Jeep Wrangler TJ. Manual — part 539
DIAGNOSIS AND TESTING - WHEEL
INSPECTION
Inspect wheels for:
• Excessive run out
• Dents or cracks
• Damaged wheel lug nut holes
• Air Leaks from any area or surface of the rim
NOTE: Do not attempt to repair a wheel by hammer-
ing, heating or welding.
If a wheel is damaged an original equipment
replacement wheel should be used. When obtaining
replacement wheels, they should be equivalent in
load carrying capacity. The diameter, width, offset,
pilot hole and bolt circle of the wheel should be the
same as the original wheel.
WARNING:
FAILURE
TO
USE
EQUIVALENT
REPLACEMENT
WHEELS
MAY
ADVERSELY
AFFECT THE SAFETY AND HANDLING OF THE
VEHICLE.
USED
WHEELS
ARE
NOT
RECOM-
MENDED. THE SERVICE HISTORY OF THE WHEEL
MAY HAVE INCLUDED SEVERE TREATMENT OR
VERY HIGH MILEAGE. THE RIM COULD FAIL WITH-
OUT WARNING.
STANDARD PROCEDURE
STANDARD PROCEDURE - WHEEL
INSTALLATION
The wheel studs and nuts are designed for specific
applications. They must be replaced with equivalent
parts. Do not use replacement parts of lesser quality
or a substitute design. All aluminum and some steel
wheels have wheel stud nuts which feature an
enlarged nose. This enlarged nose is necessary to
ensure proper retention of the aluminum wheels.
Before installing the wheel, be sure to remove any
build up of corrosion on the wheel mounting surfaces.
Ensure wheels are installed with good metal-to-metal
contact.
To install the wheel, first position it properly on
the mounting surface. All wheel nuts should then be
tightened just snug. Gradually tighten them in
sequence to the proper torque specification (Fig. 21).
WARNING:
NEVER
USE
OIL
OR
GREASE
ON
STUDS OR NUTS. INSTALLING WHEELS WITHOUT
GOOD
METAL-TO-METAL
CONTACT
OR
USING
CHROME
PLATED
LUG
NUTS
WITH
CHROME
PLATED WHEELS COULD CAUSE LOOSENING OF
WHEEL NUTS. THIS COULD AFFECT THE SAFETY
AND HANDLING OF THE VEHICLE.
WHEEL REPLACEMENT
Wheels must be replaced if they have:
• Excessive runout
• Bent or dented
• Leak air through welds
• Have damaged bolt holes
Wheel repairs employing hammering, heating, or
welding are not allowed.
Original equipment wheels are available through
your dealer. Replacement wheels from any other
source should be equivalent in:
• Load carrying capacity
• Diameter
• Width
• Offset
• Mounting configuration
Failure to use equivalent replacement wheels may
affect the safety and handling of your vehicle.
Replacement with used wheels is not recommended.
Their service history may have included severe treat-
ment.
STANDARD PROCEDURE - WHEEL
REPLACEMENT
The wheel studs and nuts are designed for specific
applications. They must be replaced with equivalent
parts. Do not use replacement parts of lesser quality
or a substitute design. All aluminum and some steel
wheels have wheel stud nuts which feature an
enlarged nose. This enlarged nose is necessary to
ensure proper retention of the aluminum wheels.
Wheels must be replaced if they have:
• Excessive runout
• Bent or dented
• Leak air through welds
• Have damaged bolt holes
Wheel repairs employing hammering, heating, or
welding are not allowed.
Fig. 21 Lug Nut Tightening Pattern
22 - 12
TIRES/WHEELS
TJ
WHEELS (Continued)
Original equipment wheels are available through
your dealer. Replacement wheels from any other
source should be equivalent in:
• Load carrying capacity
• Diameter
• Width
• Offset
• Mounting configuration
Failure to use equivalent replacement wheels may
affect the safety and handling of your vehicle.
Replacement with used wheels is not recommended.
Their service history may have included severe treat-
ment.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Lug Nut
1/2 X 20 with 60° Cone
115-156
85-115
—
STUDS
REMOVAL
(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove brake caliper, caliper adapter and
rotor, (Refer to 5 - BRAKES/HYDRAULIC/MECHAN-
ICAL/ROTORS - REMOVAL).
(4) Remove stud from hub with Remover C-4150A
(Fig. 22).
INSTALLATION
(1) Install new stud into hub flange.
(2) Install three washers onto stud, then install
lug nut with the flat side of the nut against the
washers.
(3) Tighten lug nut until the stud is pulled into
the hub flange. Verify that the stud is properly
seated into the flange.
(4) Remove lug nut and washers.
(5) Install the brake rotor, caliper adapter, and cal-
iper, (Refer to 5 - BRAKES/HYDRAULIC/MECHAN-
ICAL/ROTORS - INSTALLATION).
(6) Install wheel and tire assembly, use new lug
nut on stud or studs that were replaced. (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(7) Remove support and lower vehicle.
Fig. 22 Wheel Stud Removal
1 - REMOVER
2 - WHEEL STUD
TJ
TIRES/WHEELS
22 - 13
WHEELS (Continued)
BODY
TABLE OF CONTENTS
page
page
BODY
SAFETY PRECAUTIONS AND WARNINGS
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . 1
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
. . . . . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
. . . . . . . . . . . . . . . . . . . . . . 65
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
. . . . . . . . . . . . . . . . . . . . . 81
. . . . . . . . . . . . . . . . . . . 86
. . . . . . . . . . . . . . . . . . . . . . 90
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: Use an osha approved breathing filter
when spraying paint or solvents in a confined area.
Personal injury can result.
•
Avoid prolonged skin contact with petroleum
or alcohol – based cleaning solvents. Personal
injury can result.
•
Do not stand under a hoisted vehicle that is
not properly supported on safety stands. Personal
injury can result.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
•
Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
•
Always have a fire extinguisher ready for use
when welding.
•
Disconnect the negative (-) cable clamp from
the battery when servicing electrical components
that are live when the ignition is OFF. Damage to
electrical system can result.
•
Do not use abrasive chemicals or compounds
on painted surfaces. Damage to finish can result.
•
Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
•
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY LUBRICATION
All mechanisms and linkages should be lubricated
when necessary. This will maintain ease of operation
and provide protection against rust and excessive
wear. The weatherstrip seals should be lubricated to
prolong their life as well as to improve door sealing.
All applicable exterior and interior vehicle operat-
ing mechanisms should be inspected and cleaned.
Pivot/sliding contact areas on the mechanisms should
then be lubricated.
(1) When necessary, lubricate the operating mech-
anisms with the specified lubricants.
(2) Apply silicone lubricant to a cloth and wipe it
on door seals to avoid over-spray that can soil pas-
senger’s clothing.
(3) Before
applying
lubricant,
the
component
should be wiped clean. After lubrication, any excess
lubricant should be removed.
(4) The hood latch, latch release mechanism, latch
striker, and safety latch should be lubricated period-
ically.
(5) The door lock cylinders should be lubricated
twice each year (preferably autumn and spring):
• Spray a small amount of lock cylinder lubricant
directly into the lock cylinder.
TJ
BODY
23 - 1
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