Jeep Wrangler/YJ 1987-1995 Repair Guide

Adjustments

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SHIFT LINKAGE



1987-90 Models

See Figure 1



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Fig. Fig. 1: Gearshift linkage adjustment-1987-90

  1. Raise and support the vehicle on jackstands.
  2.  
  3. Loosen the shift rod trunnion jamnuts.
  4.  
  5. Remove the lockpin retaining the trunnion to the bell crank and disengage the trunnion at the bell crank.
  6.  
  7. Place the shift lever in Park and lock the column.
  8.  
  9. Move the transmission case lever as far into the Park (rearward) position as possible. Check that the driveshaft will not rotate in this position.
  10.  
  11. Adjust the shift rod trunnion to obtain free pin fit in the bell crank arm and tighten the trunnion jamnuts.
  12.  

All play must be eliminated for proper adjustment. Eliminate play by pulling downward on the shift rod and pressing on the outer bell crank.

  1. Move the gearshift lever to Park and Neutral and check to see if the engine starts.
  2.  
  3. Road test the vehicle.
  4.  

1991 Models

See Figure 2

  1. Shift the transmission into P and lock the steering column.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Check the condition of the shift rods, bell crank, bell crank brackets, and linkage bushings. Repair as necessary.
  6.  
  7. Loosen the shift rod trunnion jamnuts.
  8.  
  9. Remove the lockpin that retains the shift rod trunnion to the bell crank. Disengage the trunnion and shift rod at the bell crank.
  10.  
  11. Move the transmission lever rearward into the P detent. Be sure the lever is as far rearward as it will go.
  12.  
  13. Check the engagement of the park detent by trying to rotate the driveshaft with the rear wheels off of the ground. The shaft will not rotate if the park detent is engaged.
  14.  
  15. Adjust the trunnion until it will fit in the bell crank arm freely. Prevent the shift rod from turning while tightening the the bolt or nut. Tighten the jamnuts.
  16.  
  17. Install the lock pin.
  18.  

Gearshift linkage lash must be eliminated to obtain proper adjustment. Eliminate lash by pulling down on the shift rod and pressing up on the bell crank.

  1. Check engine starting in P and N ; be sure it will not start in any other gear.
  2.  



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Fig. Fig. 2: Gearshift linkage adjustment-1991-95

1992-95 Models

See Figure 2

  1. Shift the transmission into P and lock the steering column.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Check the condition of the shift rods, bell crank, bell crank brackets, and linkage bushings. Repair as necessary.
  6.  
  7. Loosen the shift rod trunnion lockbolt or nut.
  8.  
  9. Remove the lockpin that retains the shift rod trunnion to the bell crank. Disengage the trunnion and shift rod at the bell crank.
  10.  
  11. Move the transmission lever rearward into the P detent. Be sure the lever is as far rearward as it will go.
  12.  
  13. Check the engagement of the park detent by trying to rotate the driveshaft with the rear wheels off of the ground. The shaft will not rotate if the park detent is engaged.
  14.  
  15. Adjust the trunnion until it will fit in the bell crank arm freely. Prevent the shift rod from turning while tightening the the bolt or nut. Tighten the bolt or nut.
  16.  
  17. Install the lock pin.
  18.  

Gearshift linkage lash must be eliminated to obtain proper adjustment. Eliminate lash by pulling down on the shift rod and pressing up on the bell crank.

  1. Check engine starting in P and N ; be sure it will not start in any other gear.
  2.  

FRONT BAND



See Figure 3



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Fig. Fig. 3: Front band adjustment

  1. Raise and support the vehicle on jackstands. The front band adjusting screw is located on the left side of the case, just above the control levers.
  2.  
  3. Loosen the locknut and back it off about 4-5 full turns.
  4.  
  5. Make sure that the screw turns freely. Use penetrating oil if it binds.
  6.  
  7. Tighten the screw to 72 inch lbs. (8 Nm).
  8.  
  9. Back off the screw 2 1 / 2 turns for 1987-93 models. On 1994-95 models, back off the screw 2 1 / 2 turns for the 2.5L engine and 2 1 / 4 turns for the 4.0L engine.
  10.  
  11. Tighten the locknut to 35 ft. lbs. (47 Nm). Hold the screw still while tightening the locknut.
  12.  
  13. Lower the vehicle.
  14.  

REAR BAND



1987-93 Models

See Figure 4



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Fig. Fig. 4: Rear band adjustment-1987-93

  1. Raise and support the vehicle on jackstands.
  2.  
  3. Drain the fluid and remove the pan.
  4.  
  5. Loosen the adjusting screw locknut 5-6 turns, making sure the adjusting screw turns freely in the lever.
  6.  
  7. Back off the adjusting screw 4 turns, then tighten the adjusting screw to 72 inch lbs. (8 Nm) using a torque wrench and a 1 / 4 in. hex head socket.
  8.  
  9. Hold the adjusting screw still and tighten the locknut to 25 ft. lbs. (34 Nm).
  10.  
  11. Replace the pan and fill the unit with Dexron®II fluid.
  12.  

1994-95 Models

See Figure 5



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Fig. Fig. 5: Rear band adjustment

  1. Raise and support the vehicle on jackstands.
  2.  
  3. Drain the fluid and remove the pan.
  4.  
  5. Loosen the adjusting screw locknut 5-6 turns, making sure the adjusting screw turns freely in the lever.
  6.  
  7. On the 2.5L engine, tighten the adjusting screw to 41 inch lbs. (5 Nm). On the 4.0L engine, tighten the adjusting screw to 72 inch lbs. (8 Nm).
  8.  
  9. Back off the adjusting screw 7 turns for the 2.5L engine and 4 turns for the 4.0L engine.
  10.  
  11. Hold the adjusting screw still and tighten the locknut to 25 ft. lbs. (34 Nm).
  12.  
  13. Replace the pan and fill the unit with Dexron®II fluid.
  14.  

THROTTLE LINKAGE



1987-90 Models

See Figures 6, 7 and 8



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Fig. Fig. 6: Throttle linkage-1987-90



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Fig. Fig. 7: Throttle linkage adjustment-1987-90



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Fig. Fig. 8: Securing the throttle valve lever-1987-90

  1. Disconnect the throttle control rod spring at the carburetor.
  2.  
  3. Raise and support the vehicle on jackstands.
  4.  
  5. Use the throttle control rod spring to hold the throttle control lever forward against its stop, by hooking one end of the spring on the throttle control lever and the other end on the throttle linkage bell crank bracket which is attached to the transmission housing.
  6.  
  7. Block the choke plate open and move the throttle linkage off the fast idle cam.
  8.  
  9. On carburetors equipped with a throttle operated solenoid valve, turn the ignition ON to energize the solenoid, then open the throttle halfway to allow the solenoid to lock and return the carburetor to the idle position.
  10.  
  11. Loosen the retaining bolt on the throttle control adjusting link. DO NOT REMOVE THE SPRING CLIP AND NYLON WASHER!
  12.  
  13. Pull on the end of the link to eliminate play and tighten the retaining bolt.
  14.  
  15. Remove the throttle control rod spring and install it on the control rod from where it cam.
  16.  
  17. Lower the vehicle.
  18.  

THROTTLE VALVE CABLE (KICKDOWN)



1991-95 Models

See Figures 9, 10 and 11



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Fig. Fig. 9: Throttle valve cable-1991-95



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Fig. Fig. 10: Throttle cable components-1991-95



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Fig. Fig. 11: Throttle cable adjustment-1991-95

The throttle cable adjustment on these vehicles is performed entirely in the engine compartment. It is not necessary to raise the vehicle for access to any other components.

  1. Shift the transmission into PARK and shut the engine off.
  2.  
  3. Press the cable release button.
  4.  
  5. Push the cable conduit back into the cable adjuster body as far as possible.
  6.  
  7. Rotate the throttle body lever to the wide open throttle position. The cable will ratchet to the correct adjustment point as the lever is rotated.
  8.  

 
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