Jeep Wrangler TJ. Manual — part 310
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
Conventional and halogen headlamps are inter-
changeable. It is recommended that they not be
intermixed.
CONDITION
POSSIBLE CAUSES
CORRECTION
HEADLAMPS ARE DIM
WITH ENGINE IDLING OR
IGNITION TURNED OFF
1. Loose or corroded battery cables.
1. Clean and secure battery cable clamps
and posts.
2. Loose or worn generator drive
belt.
2. Adjust or replace generator drive belt.
3. Charging system output too low.
3. Test and repair charging system. (Refer
to 8 - ELECTRICAL/CHARGING -
DIAGNOSIS AND TESTING)
4. Battery has insufficient charge.
4. Test battery state-of -charge. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/
BATTERY - DIAGNOSIS AND TESTING)
5. Battery is sulfated or shorted.
5. Load test battery. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/
BATTERY - DIAGNOSIS AND TESTING)
6. Poor lighting circuit ground.
6. Test for voltage drop across ground
locations.
7. Both headlamp bulbs faulty.
7. Replace both headlamp bulbs.
HEADLAMP BULBS BURN
OUT FREQUENTLY
1. Charging system output too high.
1. Test and repair charging system. (Refer
to 8 - ELECTRICAL/CHARGING -
DIAGNOSIS AND TESTING)
2. Loose or corroded terminals or
splices in headlamp circuit.
2. Inspect and repair all connectors and
splices.
HEADLAMPS ARE DIM
WITH ENGINE RUNNING
1. Charging system output too low.
1. Test and repair charging system. (Refer
to 8 - ELECTRICAL/CHARGING -
DIAGNOSIS AND TESTING)
ABOVE IDLE*
2. Poor lighting circuit ground.
2. Test for voltage drop across ground
locations.
3. High resistance in headlamp
circuit.
3. Test amperage draw of headlamp circuit.
4. Both headlamp bulbs faulty.
4. Replace both headlamp bulbs.
HEADLAMPS FLASH
RANDOMLY
1. Poor lighting circuit ground.
1. Test for voltage drop across ground
locations.
2. High resistance in headlamp
circuit.
2. Test amperage draw of headlamp circuit.
Should not exceed 30 amps.
3. Faulty headlamps switch circuit
breaker.
3. Replace headlamp switch. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/HEADLAMP SWITCH -
REMOVAL)
TJ
LAMPS/LIGHTING - EXTERIOR
8L - 5
LAMPS/LIGHTING - EXTERIOR (Continued)
CONDITION
POSSIBLE CAUSES
CORRECTION
4. Short in headlamp circuit
Test headlamp circuit, repair as necessary.
4. Loose or corroded terminals or
splices in headlamp circuit.
4. Inspect and repair all connectors and
splices.
HEADLAMPS DO NOT
ILLUMINATE LOW OR
HIGH BEAM
1. No voltage to headlamps.
1. Repair open headlamp circuit.
2. No ground at headlamps.
2. Repair circuit ground.
3. Faulty headlamp switch.
3. Replace headlamp switch. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/HEADLAMP SWITCH -
REMOVAL)
4. Faulty headlamp dimmer
(multi-function) switch.
4. Replace multi-function switch.
5. Broken connector terminal or wire
splice in headlamp circuit.
5. Repair connector terminal or wire splice.
6. Both headlamp bulbs faulty.
6. Replace both headlamp bulbs.
*Canada vehicles must have lamps ON.
SPECIFICATIONS
EXTERIOR LAMPS
CAUTION: Do not use bulbs that have a higher can-
dle power than the bulb listed in the Bulb Applica-
tion Table. Damage to lamp can result. Do not touch
halogen bulbs with fingers or other oily surfaces.
Bulb life will be reduced.
The following Bulb Application Table lists the lamp
title on the left side of the column and trade number
or part number on the right for domestic and export
vehicles.
LAMP
BULB
Back-up lamp
1156 or P21W
Center High Mounted
Stoplamp
921 or W16W
Front Fog lamp
H3
Front Position lamp
T4W
Front Side Marker
168 or W3W
Headlamp/Sealed Beam
H6024 or H4
License Plate lamp
W5W
Export Only
Park/Turn Signal
3157 or P27/7W
Rear Fog lamp
P21W
Side Repeater lamp
W3W
LAMP
BULB
Tail/Stop
1157 or P21/5W
Underhood lamp
W5W
Underhood Retractable
Lamp
105
SPECIAL TOOLS
HEADLAMP ALIGNMENT
BRAKE LAMP SWITCH
DESCRIPTION
The brake lamp switch consists of multiple switch
contacts either normally open or closed. The switch
contacts provide brake pedal status to the various
controllers. The primary function of the switch is to
illuminate the brake lamps. The brake lamp switch
is adjustable and mounted on the brake pedal mount-
ing bracket under the instrument panel.
Headlamp Aiming Kit C-4466-A
8L - 6
LAMPS/LIGHTING - EXTERIOR
TJ
LAMPS/LIGHTING - EXTERIOR (Continued)
OPERATION
Vehicles equipped with the speed control option use
a multiple function brake lamp switch. The PCM
monitors the state of the brake lamp switch. Refer to
the Brake section for more information on brake
lamp switch service and adjustment procedures.
The primary function of the brake switch is to turn
on the brake lamps during braking. The switch is
also used to send signals to components that must
know when the brakes are applied, such as the Pow-
ertrain Control Module (PCM), which uses the signal
to cancel speed control. The Controller Antilock
Brake (CAB) uses the brake switch signal to monitor
brake pedal application. When the normally closed
switch contacts open, the CAB receives the brake
applied signal. The CAB then monitors the ABS sys-
tem to anticipate the need for a ABS stop.
DIAGNOSIS AND TESTING - BRAKE LAMP
SWITCH
The brake lamp switch operation can be tested
with an ohmmeter. The ohmmeter is used to check
continuity between the pin terminals (Fig. 1).
SWITCH CIRCUIT IDENTIFICATION
• Terminals 1 and 2: brake sensor circuit
• Terminals 3 and 4: speed control circuit if
equipped
• Terminals 5 and 6: brake lamp circuit
SWITCH CONTINUITY TEST
NOTE: Disconnect switch harness before testing
switch continuity.
With the switch plunger retracted, attach test
leads to terminal pins 1 and 2. Replace switch if
meter indicates no continuity.
With the switch plunger retracted, attach test
leads to terminal pins 3 and 4. Replace switch if
meter indicates no continuity.
With the switch plunger extended, attach test
leads to terminal pins 5 and 6. Replace switch if
meter indicates no continuity.
REMOVAL
(1) Remove the steering column cover and the
lower trim panel.
(2) Press the brake pedal downward to fully
applied position.
(3) Rotate the switch approximately 30° in coun-
terclockwise direction. Then pull the switch rearward
and out of bracket.
(4) Disconnect the switch harness and remove the
switch (Fig. 2).
INSTALLATION
(1) Pull the switch plunger all of the way out, to
fully extended position.
(2) Connect the harness connector to the switch.
(3) Press and hold the brake pedal in the applied
position.
(4) Align the tab on the switch with the notch in
the switch bracket. Then insert the switch in the
bracket and turn it clockwise about 30° to lock it in
place.
(5) Release the brake pedal, then pull the pedal
fully rearward. Pedal will set the plunger to the cor-
rect position as the pedal pushes the plunger into the
switch body. The switch will make a ratcheting sound
as it self-adjusts.
Fig. 1 Brake Lamp Switch Terminal Identification
1 - TERMINAL PINS
2 - PLUNGER TEST POSITIONS
Fig. 2 Brake Lamp Switch
1 - RETAINER
2 - TERMINALS
3 - SWITCH PLUNGER
TJ
LAMPS/LIGHTING - EXTERIOR
8L - 7
BRAKE LAMP SWITCH (Continued)
ADJUSTMENTS
ADJUSTMENT
(1) Press and hold brake pedal in applied position.
(2) Pull switch plunger all the way out to fully
extended position.
(3) Release brake pedal. Then pull pedal lightly
rearward. Pedal will set plunger to correct position
as pedal pushes plunger into switch body. Switch will
make a ratcheting sound as it self-adjusts.
CAUTION: Booster damage may occur if the pedal
pull exceeds 20 lbs.
CENTER HIGH MOUNTED
STOP LAMP UNIT
REMOVAL
NOTE: To remove to the CHMSL, it will be neces-
sary to remove spare tire from the spare tire carrier
bracket.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cover from CHMSL button contact
plate (Fig. 3).
(3) Disconnect the CHMSL wire harness from the
CHMSL button contact terminals.
(4) Disengage the CHMSL wire harness from the
retaining clips.
(5) Disengage the wire harness grommet and route
the CHMSL wire harness through the tailgate.
(6) Remove the bolts attaching CHMSL to the
spare tire carrier bracket.
(7) Remove the CHMSL from the vehicle.
INSTALLATION
(1) Position the CHMSL to the vehicle.
(2) Install the bolts that secure the CHMSL to the
spare tire carrier bracket.
(3) Route the CHMSL wire harness through the
tailgate and seat the wire harness grommet.
(4) Connect the CHMSL wire harness to the
CHMSL button contact terminals.
(5) Position the CHMSL wire harness into the
retaining clips and engage the clips.
(6) Install the CHMSL button contact plate cover.
(7) Reconnect the battery negative cable.
CENTER HIGH MOUNTED
STOP LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the screws that secure the CHMSL
lens to the CHMSL housing (Fig. 4).
(3) Remove the CHMSL lens from the CHMSL
housing.
(4) Rotate the lamp socket one-third turn counter-
clockwise and separate the lamp socket from the
CHMSL lens.
(5) Pull the lamp straight out of the socket.
INSTALLATION
(1) Install the lamp into the socket by pushing it
straight into the socket.
(2) Install the lamp socket into the CHMSL lens
by turning the socket one-third turn clockwise.
(3) Position the CHMSL lens onto the CHMSL
housing.
(4) Install the screws that secure the CHMSL lens
to the CHMSL housing.
(5) Reconnect the battery negative cable.
Fig. 3 CHMSL and Contact Buttons
1 - CHMSL
2 - CHMSL BUTTON CONTACT PLATE
3 - TAILGATE
4 - CHMSL CONTACT BUTTONS
5 - BODY
6 - SPARE TIRE CARRIER BRACKET
8L - 8
LAMPS/LIGHTING - EXTERIOR
TJ
BRAKE LAMP SWITCH (Continued)
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