Jeep CJ-7 Scrambler 1984 Manuals

Manuals and User Guides for Jeep CJ-7 Scrambler 1984. We have 1 Jeep CJ-7 Scrambler 1984 manual available for free PDF download: Workshop Manual

Jeep CJ-7 Scrambler 1984 Workshop Manual (1304 pages)

Brand: Jeep | Category: Automobile | Size: 20.99 MB

Contents
3
General Information
5
Vehicle Identification Number (VIN)
6
General Dimensions
7
Model Identification
8
Vehicle Identification Plate
8
Safety Certification Label
9
Powertrain-Driveline Combinations
10
Fluids, Lubricants, Capacities
11
Adhesives, Sealers, Cleaners
13
Towing
14
Emergency Towing
15
Recreational Towing
16
Trailer Towing and Campers
17
Lifting Methods
18
Driveline Lubrication
19
Engine Lubrication
19
Manual Transmission Lubrication
19
Automatic Transmission Lubrication
20
Transfer Case Lubrication
20
Conversion Tables
21
Engine
24
Special Tools
27
Egine - General Service and Diagnosis
29
Emission Control Components
29
Knock Sensor
29
Service Diagnosis - Mechanical
31
External Oil Leaks
31
Excessive Oil Consumption
32
No Oil Pressure
32
Low Oil Pressure
33
High Oil Pressure
33
Main Bearing Noise
34
Connecting Rod Bearing Noise
34
Piston Noise
34
Valve Actuating Component Noise
35
Service Diagnosis - Performance
37
Hard Starting (Engine Cranks Normally)
37
Rough Idle or Stalling
37
Faulty Low-Speed Operation
38
Faulty Acceleration
38
Faulty High Speed Operation
39
Misfire at All Speeds
40
Power Not up to Normal
40
Intake Backfire
41
Exhaust Backfire
41
Ping or Spark Knock
41
Surging (at Cruising to Top Speeds)
42
Diagnosis with a Scope Analyzer
43
Cylinder Compression Pressure Test
44
Cylinder Combustion Pressure Leakage Test
44
Cylinder Head Gasket Failure Diagnosis
45
Intake Manifold Leakage Diagnosis
45
Cylinder-To-Cylinder Leakage Test
45
Cylinder-To-Water Jacket Leakage Test
45
Cylinder Combustion Pressure Leakage Test Diagnosis
46
Engine Tune-Up Procedures
47
Drive Belts Check
47
Ignition System
47
Spark Plugs
47
Spark Plug Condition
48
Electrode Gap Bridging
49
Scavenger Deposit
49
Chipped Electrode Insulator
49
Preignition Damage
49
Spark Plug Overheating
50
Spark Plug and Ignition Coil Wires
50
Wire Test
50
Spark Plug and Coil Wire Resistance Values
50
Ignition Coil
51
Distributor
51
Ignition System Timing
54
Magnetic Timing Probe
54
Testing the Distributor Advance Mechanism
57
Centrifugal Advance Test
57
Vacuum Advance Test
58
Distributor Ignition Advance Curves
59
Testing the Distributor Advance Mechanisms - Off-Engine
59
Tune-Up Specifications - On-Vehicle - Four-Cylinder Engine
60
Tune-Up Specifications - On-Vehicle - Six-Cylinder Engine
62
Fuel System Inspection
63
Air Cleaner
63
Fuel Filter
63
Carburetor Idle Speed Adjustment Procedures
63
Sole-Vac Vacuum Actuator Adjustment
65
Fast Idle Speed Adjustment
65
Idle Speed Adjustment - Six-Cylinder Engine
66
2.46 Liter (150 CID) Four-Cylinder Engine
67
Engine Build Date Code
69
Oversize and Undersize Component Codes
70
Four-Cylinder Engine Cylinder Block Exploded View
71
Four-Cylinder Engine Cylinder Head Exploded View
72
Four-Cylinder Engine - Torque Specifications
74
Four-Cylinder Engine Specifications
77
Short Engine Assembly (Short Block)
79
Engine Mounting
79
Engine Holding Fixture
81
Engine Removal
82
Engine Installation
84
Cylinder Head Cover Removal and Installation
86
Valves and Actuating Components
87
Rocker Arm Assembly Removal and Installation
87
Rocker Arm Assembly Cleaning and Inspection
88
Hydraulic Valve Tappets Removal and Installation
88
Valve Spring and Oil Deflector Removal
89
Valve Spring and Oil Deflector Installation
90
Measuring the Cam Lobe Lift
91
Valve Timing
91
Vibration Damper and Pulley Removal and Installation
92
Timing Case Cover Removal and Installation
93
Crankshaft (Front) Oil Seal Replacement (Cover Installed)
95
Timing Chain
96
Timing Chain Removal
97
Timing Chain Installation
98
Camshaft Pin Replacement
99
Camshaft Removal and Installation
102
Intake Manifold Removal and Installation
107
Exhaust Manifold Removal and Installation
110
Cylinder Head Removal and Installation
111
Cylinder Head Cleaning and Inspection
112
Lubrication System Overview
115
Oil Pan Removal and Installation
116
Oil Pump Removal and Installation
117
Pistons and Connecting Rods - Replacement as an Assembly
118
Connecting Rod Bearings Removal and Installation
123
Crankshaft Removal and Installation
125
Crankshaft Main Bearings Removal and Installation
125
Rear Main Bearing Oil Seal Removal and Installation
128
Flywheel Removal and Installation
129
Ring Gear Replacement
130
4.2 Liter (258 CID) Six-Cylinder Engine Description
131
Six-Cylinder Engine Identification
133
Six Cylinder Engine Assembly - Cylinder Head View
135
Six Cylinder Engine Assembly - Cylinder Block View
136
Six Cylinder Engine Assembly - Oil Pan and Pump View
137
Six Cylinder Engine - Special Tools
138
Six Cylinder Engine - Torque Specifications
139
Six Cylinder Engine Specifications
142
Short Engine Assembly (Short Block) (Six Cylinder)
144
Engine Mounting (Six Cyinder)
144
Engine Holding Fixture (Six Cylinder)
145
Engine Removal (Six Cylinder)
145
Engine Installation (Six Cylinder)
147
Cylinder Head Cover Removal and Installation (Six Cylinder)
150
Valves and Actuating Components (Six Cylinder)
152
Rocker Arm Assembly Removal and Installation (Six Cylinder)
152
Hydraulic Valve Tappets Removal and Installation (Six Cylinder)
153
Valve Spring and Oil Deflector Removal (Six Cylinder)
154
Valve Spring and Oil Deflector Installation (Six Cylinder)
156
Measuring the Cam Lobe Lift (Six Cylinder)
156
Valve Timing (Six Cylinder)
157
Crankshaft Vibration Damper and Pulley (Six Cylinder)
158
Timing Caser Cover
159
Timing Chain (Six Cylinder)
161
Camshaft (Six Cylinder)
164
Camshaft Pin Replacement (Six Cylinder)
169
Intake and Exhaust Manifolds (Six Cylinder)
173
Cylinder Head (Six Cylinder)
177
Lubrication System (Six Cylinder)
181
Pistons and Connecting Rods (Six Cylinder)
183
Crankshaft (Six Cylinder)
187
Cylinder Block (Six Cylinder)
192
Cooling System - Special Tools
193
Cooling System - Torque Specifications
193
Cooling System Specifications
194
Engine Drive Belt Specifications
196
Cooling System Components View
197
Coolant Level
198
Draining Coolant
198
Replacing Coolant
199
Purging Air from the Cooling System
199
Water Pump Replacement
200
Removing Coolant from the Crankcase
200
Water Pump Tests
202
Intake Manifold
203
Cooling System Hoses
204
Thermostat
204
Radiator
206
Fan
209
Tempatrol Fan Test
210
Fan Shroud
211
Coolant Recovery System
212
Cylinder Block Heater
212
Cooling System Maintenance
214
Engine Flushing
214
Solvent Cleaning
214
Radiator Reverse Flushing
214
Cooling System Diagnosis
215
Transmission Fluid Cooler Repairs
215
Cooling System Service Diagnosis
216
Low Coolant Temperature Diagnosis Guide
219
Engine Overheating Diagnosis Guide
219
Cooling System Leakage Tests
221
Internal Leakage Inspection (Cooling System)
222
Combustion Leakage Test (Without Pressure Tester)
222
Drive Belt Adjustments
223
Transmission Fluid Cooler Leakage Test
223
Alternator Adjustments
224
Air Conditioner Compressor Adjustments
225
Power Steering Pump Adjustments
225
Serpentine Drive Belt
226
Fuel System - Special Tools
230
Fuel System Torque Specifications
230
Model YFA Carburetor
230
Carburetor Replacement
233
Carburetor Overhaul
234
Carburetor Disassembly
235
Carburetor Assembly
241
Metering Rod Adjustment
243
Float Level Adjustment
243
Fast Idle Cam Index Adjustment
246
Initial Choke Valve Clearance Adjustment
247
Choke Unloader Adjustment
247
TRC (Anti-Diesel) Adjustment
248
Float Drop Adjustment
249
Sole-Vac Curb Idle Speed Adjustment
256
Model BBD Carburetor
257
Model BBD Carburetor Replacement
259
Choke Mechanism Service
259
Model BBD Carburetor Exploded View
261
Model BBD Carburetor Overhaul
262
Model BBD Carburetor Disassembly
263
Model BBD Carburetor Cleaning and Inspection
266
Model BBD Carburetor Assembly
267
Vacuum Piston Gap Adjustment
270
Vacuum Piston Adjustment
270
Accelerator Pump Adjustment
271
Initial Choke Valve Clearance Adjustment
271
Fast Idle Cam Position Adjustment
272
Fuel Bowl Vent Adjustment
273
Choke Adjustment
274
Idle Speed Adjustment
274
Idle Mixture Adjustment
275
Exhaust Gas Refrigeration System Tests
277
EGR Valve
277
EGR Valve Closing Test
278
EGR Valve Replacement
279
EGR System CTO Valve
279
EGR System Thermal Vacuum Switch (TVS)
280
EGR System Forwarding Delay Valve
282
Positive Crankcase Ventilation (PCV) System
283
PCV Air Inlet Filter Maintenance
285
TAC System
286
TAC System Functional Tests
289
Air Valve Vacuum Motor Functional Test
289
Thermal Switch Functional Test
290
Air Cleaner Trap Door
291
Reverse Delay Valve Functional Test
292
Trap Door Vacuum Motor Replacement
292
Computerized Emission Control (CEC) Fuel Feedback Systems
293
Micro Computer Unit (MCU)
294
MCU Inputs
295
Coolant Temperature Switch
295
Thermal Electric Switch
296
Four-And Ten-Incn Hg Vacuum Switches
296
Oxygen Sensor
297
Wide-Open Throttle (WOT) Switch
297
Closed Throttle Switch
298
Knock Sensor
298
Altitude Jumper Wire
300
MCU Outputs
300
Fuel Feedback Systems
301
Mixture Control Solenoid
301
Stepper Motor
301
Idle Relay
302
Sole-Vac Throttlt Positioner
302
Idle Solenoid
303
Upstream and Downstream Solenoids
303
Positive Crankcase Ventilation (PCV) Valve Shut-Off Solenoid
304
Bowl Vent Solenoid
305
Intake Manifold Heater Switch
305
Key-On Mode
306
Start-Up Mode
306
Warm-Up Mode
306
Cruise Mode
307
CEC Fuel Feedback System Diagnostic Tests
307
Four-Cylinder Engine CEC System
309
Diagnostic Connectors
310
Four-Cylinder Engine Vacuum Diagram
311
CEC System - Four-Cylinder Engine Diagnostic Tests
312
Closed Loop Operational Test
320
Knock Sensor Test
321
Oxygen Sensor and Closed Loop Test
322
Basic Engine Test
325
Bowl Vent Test
330
PCV Valve Shut-Off Test
331
Idle Speed Control System Test
334
Sole-Vac Vacuum Switching Relay Test
335
Six-Cylinder Engine CEC System Wiring Diagram
338
MCU Connector
340
Wire Harness Connector
340
Six-Cylinder Engine Vacuum Diagram
341
CEC System (Six-Cylinder Engine) Diagnostic Tests
342
Exhaust System Torque Specifications
364
Restricted Exhaust System Diagnosis
365
Four-Cylinder Engine Exhaust System
366
Six-Cylinder Engine Exhaust System
367
Exhaust Manifolds Replacement
367
Muffler Removal and Installation
372
Front Exhaust Pipe Removal and Installation
373
Rear Exhaust Pipe or Tailpipe Replacement
373
Pulse Air System
374
Air Injection Check Valve
374
Air Control Valve
374
Air Switch Solenoid
376
Vacuum Storage Tank
376
Catalytic Converter Systems
377
Duel Bed (TWC and COC) Monolithic-Type Converter Replacement
377
Electrical
378
Batteries Torque Specifications
383
Battery Specifications
384
Battery Codes
384
Battery Replacement
385
Battery Maintenance
386
Frozen Electrolyte
386
Battery Charging
387
Dry Charged Battery
387
Slow Charge
388
Fast Charge
388
Booster Charging
388
Battery Testing
389
Hydrometer Test
390
Heavy Load Test
391
Diagnosis and Repair Simplification (DARS) Chart
392
Starter Motor Inoperative
393
Charging System Torque Specifications
395
Charging System Specifications
396
Alternator
396
Voltage Regulator
396
Alternator Inspection
398
Alternator Nois
398
Battery Undercharged
399
Battery Overcharged (Uses too Much Water)
401
Battery Discharge through the Alternator
402
Charging System Testing - Off-Vehicle
402
Rotor (Field) Winding Short Circuit-To-Ground Test
402
Rotor (Field) Winding Open Circuit Test
403
Rotor (Field) Winding Internal Short Circuit Test
403
Stator Windings Short Circuit-To-Ground Test
404
Stator Windings Continuity Test
405
Stator Wndings Internal Shoft Circuit Test
405
Diode Trio Short Circuit Test
405
Test with the Trio Installed
406
Test with Diode Trio Removed
407
Bridge Rectifier Test
407
Alternator Replacement
408
Alternator Overhaul
409
Drive Belt Adjustment
413
Starting System Overview
414
Starting System Specifications
415
Starting System Troubleshooting
417
Starter Motor will Not Rotate
419
Solenoid Pull-In Coil Winding Test
419
Solenoid Ground Test
420
Starter Motor Cable and Ground Cable Tests (Voltage Drop Method)
420
Starter Motor Voltage Drop Tests
421
Starter Motor Full Load Current Test
423
Neutral Safety Switch Test
424
No-Load Current Test
424
Hood-In Coil Winding Resistance Test
425
Solenoid Contact Point Connection Test
425
Insulated Brush Connection Test
426
Field Winding Terminal-To-Brush Continuity Test
426
Terminal Bracket Insulation Test
427
Armature Ground Test
427
Starter Motor Replacement
428
Armature Short Test
428
Armature Balance Test
428
Starter Motor Overhaul
430
Starter Motor Disassembly
432
Starter Motor Cleaning and Inspection
432
Field Winding Replacement
433
Solenoid Contact Point Assembly Replacement
434
Bushing Replacement
435
Drive Mechanism Replacement
435
Starting Motor Assembly
435
Neutral Safety Switch Replacement
436
Ignition System Overview
437
Ignition System Specifications
438
Electronic Ignition Control Unit
439
Ignition Coil Connector
440
SSI System Diagnosis and Repair Simplification (DARS) Chart
441
Ignition Coil Primary Circuit
441
Coil Test
444
Sensor Check and Control Unit Check
445
Ignition Feed to Electronic Control Unit
447
Engine Spark Knock (Pre-Ignition) Diagnosis
448
Fuel Octane Rating
448
Distributor Advance Tests
448
Centrifugal (Mechanical) Advance Test
448
Ignition Coil Tests
449
Primary Winding Resistance Test
449
Secondary Winding Resistance Test
449
Current Flow Test
449
Distributor Replacement
450
Ignition Coil Output Test
450
Distributor Component Replacement
453
Trigger Wheel And/Or Pickup Coil Assembly
453
Vacuum Advance Mechanism Removal and Installation
454
Cruise Command
456
Cruise Command Diagnosis
457
Cruise Command Testing
460
Servo Test
460
Control Switch Continuity Test
462
Circuitry Tests
463
Regulator Wire Harness Connector
464
Speed Control Test
464
Cruise Control Diagnosis Chart
466
Regulator Adjustment
468
Vacuum (Mechanical) Vent Valve Adjustment
469
Regulator Replacement
469
Servo Replacement
469
Servo Cable Replacement
470
Control Switch Replacement
470
Engine Instrumentation
472
Engine Instrumentation Specifications
473
Tachometer Circuit
476
Engine Instrumentation Diagnosis
476
Fuel Gauge Diagnosis
477
Oil Pressure Gauge Diagnosis
477
Instrument Cluster Replacement
478
Calibration Test
478
Coolant Temperature Gauge Diagnosis
478
Tachometer Diagnosis
478
Gauge and Meter Replacement
479
Fuel Gauge Replacement
479
Coolant Temperature Gauge Replacement
479
Voltmeter Replacement
480
Oil Pressure Gauge Replacement
480
Tachometer Replacement
480
Engine Instrumentation Diagnosis and Repair Simplification Charts
482
Fuel Gauge Not Functioning Properly
482
Gauge Fuse Blown
489
Fuel Gauge and Coolant Temperature Gauge both Malfunction
491
Oil Pressure Gauge Not Functioning Properly
492
Coolant Temperature Gauge Not Functioning Properly
497
Lighting Systems Torque Specifications
503
Lighting Systems Specifications
504
Headlamps Replacement
504
Headlamp Aiming Procedure
505
Front Parking, Side Marker and Directional Lamps
507
Fog Lamps
508
Switch Replacement
509
Aiming Fog Lamps
509
Lamp Element Replacement
509
Engine Compartment Lamp
511
Courtesy Lamps/Dome Lamps
511
Headlamp Switch Replacement
511
Dimmer Switch Replacement
512
Directional Signal Switch
512
Backup Lamp Switch Adjustment and Replacement
516
Four-Way Emergency Flasher (Hazard Warning)
517
Stoplamp Switch Adjustment
517
Stoplamp Switch Electrical Test
517
Chassis Wiring Harness
518
Main Harness Connector
518
Fusible Links Replacement
518
Ignition Switch Removal and Testing
519
Ignition Switch Installation
520
Fuse Panel
521
Circuit Breakers
521
Horn Systems
522
Horn Systems Diagnosis and Repair
523
Horn Systems Adjustment
524
Windshield Wipers
525
Wiper Blade Replacement
525
Wiper Arm Replacement
526
Pivot Shaft Body and Linkage Removal and Installation
526
Control Switch Removal and Installation
528
Control Switch Diagnosis
528
Intermittent Wipers Removal and Installation
529
Intermittent Governor
529
Wiper Motor Removal and Installation
530
Washer Pump
530
Electrical Components List
531
Circuit Index
533
Harness Codes
533
Wire Color Codes
533
Ground Locations
533
Electrical Diagrams
536
Battery Power Distribution Charge
536
Electronic Engine Control 4 Cylinder
538
Clutch
552
Clutch Assembly
553
Throwout Bearing
553
Clutch Hydraulic Fluid
553
Clutch - Special Tools
554
Clutch Specifications
555
Clutch Service Diagnosis
556
Clutch Chatter
556
Clutch Slippage or Inadequate Clutch Linkage Free Play
557
Clutch Drag or Inadequate Clutch Release
559
Clutch Pedal Pulsation
560
Clutch Related Vibrations
561
Clutch Area Noises
562
Throwout Bearing Noise
562
Transmission Clutch Shaft or Countershaft Bearing Noise
563
Crankshaft Pilot Bushing Noise
563
Clutch Service - Six-Cylinder Models
564
Clutch Torque Specifications
564
Clutch Adjustments
565
Clutch Assembly Removal and Installation
565
Clutch Component Inspection and Service
566
Clutch Linkage
567
Driven Plate
567
Clutch Cover
567
Transmission Front Bearing Cap
568
Crankshaft Pilot Bushing Removal and Installation
568
Clutch Housing Alignment
569
Flywheel
569
Transmission Clutch Shaft
569
Clutch Pedal Removal and Installation
571
Clutch Service - Four-Cylinder Models
572
Slave Cylinder Removal and Installation
578
Slave Cylinder Disassembly and Assembly
579
Clutch Hydraulic System Bleeding
580
Gearboxes
581
Gearboxes - Special Tools
583
Gearboxes Torque Specifications
586
Gearboxes Specifications
587
Transmission Gear Ratios
588
Gearshift Pattern Chart
588
Transmission Lubricants
589
Transmission Identification
589
Gearboxes Service Diagnosis
590
Transmission Shifts Hard
590
Gear Clash When Shifting from One Gear to Another
590
Transmission Noisy
590
Jumps out of Gear
591
Will Not Shift into One Gear
591
Locked in One Gear - Can Not be Shifted out
591
Transfer Case Difficult to Shift
592
Transfer Case Noisy in All Drive Modes
592
Noisy in - or Jumps out of Four Wheel Drive Low Range
592
Abnormal Tire Wear
592
Model T4 and T5 Transmissions View
593
Model T4 and T5 Transmissions Removal
597
Model T4 and T5 Transmissions Installation
598
Model T-176 Transmission View
600
Model T-176 Transmission Torque Specifications
601
Model T-176 Transmission Removal and Installation
602
Model T-176 Transmission Disassembly
604
Mainshaft Geartrain Disassembly
606
Mainshaft Geartrain Cleaning and Inspection
607
Gear, Shaft and Synchronizer Assemblies
607
Mainshaft Geartrain Assembly
608
Shift Control Housing View
613
Shift Control Housing Disassembly and Assembly
614
Model 300 Transfer Case View
616
Transfer Case Shift Pattern
617
Transfer Case Lubrication (Model 300)
617
Model 300 Transfer Case - Special Tools
618
Model 300 Transfer Case - Torque Specifications
619
Transfer Case Shift Linkage Removal and Disassembly
619
Shift Rod Oil Seal Removal
621
Shift Rod Oil Seal Installation
622
Front/Rear Yoke Oil Seal Removal
622
Front/Rear Yoke Oil Seal Installation
623
Rear Bearing Cap/Speedometer Drive Gear Removal
623
Rear Bearing Cap/Speedometer Drive Gear Installation
624
Model 300 Transfer Case Disassembly
624
Model 300 Transfer Case Cleaning and Inspection
628
Model 300 Transfer Case Assembly
628
Automatic Transmission
633
Automatic Transmission - Special Tools
635
Automatic Transmission Specifications
636
Fluid Capacity
638
Transmission and Torque Converter Identification
638
Automatic Transmission Diagnostic and Test Procedures
639
Fluid Level and Condition (Automatic Transmission)
640
Flushing Oil Cooler and Cooler Lines
641
Throttle Linkage
641
Gearshift Linkage
642
Lockup Torque Converter Service Diagnosis
642
Lockup Torque Converter Service Diagnosis (Automatic Transmission)
643
Road Test
645
Clutch and Band Application Chart
645
Hydraulic Pressure Tests
646
Pressure Test Port Location
647
Hydraulic Pressure Test Diagnosis
650
Air Pressure Tests
651
Converter Housing Fluid Leak Diagnosis
651
Rear Clutch Test
651
Front Servo Test
651
Leak Diagnosis Procedure
652
Stall Test
653
Automatic Transmission Service Diagnosis
655
Gearshift Linkage Adjustment
660
Throttle Linkage Adjustment
661
Front Band Adjustment
662
Rear Band Adjustment
663
Oil Filter Removal and Installation
664
Valve Body Hydraulic Control Pressure Adjustments
665
Line Pressure Adjustment
665
Valve Body
666
Throttle Pressure Adjustment
666
Governor Valve Removal
668
Governor Valve Disassembly
669
Governor Valve Cleaning and Inspection
669
Governor Valve Assembly
669
Governor Valve Installation
670
Park Lock Component Disassembly, Inspection and Assembly
671
Neutral Start and Backup Lamp Switch
672
Neutral Start Circuit Removal and Installation
672
Backup Lamp Circuit
672
Automatic Transmission Out-Of-Vehicle Service
673
Automatic Transmission Removal
673
Automatic Transmission Installation
674
Steering and Front Axle
676
Steering and Front Axle - Special Tools
678
Steering Columns Torque Specifications
683
Steering Columns Service Diagnosis
684
Lock System Service Diagnosis
685
Steering Column Service Diagnosis
686
Ignition System Service Diagnosis
689
Turn Signal Service Diagnosis
690
Steering Wheel Removal and Installation
694
Sport Steering Wheel Skirt Replacement
695
Steering Column Removal and Installation
696
Steering Column Alignment
697
Standard Column Overhaul
698
Steering Column View - Automatic Transmission
698
Steering Column View - Manual Transmission
699
Steering Column Disassembly
700
Steering Column Assembly
705
Tilt Column Overhaul
712
Column Assembly
720
Turn Signal Switch Removal and Installation
724
Ignition Lock Cylinder Service
725
Key Lost
725
Lock Cylinder Defective - Ignition Key Available - no Key Code Number
725
Key Coding
727
Manual Steering Gear
729
Manual Steering Gear Specifications
730
Manual Steering Gear Service Diagnosis
731
Hard or Erratic Steering
731
Play or Looseness in Steering
731
Wheel Shimmy or Tramp
731
Vehicle Leads to One Side
732
Steering Gear Service on Vehicle
733
Steering Gear Adjustment
733
Worm Bearing Preload and Pitman Shaft Overcenter Drag Torque
733
Pitman Shaft Seal Replacement
734
Steering Gear Removal
735
Side Cover and Gasket Replacement
735
Steering Gear Installation
736
Steering Gear Disassembly
737
Wormshaft and Ball Nut Disassembly, Cleaning and Assembly
739
Worm Bearing Adjuster Disassembly, Cleaning and Assembly
740
Steering Gear Housing and Pitman Shaft Disassembly and Assembly
741
Steering Gear Assembly
743
Manual Steering Gear Special Adjustments (on Bench)
744
Worm Bearing Preload Adjustment
745
Pitman Shaft Overcenter Drag Torque Adjustment
746
Power Steering Gear - Special Tools
747
Power Steering Gear Specifications
748
Power Steering Gear Service Diagnosis
750
Power Steering Gear Leak Inspection
755
Pump Leak Points and Corrective Action
756
Power Steering Gear On-Vehicle Service
760
Power Steering Gear Removal and Installation
762
Power Steering Gear Disassembly
763
Subassembly Overhaul
767
Gear Housing Disassembly, Cleaning and Inspection
767
Gear Housing Assembly
768
Adjuster Plug Disassembly
769
Adjuster Plug Cleaning and Assembly
770
Valve Body and Stub Shaft Disassembly
771
Valve Body and Stub Shaft Cleaning, Inspection, Assembly
773
Pitman Shaft and Side Cover Inspection
774
Rack Piston - Wormshaft Disassembly
774
Rack Piston - Wormshaft Inspection and Assembly
775
Hose Connector Seats and Poppet Check Valve Replacement
776
Steering Gear Assembly and Adjustment
778
Worm Shaft Bearing Preload
781
Pitman Shaft Overcenter Drag Torque
782
Power Steering Pump - Special Tools
784
Power Steering Pump Specifications
785
Power Steering Pump Leak Inspection and Diagnosis
786
Power Steering Pump Leak Points and Corrective Action
788
Power Steering Pump Hydraulic Pressure Test
789
Power Steering Hydraulic System Pressure Test Procedure
791
Power Steering Pump Service Diagnosis
793
Pump Shaft Seal and Pump Pulley Replacement
795
Power Steering Pump Removal
796
Flow Control Valve Replacement
796
Power Steering Pump Disassembly
797
Power Steering Pump Cleaning and Inspection
801
Power Steering Pump Assembly
801
Power Steering Pump Fluid Level and Initial Operation
805
Steering Linkage
806
Steering Linkage Torque Specifications
807
Steering Linkage Specifications
808
Tie Rod Removal and Installation
808
Connecting Rod Removal and Installation
808
Steering Damper Removal and Installation
809
Front Wheel Alignment
809
Toe-In
810
Camber
810
Steering Wheel Spoke Adjustment
811
Front Wheel Shimmy
811
Caster
811
Front Axle
813
Front Axle Torque Specifications
817
Front Axle Specifications
818
Axle Testing and Diagnosis
818
Tire Noise Diagnosis
818
Axle Identification
819
Backlash
819
Other Axle Conditions
819
Axle Radio and Code Letter Chart
819
Axle Housing Service
820
High Steering Effort
820
Ball Stud Preload Measurement
820
Ball Stud Preload Correction
821
Pinion Seal and Yoke Removal and Installation
822
Axle Shaft Removal and Installation
823
Axle Shaft Universal Joint Replacement
824
Steering Knuckle Removal
825
Steering Knuckle Ball Studs
827
Lower Ball Stud Removal
827
Upper Ball Stud Removal
828
Steering Knuckle Installation
829
Upper Ball Stud Installation
829
Axle Shaft Seal Replacement
830
Spindle Bearing Replacement
831
Axle Housing Inner Oil Seal
831
Axle Removal
831
Axle Installation
832
Turning Angle Adjustment
833
Differential Overhaul
833
Differential Disassembly
835
Pinion Gear Removal
836
Pinion Rear Bearing Removal
837
Differential Bearing Removal
837
Pinion Bearing Cup Removal
837
Differential Cleaning and Inspection
837
Differential Assembly
838
Pinion Gear Installation and Depth Adjustment
838
Pinion Variance Chart
839
Pinion Bearing Preload Adjustment
843
Differential Side Gear Adjustment
843
Differential Bearing Preload and Ring Gear Backlash Adjustment
844
Front Drive Hubs Specifications
847
Front Drive Hubs Lubrication
847
Front Drive Hubs Diagnosis
849
Hub Noisy Operation
849
Hub Lubricant Leaks
849
Hub Internal Damage
849
Hub Service
850
Hub Removal/Installation
850
Rear Axle Identification
852
Rear Axle - Special Tools
853
Rear Axle Specifications
857
Rear Axle Hub Replacement
858
Rear Axle Shaft and Bearing Replacement
860
Rear Axle Shaft End Play Adjustment
862
Pinion Seal or Axle Yoke Replacement
863
Rear Axle Assembly Removal and Installation
865
Standard Differential Overhaul
868
Standard Differential Specification
869
Standard Differential Disassembly
871
Standard Differential Cleaning and Inspection
873
Standard Differential Assembly and Adjustments
875
Pinion Gear Depth Measurement and Adjustment
875
Pinion Depth Measurement and Adjustment
877
Pinion Gear Installation and Bearing Preload Adjustment
880
Differential Bearing Installation
881
Differential Pinion and Side Gear Installation
881
Differential Bearing End Play Adjustment
882
Ring Gear Installation
883
Ring Gear Backlash Adjustment
883
Differential Bearing Preload Adjustment
884
Rear Axle Assembly
885
Trac-Lok Differential
886
Trac-Lok Differential Torque Specifications
888
Trac-Lok Differential Lubrication
889
Trac-Lok Differential Diagnosis
889
Trac-Lok Differential Operational Test
889
Trac-Lok Differential Overhaul
890
Trac-Lok Differential Inspection
893
Trac-Lok Differential Assembly
894
Trac-Lok Differential Service Replacement
896
Propeller Shaft Application
897
Propeller Shaft Specifications
898
Driveline Vibration
899
Universal Joint Angle Measurement and Adjustment
905
Propeller Shaft Lubrication
905
Propeller Shaft Service
905
Universal Joint Service
906
Suspension
908
Suspension Torque Specifications
910
Tire Construction
911
Tire Size and Load Rating
912
Tire Inflation Pressure and Capacity
913
Tire Maintenance and Condition
914
Polyspare Tire
914
Radial, Wide Tread and Snow Tire Applications
914
Tire Rotation
915
Tire Roughness
916
Tire Tramp
916
Wheel and Tire Runout
918
Tire and Wheel Vibration
920
Vibration Diagnosis Chart
922
Tire Repair
924
Wheel Maintenance and Condition
924
Wheel Balancing
924
Wheel Bearing Adjustment
925
Front Wheel Bearing Adjustment
925
Rear Wheel Bearing Adjustment
926
Front Spring and Shock Absorber View
927
Rear Spring and Shock Absorber View
928
Suspension Springs Torque Specifications
929
Suspension Jounce and Windup Bumpers
930
Shock Absorbers Removal and Installation
930
Stabilizer Bar
931
Front Spring Removal and Installation
931
Rear Spring Removal and Installation
932
Spring Bushing
933
Small Bushing Replacement
933
Large Bushing Replacement
934
Brake System
936
Brake System - Special Tools
937
Brake System Torque Specifications
939
Brake System Specifications
940
Brake Fluid
941
Brake Size and Application Chart
941
Brake System Diagnosis
942
Low Brake Pedal
944
Fading Brake Pedal
945
Decreasing Brake Pedal Travel
946
Spongy Brake Pedal
946
Hard Brake Pedal
947
Grabbing Brakes
948
Dragging Brakes
949
Vehicle Moves to One Side When Brakes Are Applied
949
Noisy Brakes
950
Pulsating Brake Pedal
950
Brakelamp Switch Adjustment
951
Master Cylinder Torque Specifications
953
Master Cylinder Removal and Installation
953
Master Cylinder Disassembly
954
Master Cylinder Cleaning and Inspection
955
Master Cylinder Assembly
955
Master Cylinder Fluid Level
957
Brake Booster Torque Specifications
958
Brake Booster Removal and Installation
958
Front Brake Pads Removal and Installation
960
Front Brake Rotor Removal
963
Front Brake Rotor Inspection
963
Front Brake Rotor Measurement
964
Front Brake Rotor Refinishing
965
Front Brake Rotor Installation
966
Front Brake Caliper Removal
967
Front Brake Caliper Installation
968
Front Brake Caliper Disassembly
969
Front Brake Caliper Cleaning and Inspection
970
Front Brake Caliper Assembly
970
Rear Brakeshoes Removal
972
Rear Brakeshoes Cleaning and Inspection
972
Rear Brakeshoes Installation
973
Rear Brakeshoes Adjustment
974
Rear Wheel Cylinder Torque Specifications
975
Rear Wheel Cylinder Removal and Installation
976
Rear Wheel Cylinder Disassembly
977
Rear Wheel Cylinder Cleaning and Inspection
978
Rear Wheel Cylinder Assembly
978
Combination Valve
979
Parking Brake Exploded View
980
Parking Brake Adjustment
981
Parking Brake Removal and Installation
981
Brake System Pressure Bleeding
983
Brake System Manual Bleeding
984
Heating and Air Conditioning
986
Heater and Defroster Operation
987
Fresh Air Ventilation
988
Heating System Service Diagnosis
989
Heating System View
990
Fan Control Switch Removal and Installation
992
Control Cables Adjustment
992
Control Cables Replacement
992
Heater Core Removal and Installation
993
Defroster Duct Removal and Installation
994
Fresh Air Intake Duct Removal and Installation
995
Air Conditioner System Overview
996
Air Conditioner System - Special Tools
998
Air Conditioner System Torque Specifications
1000
Refrigerant Safety Precautions
1000
Service Valves
1001
Discharge Service Valve Adapters
1002
Connecting a Pressure Gauge and Manifold Assembly
1003
Air Conditioner System Pressure Check
1003
A/C System Diagnosis
1004
Insufficient or no Cooled Air
1004
A/C System Pressure Diagnosis
1005
A/C System Performance Diagnosis
1006
A/C System Discharge
1007
A/C System Evacuation
1007
Air Conditioner System Leak Tests
1010
Halide Torch Leak Detection
1010
Flushing
1011
Air Conditioner System Charge
1012
Temperature Control Thermostat
1014
Fan Switch
1014
Condenser Removal and Installation
1015
Sight Glass
1016
Receiver/Drier Removal and Installation
1016
Evaporating Housing Removal and Installation
1017
Expansion Valve Replacement
1019
Magnetic Clutch
1020
Compressor
1022
Compressor - Service Valve Leak Diagnosis
1024
Compressor Isolation
1024
Compressor Removal and Installation
1025
Front Seal Replacement
1025
Cylinder Head, Valve Plate and Gasket Removal and Installation
1030
Compressor - Checking the Oil Level
1032
Air Conditioner System Troubleshooting Chart
1034
Accessories
1035
Spare Tire Carriers
1036
Roll Bars
1038
Soft Top with Metal Doors Adjustment
1040
Storage Compartment
1041
Lock Cylinder
1042
Wooden Rails
1043
Wood Refinishing
1043
Radio Sound Systems
1044
AM Radio
1044
AM/FM Multiplex Radio
1045
Am/Fm/Cassette Stereo Radio
1045
Radio Replacement
1046
Tape Head and Capstan Cleaning
1046
AM/FM Cassette Radio Dial Illumination
1047
Antenna Trimmer
1048
Radio Interference
1048
Noise Radiated Upward from the Instrument Panel
1049
Noise Radiated from the Engine Compartment
1050
Primary Ignition Noise
1050
Secondary Ignition Noise
1050
Alternator Whine (Antenna)
1051
A-Line (Power Feed Wire to Radio)
1051
Alternator Whine (A-Line)
1052
Wiring Harness Close to Ignition Wiring
1052
Instrument Cluster Radio Noise Suppressor
1052
Poor Radio Ground
1053
Other Sources of Interference
1053
Antennas
1054
Speakers
1055
Speaker Replacement
1056
Speaker Harness Test
1056
Engine - Altitude Performance Adjustments
1061
Broken Cylinder Head Bolt
1065
Four-Cylinder Engine Cold Operation
1067
Workshop Manual Update
1071
Model YFA Carburetor Specifications
1071
Suspension Spring Identification and Application
1073
Vehicle Altitude - Spring Identification
1074
Spring Application
1075
Exhaust Manifold Stud Damage - 2.46L Engines
1077
Rear Ride Height Adjustment
1082
New Crankshaft Rear Main Bearing Oil Seal
1085
Automatic Transmissions Overhaul
1090
Automatic Transmission Torque Specifications
1098
Thrust Washer Chart
1099
Valve Body Hydraulic Control Pressure Adjustment
1132
Accumulator Piston and Spring Inspection
1133
Adapter Housing Bearing and Seal Replacement
1133
Park Lock Sprag Disassembly and Assembly
1134
Governor Disassembly and Assembly
1134
Oil Pump and Reaction Shaft Support - 900 Series
1136
Pump Bushing Replacement
1138
Reaction Shaft Bushing Replacement
1139
Oil Pump and Reaction Shaft Support - Model 727
1141
Front Clutch - 900 Series
1146
Front Clutch - Model 727
1150
Retainer Bushing Replacement - Model 727
1152
Rear Clutch - 900 Series
1154
Rear Clutch - Model 727
1157
Planetary Gear Assembly - 900 Series
1161
Planetary Gear Assembly - Model 727
1165
Overrunning Clutch
1169
Cam Replacement - 900 Series
1169
Cam Replacement - Model 727
1171
Front Servo
1172
Rear Servo
1174
Rear Band - 900 Series
1176
Rear Band - Model 727
1177
Planetary Gear Assembly and Output Shaft
1179
Front and Rear Clutch Assemblies
1179
Front Band
1180
Oil Pump and Reaction Shaft Support
1181
Thrust Washer Chart - Model 727
1181
Governor and Park Gear
1182
Output Shaft Bearing and Adapter Housing
1182
Valve Body and Accumulator Piston
1183
Rear/Front Band Adjustment
1184
Manual Transmission T4/5
1185
T4/5 Manual Transmission Identification
1187
Gearshift Patterns (T4/5)
1187
T4/5 Manual Transmission Lubrication
1188
T4/5 Manual Transmission Specifications
1188
T4 Manual Transmission Exploded View
1191
T4 Manual Transmission Overhaul
1193
T5 Manual Transmission Overhaul
1213
T5 Manual Transmission Exploded View
1214
Gearboxes - Transmission Lubricant
1241
4.0/4.2L Six-Cylinder Engine
1242
Engine Specifications - 4.0L
1259
Engine Specifications - 4.2L
1261
Intake Manifold Removal (4.0L/4.2L)
1263
Exhaust Manifold Removal (4.0L/4.2L)
1263
Cylinder Head Cover Removal (4.0L/4.2L)
1264
Cylinder Head Removal (4.0L/4.2L)
1265
Hydraulic Valve Tappet
1266
Valve Stem Oil Deflector Replacement
1268
Valve Guide Replacement
1268
Valve Stem-To-Guide Clearance Measurement
1268
Valve Spring Tension Test
1269
Cylinder Block Disassembly
1270
Hydraulic Valve Tappet Disassembly and Assembly
1270
Water Pump Removal
1271
Vibration Damper Removal
1271
Timing Case Cover Removal
1271
Camshaft Removal
1271
Oil Pan Removal
1272
Oil Pump Removal
1272
Lubrication System Components (4.0L/4.2L)
1273
Oil Pump Gear End Clearance Measurement
1275
Oil Pump Gear-To-Body Clearance Measurment
1276
Connecting Rod and Piston Removal
1277
Crankshaft Removal
1277
Cylinder Bore Measurement
1278
Cylinder Bore Resurfacing
1278
Piston Pin Removal and Inspection
1279
Piston Pin Installation
1279
Cylinder Block Assembly
1280
Piston Fitting
1280
Piston Ring Fitting
1281
Piston Ring Side Clearance Measurements
1281
Piston Ring Installation
1282
Crankshaft Installation
1283
Crankshaft End Play Measurement
1283
Main Bearing Description
1284
Main Bearing-To-Journal Clearance Measurement
1284
Main Bearing Journal Diameter Measurement
1285
Main Bearing Fitting Chart
1286
Rear Main Bearing Oil Seal Installation
1287
Connecting Rod Installation
1288
Connecting Rod Bearing Installation
1289
Connecting Rod Bearing-To-Journal Clearance Measurement
1290
Side Clearance Measurement
1291
Connecting Rod Bearing Fitting Chart
1292
Oil Pump Assembly and Installation
1293
Camshaft Bearing
1294
Camshaft Installation
1294
Timing Case Cover Installation
1295
Oil Pan Installation
1296
Water Pump Installation
1297
Fuel Pump Installation
1297
Vibration Damper Installation
1297
Valve Installation
1297
Hydraulic Valve Tappet Assembly
1298
Hydraulic Valve Tappet Leak-Down Test
1298
Hydraulic Valve Tappet Installation
1299
Cylinder Head Installation
1300
Cylinder Head Cover Installation
1302
Intake Manifold Installation
1303
Exhaust Manifold Installation
1303

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Jeep CJ-7 Scrambler 1984 Workshop Manual (1304 pages)

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