIL PRESSURE $['1o[R START SOLE1II010 I"." TERMI TO CO'lN. ICI RCUIT 8R("I((R FUol C01llN.IIGN SW ST .. RT TERM.I TO SOLENOID (ST .. RT HRM.I CONN ITRANSMISSION SOLENOIDI IT.C.s.1 TO V ... CUUM SW CONN ISENWR SW I TO VACUUM SW. CONN (lGN SW ION TERM I TO COIL (01 YERM.-RESIST"NCE WIRE' J!I P. M.. II ST"RT SOLENOID (ION I TO "LTERN" TOR REGU~"TOR (lONITIONI COIL (0) TERM TO ST .. RTlNO SOLENOID IIO .. iTlONI "L 1£RN... TOR REGUL"TOR IOROUNO TUIM _I TO ... LTER ..... TOR (ORO I AL fERN"TOR REGUL"'OR IFIELO TERM.ITO"'L HRNATOR IFiELO TlRM I

n .c.s.)

""

VELLOW OAlEH ILACIe ORHN_

OVERRIDE SW 1

I

"

,.

-1~1-';'-1-;~~:'f-'ii;----r:,;0:'~':.11.!.~~N!'~';';0:'~L ., .." GII ... Y

~APLE

0 ·12 0 ·1 . O.

" ,., ro" ~,

0 _.3 0.' D·~~

." '" '" ." , .~

""" ""

" " """

'"

LT BLUE PINK VlLlOW GillEN IlACK GREEN WH. YELLOW

"

HIINATOII IAUX . TEAM. ) TO ... LTEAN .. TOR REO (FIElD TEAM .I CONN I INDICATORI TO OIL PIIESSURE SlNOIR START . SOLENOID 1"11" TEAM .I TO CONN. ICIRCUIT BAUI(EA fUOI CONN . IIONITION $W START nllM _1 TO$OLENOID (STAII T nAMJ CONN. (lONITlON $W IGN TEAM I TOCOI~ (0) TERM. IIESISTANCI WIAl uon ST ... AT SOLENOID (IGN.! fO .. l HIIH"TOIIREGUL .. TOII IIG N ) COIl (0) HIIM . TO $TA AT . SOLENOID I1ON.I "L TEAN"IOA AEGUlAlOR IGRo. TEIIMI TO ... LTERN ... TOR IGRD TERM.! "LTEAN"'OA I TEAM .I 5"I .. RT

,,

_IU

CONH (GAS GAOE INSlII UNIT,

YElLOW

CONN

lIGHT 'LUE OIlANGl GllnN WH TR .

CONN ITUIIN SIG N... L SW I TO CONN ( I l T.! CONN (TURH SlGN"L SW.I TO CONN (AT. STOI" SlONAL LIGHT, CONN (I .. CK U, LT SW I TO COHN. (I"CK lW LID"' (L f • RT I

1972 Ind 1973 model wi ring dllgram key

10

10-14

Chapter 10 Chassis electrical system

~;:::

.. "'''..

. ......-. -,

.H •• _ "

",

.-"

.-

-.. ~

Fig . 10.30

1972 and 1973 model wiring diagram

.,

.,

O•

'"

10-15

Chapter 10 Chassis electrical system

......

:-,:.

::!:' .... " .....

..~ I

~._J

"""

1.-

...

TJ

-_."

....':::.

."•. "".E=

...

""

I

...

,. "",

..... .-.

.-,~,,,..

o

...

..••

ill!j~~~~ ....-

I L.; " . c;_

..

,>llt

Dimmer SWItch DirectiOl'llI SilJ'lll Switch Distributor, 6 Cyllrlder Distributor, V·8 ElectronIC IlJ'IitiOrll'Kk , 6 Cylinder

•

1974 and 1975 model wiring diagram

Back.up L.amp, Left Rear

Backup Lamp SWilch, 6 Cylinder

•

E< B·9 & B·IO

D·J C·J C·,

Heldl.mp Ground, Righi Hener Blower Molor

Ign itiorl SWItch Instrument GiustI' Instrument P,nel Liltrts Ground llltrt Switch li!1'rt Switch Ught

1974 and 1975 model wiring diagram key

E·l0

•• D, ' ·8 D·'

,., D·' ,.,

.,,.

,. C8

D.

A·8 & A·9

C·, 0·8 E·8 & E·g

'8

10 -17

Chapter 10 Chassis electrical system

•

•

•

1

~.,,-.-

.... " . ,.... 3·:-':· .

"

"

-

•

... '"'"""-.-, . ...• ...._.-,.......'_. ::::: ".;-:. ..... . ..,-,........ .. . ,.-,.......--"" ~

,

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, I·

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,- §

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,,,._-,-

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.

.... '"'.

...--..... .,,-.. "--.,,._, ""-~-

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.. ';i,::,:,~:::; . ,,"

.. ........

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"

1

. l

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... "..

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,

....

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.

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,

1 Fig . 10.3 3

NOM EN CLATURE

_ ... .

~

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.

'-----

J

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..-..'. . , . ,. ...

•

... -.... -

"~

. "

•

1

1. •

J

'1

"

LOCATION

Splice "M"

Mi.ker 8. RenectOt . Right Fro nt

..,

Starte , Solenoid

Marker 8. R.n.ctQf . Right RUf

A· IO

Steering Column Conne Ground. Left

_limp C,,,,,n _ Ouodr.T,o< Switch ConMctor e.'180 £·3 Ugh1Sw,tch ligh1SwItch Ught M.,q,80 1I.1Ioaor. L.1t F""'t

1978 model wirin g diagram kay

",. ,., ,.,

•

-

10-21

Chapter 10 Chassis electrical system

•

,

•

"

..

'~Q;-"'l '-..~:.~ I [ ' ~ 0 ......,

,

....

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c' .

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.

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•

,

• Fig. 10.37

MOth, 8< A.fIKlor. ull RI., Mon. .. 8< AltfiK\o,. A,ght F,onl Morh, 8< R.IIeefo,. A,ght AI" Oll~,

E·1G

"A" '" ...·,G

....... ~

O,II' ......... ~Llght

o. ,.,

P, ...... So"""'.!! CyHtoao, 0" 1',...... ,. So"""'. V.a ~Ot~ 8< Slen" L.... p, ufl F,ont ~.~8--"

CLO< ' . _ . .

l

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n ( j'' " .r. ~ _..... """""', ........

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•

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Fig . 10 .42

1980 through 1983 model wiring diagram tcontlnued l

...........,,_ ..... .-"

,-..'

.,

.-.." ..., ..,_M .... ......n ~

10-27

Chapter 10 Chassis electrical system

________ ___ _

,I

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