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Unread 09-02-2005, 06:05 PM   #46
Meerkat
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Ignition System - Cross Fire/Ignition Wire Induction

3.9L Engine



1. Coil Wire Routing (Figure 11 and 12)
A. Remove the coil wire from the distributor cap tower terminal.

B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover.

C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11).

D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end.
E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs).
F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.).
G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs).
H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12).

NOTE :THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD.
Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal.
J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine.

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Unread 09-02-2005, 06:06 PM   #47
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Memory Power Seat - Travel Range
NO: 08-44-98
GROUP: Electrical
DATE: Dec. 11, 1998
SUBJECT:
Memory Power Seat
Travel Range
MODELS:
1996-1999 (NS) Town & Country
1996-1999 (GS) Chrysler Voyager
1996-1998 (ZJ) Grand Cherokee
1996-1998 (ZG) Grand Cherokee (International Market)
DISCUSSION:
The Memory Seat/Mirror Module (MSMM) (on ZJ/ZG the module is for the seat only) detects and remembers where the end of seat travel (called "soft stop") is in each direction. A soft stop is set in MSMM memory when the position sensing feedback voltage, controlled by a potentiometer on the motor end, fails to change. The feedback voltage potentiometers vary the position sensing feedback voltage based on seat position/movement (no movement, no change in position sensing feedback voltage). The seat motor automatically stops at the soft stop on any subsequent movement so the motor does not run into a stall condition (end of travel).
The soft stop limits will be updated any time the MSMM senses a mechanical stall (such as when something is stuck under or behind the seat that causes the seat to stop moving). These soft stops can prevent the seat from being able to have memory positions set over the full range of travel. Also, positions that were previously programmed to locations beyond an updated soft stop limit will not be recalled as they are "out of range."
When a new MSMM or seat track is installed into a vehicle, the soft stops must be programmed into the MSMM memory for proper operation, the last paragraph of this TSB explains the procedure to properly set soft stops. Failure to properly set soft stops could result in intermittent memory seat operation.
There are two potential reasons for intermittent memory functioning of the seats. The first possibility is the soft stops learned by the MSMM may need to be reset. New soft stops are learned by the MSMM any time movement is restricted. (This could be as simple as hitting an obstruction in the seat's path or a person shifting their body while a power seat motor is in operation.)
The second reason only applies to NS/GS-vehicles, intermittent operation of the memory seat can be caused by a poor connection at pin 23 of the P34 connector which is located near the right side of the steering column. This circuit is used to communicate and control the seat module. This circuit "locks out" movement when the vehicle is not in park and also causes seat position recall when used with the Remote Keyless Entry (RKE) feature. The P34 connector should be inspected for fully seated and clean contacts.
To check and reset the soft stop limits in memory, use the control switches on the side of the seat to move the seat in one direction to the end of travel, then energize the seat again in the same direction until it stops and for three additional seconds after it stops. The amount that the seat moved upon the second energizing is the amount the soft stop has been reprogrammed. Repeat this procedure for each of the directions of movement (one at a time).
NOTE :IF THE SEAT TRACK ASSEMBLY OR MSMM HAVE NOT BEEN REPLACED, THIS METHOD OF SOFT STOP RESET LEAVES THE CUSTOMER'S SETTINGS PROGRAMMED IN THE MSMM (AS OPPOSED TO USING DIAGNOSTIC MODES 1 AND 2 DESCRIBED IN THE SERVICE MANUAL).
POLICY: Information Only
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Unread 09-02-2005, 06:07 PM   #48
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PCM - Light Spark Knock Condition
NO: 18-24-98
GROUP: Vehicle Performance
DATE: Jul. 31, 1998
SUBJECT:
Light Spark Knock
Timing Retard Feature
MODELS:
1996 - 1997 (AB) Ram Van
1996 - 1997 (AN) Dakota
1996 - 1997 (BR) Ram Truck
1996 - 1997 (XJ) Cherokee
1996 - 1997 (ZJ) GrandCherokee
1996 - 1997 (ZG) Grand Cherokee (International Markets)
NOTE :THIS INFORMATION APPLIES TO VEHICLES EOUIPPED WITH A 2.5L, 4.OL, 3.9L, 5.2L AND 5.9L LIGHT DUTY GASOLINE ENGINES.
SYMPTOM/CONDITION:
Some vehicles may exhibit light spark knock with a warm engine under load.
DISCUSSION:
Determine when the customer exhibits this condition and verify it by driving the vehicle in similar conditions. If the vehicle exhibits light spark knock with a warm engine under load perform the flash update procedure. Once the flash procedure is completed, spark advance/retard may be adjusted.
NOTE :THE DRB III(R) MUST BE OPERATING AT RELEASE 25.5 OR HIGHER.
Select DRB III(R) stand alone, current model year diagnostics, engine, and miscellaneous. When in miscellaneous, spark advance will be available. Use the arrow keys to retard timing in 20 increments to a maximum of A. When the DRB III(R) screen reads 0 the vehicle will be set at maximum advance and when at -4 it will be set at maximum retard.
NOTE :THE IGNITION KEY MUST BE CYCLED FOR THE CHANGES TO TAKE EFFECT.
After performing the spark advance/retard feature, drive the vehicle to verify that the light spark knock is gone.
This feature will not compensate for heavy spark knock conditions. If heavy knock is experienced, funher diagnosis and testing will be required.
NOTE :WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY.
EQUIPMENT/PARTS REQUIRED:
1 CH6OOO ScanTool (DRBIII(R))
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7OOO/7001 J1962 Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE :THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1165 OR HIGHER MUST BE INSTALLED. THE DRB III(R) MUST BE OPERATING AT RELEASE 25.5 OR HIGHER.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-41-96 0.5 Hrs.
FAILURE CODE: FM - Flash Module
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Unread 09-02-2005, 06:09 PM   #49
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PCM - Light Spark Knock Condition
Repair Procedure


This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software.
1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up.
3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III(R) MAIN MENU Screen.
4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU.
6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III(R) on the MDS, then press NEXT MENU.
7. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the PCM.
8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the POM has already been updated, then another condition exists that will require further diagnosis and repair.
9. The MDS and DRB III(R) will prompt for any operator action needed during the remainder of the programming process.
NOTE :THE FOLLOWING STEPS ARE REQUIRED BY LAW.


10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.


11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2).
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Unread 09-02-2005, 06:12 PM   #50
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Radio/CD Player - Erratic Channel/Track Changes

NO: 08-50-98
GROUP: Electrical
DATE: Nov. 27, 1998
SUBJECT:
Radio Station Or CD Track
Changes When Steering Wheel
Volume Switch Is Activated
MODELS:
1996 through 1998 (ZJ) Grand Cherokee
NOTE :THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH REMOTE STEERING WHEEL MOUNTED RADIO CONTROLS AND RBN AND RAZ SALES CODE RADIOS.
DISCUSSION:
Some customers may experience an intermittent condition where the radio station or CD Track could change when the steering wheel mounted volume switch is activated. This condition may be due to a communication error between the multiplexed steering column switch and the Body Controller Module (BCM). A revised BCM has been released which will filter out any erroneous signals. The new BCM part number is 56042409AF. This part is only available through the Huntsville Service Centers (Dial Function 11).
POLICY: Information Only
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Unread 09-02-2005, 06:14 PM   #51
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Roof/Sunroof - Water Leaks

NO: 23-14-97 Rev. A
GROUP: Body
DATE: Sep. 12, 1997
SUBJECT:
Roof/Sun Roof Water Leaks
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NUMBER 23-14-97 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE BULLETIN ADDS A PROCEDURE TO INSPECT FOR THE PRESENCE OF A DRAIN TROUGH ON THE SUN ROOF. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1996 - 1997 (ZJ) Grand Cherokee
DISCUSSION:
Water leaks may be present causing wet carpets or water spilling from the headliner during turns or while braking. Water leaks in the roof area may be difficult to diagnose. The sun roof contains a drip trough designed to catch any water leaking from around the sun roof opening and drain it out any of four drain tubes located in the body. These tubes are routed through interior body panels and are not easily accessible. Water testing may not reveal the location of the leaks if they are performed on a level surface such as a garage floor. If one or more of the drain tubes are restricted, water will drain out the remaining tubes if the vehicle is on a level surface. The problem occurs when the vehicle is parked on an incline. If a tube on one end of the vehicle is plugged and the vehicle is parked with the other end even a few inches higher, water will over flow the trough and spill onto the headliner. The headliner will retain the water, or it will run down one of the sides and enter the passengers' compartment.


The front drain tubes are routed in the rocker panel area and the rear tubes are routed into the quarter panel area behind the wheel wells. All four tubes must be clear of any restrictions. Water can be poured into the trough with the headliner in place. Pour water into the trough and observe the under body for water to be draining out of all four locations. The absence of water in any location may indicate that one of the drain tubes is kinked or plugged.
Make sure that there are no leaks where the drain tube connects to metal tubes on the trough.
Check the roof rack screws. They should have a pre-applied thread sealer on them. If no sealer is present, apply MOPAR Lock & Seal or equivalent to the threads. If no sealer is present, a slow leak can be present and water can drip directly on the headliner.

Inspect the rear drain tube adapter in the quarter panel. This is a dual purpose adaptor. It serves as the exit point for the drain tube and as the drain for the quarter panel. Make sure that the drain is open and that the drain holes for the quarter panel are not covered by the tube or by grease used in the installation.
** The sun roof contains a drip trough or channel, which travels with the glass and is intended to catch any water that may leak at the rear of the sun roof. This trough can be damaged and break away from the mechanism. The trough is visible at the rear of the opening with the sun roof forward and up at the rear. Inspect for the presence of the trough whenever leaks are present. If the trough is not attached to the assembly, it is usually sitting inside sun roof. The trough is available as a separate part and can be replaced by removing the sun roof glass. Make sure to inspect inside the sun roof mechanism and remove the old trough if it is present.
POLICY: Information Only
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Unread 09-02-2005, 06:15 PM   #52
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Transfer Case Shifter - Creaking/Thumping Noise

NO: 21-09-98
GROUP: Transmission
DATE: Jul. 31, 1998
SUBJECT:
Transfer Case Shifter Noise
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NUMBER 21-02-97 REV. A, DATED, JULY 11, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILE AND NOTE IN THE 1997 BOUND TECHNICAL SERVICE BULLETIN MANUAL, PUBLICATION NUMBER 81-699-98004. THE BULLETIN ADDS MODELS AND ADDITIONAL PARTS. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1993 - **1998** (ZJ) Grand Cherokee/Grand Wagoneer
1994 - **1998** (ZG) Grand Cherokee (International Market)
**1997 - 1999 (TJ) Wrangler**
**1995 - 1999 (XJ) Cherokee**
SYMPTOM/CONDITION:
A thumping or creaking noise may be heard coming from the transmission tunnel area on acceleration or while driving over bumpy roads.
DIAGNOSIS:
Road test the vehicle, if the noise is present and there are no worn or damaged parts relating to the transfer case shift mechanism, perform the Repair Procedure.
PARTS REQUIRED:
1 04886481AA Repair Kit, Transfer Case Shifter (ZJ/ZG)
**1 05014148AA Repair Kit, Transfer Case Shifter (TJ/XJ)**
REPAIR PROCEDURE:
This bulletin involves installing a transfer case shifter repair kit.
1. Disconnect the shift rods from the torque shaft.


2. Remove the torque shaft by prying the shaft out of the green torque shaft bushing in the transmission bracket. (Refer to Figure 1) Install new bushings on the torque shaft for XJ and TJ.
3. Remove the bronze bushing/retainer and rubber gasket from the body bracket.
4. Remove the green torque shaft bushing from the transmission bracket and install the new bushing supplied in the kit. Insert the new gasket into the body bracket.
5. Install the bronze bushing/retainer and tightening the screws to 5 Nm (45 in. lbs.).
**NOTE :TJ AND XJ MODELS USE THE ORIGINAL TORQUE SHAFT WITH THE NEW PARTS SUPPLIED IN THE XJ/TJ KIT. ZJ/ZG REQUIRE REPLACEMENT OF THE TORQUE SHAFT WHICH IS SUPPLIED IN THE ZJ/ZG KIT.**
6. Slide the boot on to the torque shaft and apply multipurpose grease (MOPAR p/n 04318063 or equivalent) to the area that the bronze bushing will contact.
7. Install the torque shaft and seat the boot on the bushing retainer flange.
8. Connect the transfer case shift linkage and adjust as necessary.

POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: **21-03-10-93** 0.6 Hrs.

FAILURE CODE: P8 - New Part
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Unread 09-04-2005, 08:51 PM   #53
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A/T - Overdrive Unavailable in Cold Temperatures

NO: 21-06-97 Rev. A
GROUP: Transmission
DATE: Dec. 19, 1997
SUBJECT:
Overdrive Unavailable in Extreme Cold Temperatures, Bypass Kit Installation, Inhibitor Programming
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-06-97, DATED MAR. 21, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE MARKED WITH **ASTERISKS** AND INCLUDE MODEL CHANGES AND PART NUMBER ADDITIONS FOR V-10 APPLICATIONS.
MODELS:
1996 - **1998** (AB) Ram Van/Wagon
1996 (AN) Dakota
1996 - **1998** (BRIBE) Ram Truck
1996 - **1998** (ZJ) Grand Cherokee
NOTE :THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINES AND A 42RE, 44RE, 46RE, OR 47RE TRANSMISSION.
SYMPTOM/CONDITION:
At ambient temperatures of -20 C (-5 F) or below, the Powertrain Control Module (PCM) will electronically inhibit the transmission from shifting into overdrive. This will protect the transmission from damage if the transmission fluid begins to freeze. In extreme cold climatic regions, this feature can cause customer dissatisfaction due to elimination of overdrive and less than optimal fuel economy.
DIAGNOSIS:
The cold weather by-pass kit along with disabling the inhibitor feature should only be incorporated for vehicles used in areas of extended cold ambient temperatures.
NOTE : THIS KIT WILL DECREASE THE MAXIMUM COOLING CAPACITY OF THE TRANSMISSION'S COOLING SYSTEM. AS A RESULT, IT IS NOT RECOMMENDED THAT THIS BULLETIN BE PERFORMED UNLESS THE ABOVE STATED CONDITION EXISTS. ALSO, IF THE VEHICLE IS USED FOR MODERATE TO HEAVY TOWING IT IS NOT RECOMMENDED.


PARTS/EQUIPMENT REQUIRED:
**1 04798668 Kit, By-Pass V-10 Applications**
1 04874284 Kit, Universal By-Pass (See Figure 1 for kit contents)
AR(1) 04318044 Thread Sealant
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE : THE MDS AND DRB III ARE ALSO REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED.
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Unread 09-04-2005, 08:53 PM   #54
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A/T - Overdrive Unavailable in Cold Temperatures
Repair Procedure
Bypass Kit Installation


1. Record all radio pre-sets and disconnect the negative battery cable.
2. Raise the vehicle for access to the transmission housing. The bypass assembly will be connected to the existing transmission lines and mounted to the transmission housing by means of a bypass adapter.
3. During this installation procedure, some transmission fluid will be lost when the transmission cooler lines are cut (allowing bypass assembly installation). Take proper precautions and check transmission fluid fill level upon completing the installation.
4. It the cold weather bypass kit has provision for an in-line temperature sensor, the threaded "therm-o-well" (in the pressure "P" line of the kit) must be plugged with either the temperature sensor from the existing transmission line or the standard pipe plug provided. Consequently, if the vehicle being serviced is equipped with a temperature sensor (i.e., heavy duty BR truck), remove the temperature sensor from the existing line by un-threading and install it in the "pressure" line provided with the kit. Use Mopar Thread Sealant, p/n 04318044, to ensure a leak free seal.
5. Disconnect the pressure and return lines from the transmission housing fittings.
6. Remove and discard the fittings from the transmission housing.
7. Apply Mopar Thread Sealant, p/n 04318044, to the threaded bypass adapter (# 2 Figure 1).
8. Install the threaded bypass adapter securely into the front pressure port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.).
9. Make sure the snap ring and O-ring are properly installed in their respective grooves on the nose of the bypass assembly block. Lubricate the O-ring with ATF.
10. Position the bypass assembly block such that the return port fitting "R" is pointed directly up and the two other fittings are pointed forward.
11. Firmly press the male nose of the bypass assembly into the female body of the threaded bypass adapter until it snaps into place. After snapping into place, the bypass assembly is permanently attached to the adapter.
NOTE : THE BYPASS ASSEMBLY CAN ROTATE INSIDE THE ADAPTER, AND REMOVAL OF THE BLOCK FROM THE TRANSMISSION HOUSING (IF REQUIRED) CAN BE ACCOMPLISHED BY UN-THREADING THE ADAPTER.
CAUTION :IF FLUSHING THE BYPASS ASSEMBLY IS REQUIRED, IT MUST BE REMOVED FROM THE TRANSMISSION HOUSING AND FORWARD FLUSHED ONLY. FAILING TO REMOVE THE VALVE AND REVERSE FLUSHING WILL RESULT IN TRANSMISSION FAILURE BY PLUGGING THE BYPASS VALVES INTERNAL ORIFICE AND DRAIN BACK VALVE.
12. Apply Mopar Thread Sealant, p/n 04318044, to the threaded end (transmission housing end) of the compression fitting.
13. Install the threaded compression fitting securely into the rear return port of the transmission housing and torque to 17.6 Nm (13 ft. lbs.).


14. Using a small tubing cutter, cut the existing pressure line at approximately 120 mm (5 in.) from the transmission housing end. Repeat the procedure for the existing return line.
CAUTION : AFTER CUTTING THE PRESSURE LINE, MARK IT WITH A PIECE OF TAPE FOR IDENTIFICATION.
15. Identify the proper return line ("R" line) by using the marked labels attached to the tubes.
16. Connect the "R" line to the bypass assembly block and the rearward return port of the transmission housing. Tighten the compression fitting finger tight, and then wrench tighten it an additional 1/2 turn. Tighten the inverted flare nut to 6.78 Nm (60 in. lbs.).
17. Select the appropriate "RR" and "P" tubes for the application. Mixing or matching may be required to provide the best routing for your application.
18. Loosely connect the pressure line "P" to the pressure port fitting "P" on the bypass assembly block.
19. Loosely connect the radiator return line, "RR" to the "RR" port fitting, on the bypass assembly block.
NOTE URING THE INSTALLATION OF THE "P" AND "RR" LINES, THE ORDER MAY BE REVERSED TO AID IN THE ASSEMBLY PROCESS.
NOTE : ON 5.2L ZJ MODELS, THE THROTTLE VALVE CABLE AND BRACKET MAY REQUIRE REMOVAL FOR BYPASS TUBE CLEARANCE. ONCE THE TUBES ARE INSTALLED LOOSELY, INSTALL THE BRACKET AND THROTTLE VALVE CABLE. MAKE ANY ADJUSTMENTS FOR CLEARANCE AND TIGHTEN THE BYPASS TUBES AND BRACKET ASSEMBLY.
20. Make sure that the existing return line is properly re-attached to the hanger bracket and lay the new return line, "RR", beside it.
21. Install the hose bracket (# 12 in Figure 1) required for the overhead line application. The bracket will replace the existing bracket at the starter mount location. It may require slight modification to provide the best clearance from the exhaust system.
22. Attach clamp (# 11 in Figure 1) and the rubber hose to the "RR" tube to determine the approximate rubber hose routing. For connection to the existing return line, the line may be cut again to provide optimum line routing.
CAUTION : WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM.
23. Cut the rubber hose so that it has sufficient length to be attached to the existing return line.
24. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing return line.
25. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1).
26. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Make modifications as necessary to provide the best routing.
27. Disconnect the "RR" tube from the Bypass Block for access to the "P" port on the block assembly.
28. Attach a clamp and the rubber hose to the "P" tube and determine the approximate rubber hose routing. For connection to the existing pressure line, the line may be cut again to provide optimum line routing.
CAUTION :WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM.
29. Cut the rubber hose so that it has sufficient length to be attached to the existing pressure line.
30. Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing pressure line.
31. Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1).
32. Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Use tie straps and rubber bumpers on the hose to protect the hose from metal surfaces that may cause chaffing.
33. Torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line.
34. Connect the "RR" ling and torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the "P" line.
35. Re-check to ensure that all connections have been securely tightened and there is sufficient clearance around the exhaust system.
36. If applicable, connect the wire harness to the temperature sensor.
37. Lower the vehicle.
38. Re-connect the negative battery cable and reset the radio stations recorded in step one.
39. Check and adjust the transmission fluid level as outlined in the appropriate Service Manual.
40. Raise the vehicle and check for leaks (idle in Neutral).
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Unread 09-04-2005, 08:56 PM   #55
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A/T - Overdrive Unavailable in Cold Temperatures
Repair Procedure
Flash Programming (1996 Models)


NOTE : THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS UPDATE. THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED.
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process.
NOTE : THE FOLLOWING STEPS ARE REQUIRED BY LAW.


9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020. Attach the label to the PCM and cover the label with the clear plastic overlay.


10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label.
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Unread 09-04-2005, 08:57 PM   #56
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A/T - Overdrive Unavailable in Cold Temperatures
Repair Procedure
Programming Cold Overdrive Feature (All Applications)


Using the DRB III, use the following procedures to program the overdrive cutoff feature.
1. Connect the DRB III (Scan Tool) to the vehicle and power it up.
2. Use the arrow keys and select # 1 DRB III STANDALONE on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select # 1 1994 - 1998 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU.
4. Use the arrow keys and select # 1 ENGINE on the DRB III SELECT SYSTEM MENU.
5. The module ID screen will appear, press enter to move to next menu.
6. From the SELECT FUNCTION MENU, press the right arrow key for the next page and select # 1 MISCELLANEOUS.
7. From the SELECT MISCELLANEOUS FUNCTION MENU, press the right arrow key for the next page and select # 1 COLD OVERDRIVE FEATURE.
8. Follow the steps presented on the DRB III which will prompt you through the feature selection.
9. When the password is asked for use: 84362172.
10. Follow the remaining prompts for overdrive feature verification.
NOTE : IT IS IMPERATIVE THAT THE TRANSMISSION COOLER BYPASS KIT BE INSTALLED PRIOR TO DISABLING THE INHIBITOR FEATURE. TRANSMISSION DAMAGE MAY OCCUR IF THE BYPASS KIT IS NOT INSTALLED.
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Unread 09-04-2005, 08:58 PM   #57
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Engine - Coolant Recommendations

NO: 07-03-97
GROUP: Cooling
DATE: May 9, 1997
SUBJECT:
Engine Coolant Usage
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE BULLETIN IS REVISED.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1997 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/
Power Ram/Power Ram Cab & Chassis
1989 - 1993 (AG) Daytona
1989 (AH) Lancer/LeBaron GTS
1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1989 - 1997 (AN) Dakota
1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 1997 (BR) Ram Truck
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1997 (FJ) Sebring/Avenger/Talon
1996 - 1997 (GS) Chrysler Voyager (European Market)
1995 - 1997 (JA) Cirrus/Stratus/Breeze
1996 - 1997 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1989 - 1992 (MJ) Comanche
1996 - 1997 (NS) Town & Country/Caravan/Voyager
1995 - 1997 (PL) Neon
1997 (PR) Prowler
1992 - 1997 (SR) Viper/Viper Coupe
1997 (TJ) Wrangler
1989 - 1997 (XJ) Cherokee
1989 - 1995 (YJ) Wrangler
1993 - 1997 (ZJ) Grand Cherokee
DISCUSSION:
Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals. Based on recent test data, most owners should not experience significant effects on cooling system performance when using propylene glycol based coolant. The use of national brand propylene glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170 (or equivalent ASTM D5216) is acceptable for Chrysler built vehicles.
NOTE: ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A SUITABLE ENGINE COOLANT.
However, owners should be discouraged from changing their engine coolant prior to the regularly scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the risk of environmental exposure.
Sufficient freeze protection for the region should be maintained. However, do not use more than a 55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the temperatures for your region fall below this, use ethylene glycol coolant.
Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in cooling performance. If this is noticed, the system should be changed back to ethylene glycol coolant.
The two types of coolant should not be mixed. The standard testers for measuring freeze protection will not provide an accurate reading when this occurs. If the cooling system is changed to propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling system flush procedure. The freeze protection of propylene glycol cannot be measured with a standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol is the preferred test tool.
POLICY: Information Only
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Unread 09-04-2005, 08:59 PM   #58
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Evaporator/Cowl Screen - Revision

NO: 24-17-97
GROUP: Heating & A/C
DATE: Dec. 31, 1997
SUBJECT:
Evaporator service/Cowl Screen
MODELS:
1993 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer
1993 - 1997 (ZG) Grand Cherokee (International Markets)
DISCUSSION:
A revised cowl plenum screen has been released which contains a fine mesh screen to minimize debris from entering the heater A/C housing. A build up of organic debris can decay and form acids which over time may contribute to evaporator corrosion/odor. When an evaporator is replace for leaks, the new screen should be installed as a precaution. Inspect the plenum area for any open holes or missing plugs which would allow leaves or other debris to enter the heater A/C housing. All of these areas should be sealed.
PARTS REQUIRED:
1 55036542 Screen, cowl plenum
REPAIR PROCEDURE:
This bulletin involves installing a revised cowl plenum screen.
1. Remove the windshield wiper arms.
2. Remove the cowl grille.
3. Remove the cowl screen.


4. Install the new screen, p/n 55036542. (See Figure 1)
5. Install the cowl grille.
6. Install the wiper arms.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-02-08-97 0.3 Hrs.

FAILURE CODE: P8 - New Part
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Unread 09-04-2005, 09:00 PM   #59
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Door Check Roller - Worn/Broken/Missing

NO: 23-53-97
GROUP: Body
DATE: Oct. 3, 1997
SUBJECT:
Door Check Roller Repair
MODELS:
1993 - 1997 (ZJ) Grand Cherokee, Grand Wagoneer
1993 - 1997 (ZG) Grand Cherokee
SYMPTOM/CONDITION:
A new door check roller has been released which will allow for the replacement of door check rollers without replacement of the entire hinge assembly. The roller is an improved design which may also reduce noise associated with the door check rollers used previously. The roller can be used on any ZJ body vehicle including early models which were equipped with the stamped star wheel type roller.
DIAGNOSIS:
Inspect the door check roller, if the roller is worn, broken or the missing, perform the Repair Procedure.
PARTS REQUIRED:
AR 05011164AA Door Check Roller (2 required for each front door, 1
required for each rear door)
REPAIR PROCEDURE:
This bulletin involves replacement of the door check roller. The repair requires a qualified welder experienced in MIG welding.
1. Disconnect the battery negative cable.
2. Front doors require removal from the vehicle. If the repair is being performed on a rear door, proceed to step 7.
3. Disconnect the wiring harness and pull the harness boot and harness from the door to allow for door removal.
4. Scribe marks on the door hinges to facilitate later installation of the door.
5. Remove the door from the vehicle and place the door on a protected work bench to assure that the paint is not damaged during the repair.
6. Using a die grinder, grind away the rivet material from the bottom side of the roller shaft. Use care not to remove excessive material from the hinge.

7. Remove the roller by tapping it out of the hinge with a punch. If the roller shaft is difficult to remove, it may be necessary to drill the shaft out of the hinge using a 1/4 inch drill.
8. The new roller will be welded into place. To facilitate the welding process, remove the plating from the end of the new roller with sand paper. Install the new roller by pressing it into place with a 3 inch or larger C clamp, using a small socket or suitable tool to prevent any pressure from being applied to the outer bearing. Applying pressure to the outer bearing will damage the rollers and cause premature failure.
9. On front doors, repeat the roller removal and installation process for the second roller.
10. Place a wet rag around the roller bearing to minimize risk of heat damage to the bearing or dust seals. Using a MIG, wire weld process, puddle weld the bottom of the roller shaft to the hinge. This process requires a qualified welder skilled in MIG welding. The maximum weld build up cannot exceed 1.0 mm. If the weld build up is in excess of 1.0 mm, the weld must be filed to allow for clearance between the weld and the hinge when the door is closed.
11. Install the front door(s) on the vehicle. Install the harness and trim panel. Adjust the door to the opening.
12. Prime and paint the affected area.
13. Lubricate the hinge roller and torsion bar MOPAR Spray White Lube, p/n 04318066 or equivalent.
14. Connect the battery negative cable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: Replace Door Check Roller - Right Front Door
23-40-20-94 1.0 Hrs.

Replace Door Check Roller - Left Front Door
23-40-20-95 1.0 Hrs.

Replace Door Check Roller - Right Rear Door
23-40-20-96 0.6 Hrs.

Replace Door Check Roller - Right Rear Door
23-40-20-97 0.6 Hrs.
FAILURE CODE: P8 - New Part
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Unread 09-04-2005, 09:02 PM   #60
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Door Trim Panel - Vinyl or Paint Peeling

NO: 23-51-97
GROUP: Body
DATE: Sep. 19, 1997
SUBJECT:
Door Trim Panel Vinyl or Paint Peeling
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NUMBER 23-50-96 REV. C, DATED DEC. 20, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1996 BOUND TECHNICAL SERVICE BULLETIN MANUAL. THE BULLETIN ADDS PART NUMBERS TO ADDRESS LIMITED MODELS WITH WOOD GRAIN TRIM ACCENTS. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
1996 (ZJ) Grand Cherokee
SYMPTOM/CONDITION:
The vinyl may peel and separate from the bolster on the door trim panel near the arm rest or paint may peel from the door trim panel pull handle. A repair kit has been developed which eliminates the need to replace the door trim panel. These parts contain an improved paint formula which is less susceptible to contamination from hand creams and sun tan lotions.
DIAGNOSIS:
Inspect the door trim panel, if the vinyl is peeling or paint is peeling from the pull handle, perform the Repair Procedure.
**PARTS REQUIRED**:


Laredo Models


**Limited Models**
REPAIR PROCEDURE:
This bulletin involves installing a door trim panel repair kit.
1. Remove the door trim panel and place it on a clean, protected work bench surface.


2. Locate the heat stakes shown in Figure 1 and drill out the heat stakes on the outer perimeter of the bolster using a 23/64 in. Drill. Make sure to position the drill in the center of the heat stakes when drilling.
3. Remove the 3 door handle screws.

4. Remove any left over heat stake material with a die grinder or suitable tool to remove assure a smooth surface after drilling.
5. Insert the new bolster and wood grain trim accent into the trim panel and install the retainers onto the posts (See Figure 1). Seat the retainers fully using an 11/32 in. nut driver or socket to push them into place, making sure that the new bolster is tight against the trim panel. Install the screws in the locations shown. The front door requires two additional screws in the area of the door switch module.
6. Transfer door switch module to the new assembly.
7. Install the switch module screws.
8. Install the door handle screws.

9. Transfer the sound deadener to the new assembly using care to keep it below the upper retainers to avoid contact with them.
10. Install the trim panel replacing any damaged retainers with the new ones supplied in the kit.
TIME ALLOWANCE:
Labor Operation No:
Install Door Trim Panel Repair Kit - One Front Door
23-20-22-94 0.6 Hrs.

Install Door Trim Panel Repair Kit - Both Front Doors
23-20-22-95 1.1 Hrs.

Install Door Trim Panel Repair Kit - One Rear Door
23-20-22-97 0.5 Hrs.

Install Door Trim Panel Repair Kit - Both Rear Doors
23-20-22-98 0.9 Hrs.

FAILURE CODE: P8 - New Part
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