Jeep Wrangler 2001 Service Manual
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Jeep Wrangler 2001 Service Manual

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Table of Contents

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INs
Introduction
0s
Lubrication & Maintenance
7s
8As
8Js
8Os
8Wa
14s
21s
Service Manual Comment Forms
(Rear of Manual)

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Summary of Contents for Jeep Wrangler 2001

  • Page 1 GROUP TAB LOCATOR Introduction Lubrication & Maintenance Cooling Audio Instrument Cluster Restraints Wiring Fuel System Transmission/Transaxle Service Manual Comment Forms (Rear of Manual)
  • Page 2 2001 JEEP WRANGLER INTRODUCTION INTRODUCTION TABLE OF CONTENTS page page VEHICLE DATA-SUPPLEMENT BODY CODE PLATE DESCRIPTION ......1 DESCRIPTION .
  • Page 3 2001 JEEP WRANGLER INTRODUCTION BODY CODE PLATE (Continued) BODY CODE PLATE—LINE 3 DIGITS 1 THROUGH 12 Vehicle Order Number DIGITS 13, 14, AND 15 Roof • VJN = Soft Top White • VJU = Soft Top Spice • VJX = Soft Top Black •...

  • Page 4: Vehicle Identification Number

    2001 JEEP WRANGLER INTRODUCTION BODY CODE PLATE (Continued) • ERH = 4.0L 6 cyl. MPI Gasoline VEHICLE IDENTIFICATION NUMBER BODY CODE PLATE—LINE 1 DESCRIPTION DIGITS 1, 2, AND 3 The Vehicle Identification Number (VIN) plate is Transmission Codes • DDQ = AX5 5–speed Manual located on the lower windshield fence near the left •...
  • Page 5 2001 JEEP WRANGLER...
  • Page 6 2001 JEEP WRANGLER LUBRICATION & MAINTENANCE 0s - 1 LUBRICATION & MAINTENANCE TABLE OF CONTENTS page page LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES DESCRIPTION ......1 DESCRIPTION .

  • Page 7: Specifications

    2001 JEEP WRANGLER 0s - 2 LUBRICATION & MAINTENANCE LUBRICATION & MAINTENANCE (Continued) SULFUR IN GASOLINE NOTE: Intentional tampering with emissions control systems can result in civil penalties being assessed If you live in the northeast United States, your vehicle against you.
  • Page 8 2001 JEEP WRANGLER LUBRICATION & MAINTENANCE 0s - 3 COOLANT PERFORMANCE FLUID TYPES The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating DESCRIPTION - ENGINE COOLANT conditions. The coolant performance of various mix- tures follows: WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL...

  • Page 9: Maintenance Schedules

    2001 JEEP WRANGLER 0s - 4 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) DESCRIPTION - ENGINE OIL CONTAINER IDENTIFICATION Standard engine oil identification notations have WARNING: NEW OR USED ENGINE OIL CAN BE been adopted to aid in the proper selection of engine IRRITATING TO THE SKIN.
  • Page 10 2001 JEEP WRANGLER LUBRICATION & MAINTENANCE 0s - 5 MAINTENANCE SCHEDULES (Continued) • Inspect manual transmission fluid level (if • Lubricate steering linkage joints and outer tie equipped). rod ends. • After completion of off-road operation, the 60,000 Miles (96 000 km) or at 48 months underside of the vehicle should be thoroughly •...
  • Page 11 2001 JEEP WRANGLER 0s - 6 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) • Trailer towing 97,500 Miles (156 000 km) or at 78 months • Taxi, Police, or delivery service (commercial ser- • Change engine oil. • Replace engine oil filter.
  • Page 12 2001 JEEP WRANGLER LUBRICATION & MAINTENANCE 0s - 7 MAINTENANCE SCHEDULES (Continued) • Inspect brake linings. 27,000 Miles (43 000 km) • Lubricate steering and suspension ball joints. • Change engine oil. • Replace engine oil filter. 51,000 Miles (82 000 km) •...
  • Page 13 2001 JEEP WRANGLER 0s - 8 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) • Lubricate steering linkage tie rod ends. 93,000 Miles (149 000 km) • Drain and refill front and rear axles.‡ • Change engine oil. • Inspect brake linings.
  • Page 14 2001 JEEP WRANGLER LUBRICATION & MAINTENANCE 0s - 9 MAINTENANCE SCHEDULES (Continued) • Drain and refill transfer case fluid. 120,000 Miles (192 000 km) • Drain and refill front and rear axles.‡ • Change engine oil. • Inspect brake linings.
  • Page 15 2001 JEEP WRANGLER...

  • Page 16: Table Of Contents

    2001 JEEP WRANGLER COOLING 7s - 1 COOLING TABLE OF CONTENTS page page COOLING STANDARD PROCEDURE ....8 DESCRIPTION ......1 COOLING SYSTEM - REVERSE FLUSHING.
  • Page 17 2001 JEEP WRANGLER 7s - 2 COOLING COOLING (Continued) OPERATION - HOSE CLAMPS DIAGNOSIS AND TESTING - PRELIMINARY The worm type hose clamp uses a specified torque CHECKS value to maintain proper tension on a hose connec- tion. ENGINE COOLING SYSTEM OVERHEATING...
  • Page 18 2001 JEEP WRANGLER COOLING 7s - 3 COOLING (Continued) COOLING SYSTEM DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS 1. Has a Diagnostic Trouble Code 1. (Refer to 25 - EMISSIONS (DTC) been set indicating a stuck CONTROL - DESCRIPTION) for...
  • Page 19 2001 JEEP WRANGLER 7s - 4 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 3. Is the temperature warning 3. (Refer to 8 - ELECTRICAL/ illuminating unnecessarily? INSTRUMENT CLUSTER - SCHEMATIC - ELECTRICAL). 4. Coolant low in coolant reserve/ 4. Check for coolant leaks and overflow tank and radiator? repair as necessary.
  • Page 20 2001 JEEP WRANGLER COOLING 7s - 5 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 13. Fuel or ignition system 13. Refer to 14 - Fuel System or 8 - problems. Electrical for diagnosis and testing procedures. 14. Dragging brakes. 14. Check and correct as necessary.
  • Page 21 2001 JEEP WRANGLER 7s - 6 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 6. Cylinder head gasket leaking 6. (a) Check for cylinder head allowing exhaust gas to enter gasket leaks. (Refer to 7 - cooling system causing a COOLING - DIAGNOSIS AND thermostat to open late.
  • Page 22 2001 JEEP WRANGLER COOLING 7s - 7 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION (c) Vent at coolant reserve/overflow tank is plugged. Clean vent and repair as necessary. (d) Reserve/overflow tank is internally blocked or plugged. Check for blockage and repair as necessary.
  • Page 23 2001 JEEP WRANGLER 7s - 8 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION STEAM IS COMING FROM THE 1. During wet weather, moisture 1. Occasional steam emitting from FRONT OF VEHICLE NEAR THE (snow, ice or rain condensation) on this area is normal. No repair is...
  • Page 24 2001 JEEP WRANGLER COOLING 7s - 9 COOLING (Continued) CAUTION: Be sure that the heater control valve is Remove the lead away hose, flushing gun, water closed (heat off). This is done to prevent coolant supply hose and air supply hose. Remove the thermo-...
  • Page 25 2001 JEEP WRANGLER 7s - 10 ACCESSORY DRIVE ACCESSORY DRIVE TABLE OF CONTENTS page page BELT TENSIONERS - 2.5L REMOVAL ......11 REMOVAL .
  • Page 26 2001 JEEP WRANGLER ACCESSORY DRIVE 7s - 11 BELT TENSIONERS - 4.0L (Continued) (2) Remove tensioner assembly from mounting bracket (Fig. 3). Fig. 2 Accessory Drive Belt Wear Indicator - 4.0L Engine 1 - INDICATOR MARK 2 - MINIMUM TENSION MARK...
  • Page 27 2001 JEEP WRANGLER 7s - 12 ENGINE ENGINE TABLE OF CONTENTS page page COOLANT RECOVERY CONTAINER OPERATION......12 REMOVAL .
  • Page 28 2001 JEEP WRANGLER ENGINE 7s - 13 ENGINE COOLANT TEMP SENSOR (Continued) REMOVAL (1) Partially drain cooling system until coolant level is below cylinder head. (Refer to 7 - COOLING - STANDARD PROCEDURE). WARNING: HOT, PRESSURIZED COOLANT CAN (2) Disconnect coolant temperature sensor wire CAUSE INJURY BY SCALDING.
  • Page 29 2001 JEEP WRANGLER 7s - 14 TRANSMISSION TRANSMISSION TABLE OF CONTENTS page page TRANS COOLER FLUSHING COOLERS AND TUBES ..14 STANDARD PROCEDURE ....14 (4) Disconnect the cooler lines at the transmission.
  • Page 30 2001 JEEP WRANGLER AUDIO 8As - 1 AUDIO TABLE OF CONTENTS page page AUDIO INSTALLATION......2 DESCRIPTION .
  • Page 31 2001 JEEP WRANGLER 8As - 2 AUDIO AMPLIFIED SUBWOOFER (Continued) inoperative speaker location(s) from radio (4) Unscrew the antenna mast from the antenna receiver wire harness connectors and to the amplified body base on the right outer cowl side panel (Fig. 1).
  • Page 32 2001 JEEP WRANGLER AUDIO 8As - 3 ANTENNA BODY & CABLE (Continued) (1) From outside the vehicle, feed the antenna cable and base assembly through the outer cowl side panel. (2) From inside the passenger compartment, pull the cable and grommet into the hole in the inside cowl side panel until the grommet is seated.
  • Page 33 2001 JEEP WRANGLER 8As - 4 AUDIO RADIO (Continued) (12) Reach through the instrument panel glove box (4) Connect the radio wire harness connectors to opening to access and remove the screw that secures the rear of the radio. the CD radio bracket and the ground strap to the (5) Install the two radio retaining screws.
  • Page 34 2001 JEEP WRANGLER AUDIO 8As - 5 SPEAKER (Continued) (1) Connect the speaker wire connector to the speaker. (2) Position the speaker to the instrument panel. (3) Install the four speaker retaining screws. Tighten the screws to 1.1 N·m (10.in.lbs).
  • Page 35 2001 JEEP WRANGLER 8As - 6 AUDIO SOUND BAR (Continued) (6) Unplug the sound bar wire harness connector. (7) Lift each outboard end flap of the sound bar cover over the top of the sport bar far enough to access the mounting screws (Fig. 8).
  • Page 36 2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 1 INSTRUMENT CLUSTER TABLE OF CONTENTS page page INSTRUMENT CLUSTER OPERATION......24 DESCRIPTION .
  • Page 37 2001 JEEP WRANGLER 8Js - 2 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) DESCRIPTION cluster bezel. The molded plastic EMIC housing has four integral mounting tabs, two on the lower edge of the housing and one on each side. The EMIC is secured to the instrument panel structural support with four screws.
  • Page 38 2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 3 INSTRUMENT CLUSTER (Continued) The EMIC module incorporates a blue-green elec- cuits are integral to several wire harnesses, which tronic digital VFD for displaying odometer, trip are routed throughout the vehicle and retained by odometer, and diagnostic information.
  • Page 39 2001 JEEP WRANGLER 8Js - 4 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) extreme position and the microprocessor turns on the through it to maintain a constant magnetic field Check Gauges indicator to provide a distinct visual strength. Current flow through the second coil indication of a problem to the vehicle operator.
  • Page 40 2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 5 INSTRUMENT CLUSTER (Continued) information for additional details on these VFD func- PCI data bus and the data bus message inputs to the tions. EMIC that control each indicator requires the use of...
  • Page 41 2001 JEEP WRANGLER 8Js - 6 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) (Refer to 8 - ELECTRICAL/CHIME/BUZZER - defogger switch sense circuit and its control logic to OPERATION). The hard wired chime inputs to the determine the correct output to the rear window EMIC are diagnosed using conventional diagnostic defogger relay.
  • Page 42 2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 7 INSTRUMENT CLUSTER (Continued) of wire harness routing and retention, connector pin- (6) Turn the ignition switch to the On position. out information and location views for the various Check for battery voltage at the fused ignition switch wire harness connectors, splices and grounds.
  • Page 43 2001 JEEP WRANGLER 8Js - 8 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) The instrument cluster actuator test will put the (b) The cluster will scroll the number “8” across instrument cluster into its self-diagnostic mode. In the odometer/trip odometer VFD to confirm the...
  • Page 44 2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 9 INSTRUMENT CLUSTER (Continued) INSTRUMENT CLUSTER FAILURE MESSAGE VFD Message Description Correction buS b0 PCM - MIL Message The cluster is not receiving a MIL lamp message from the PCM. A DRBIII scan tool is required for further diagnosis.
  • Page 45 2001 JEEP WRANGLER 8Js - 10 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) (4) Disconnect the floor wire harness connector (2) Check for continuity between the door ajar from the seat belt switch pigtail wire connector. switch output fuse (Fuse 4 - 10 ampere) in the fuse Check for continuity between the seat belt switch block and a good ground.
  • Page 46 2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 11 INSTRUMENT CLUSTER (Continued) CLUSTER ILLUMINATION DIAGNOSIS WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE The diagnosis found here addresses an inoperative ATTEMPTING ANY STEERING WHEEL, STEERING instrument cluster illumination lamp condition. If...
  • Page 47 2001 JEEP WRANGLER 8Js - 12 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) and a good ground. There should be no continuity. If OK, go to Step 3. If not OK, repair the shorted panel lamp dimmer signal circuit between the instrument cluster and the left multi-function switch as required.
  • Page 48 2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 13 INSTRUMENT CLUSTER (Continued) (4) Gently pull the cluster lens away from the clus- ter housing. TRIP ODOMETER RESET KNOB BOOT (1) Disconnect and isolate the battery negative cable. (2) Remove the instrument cluster from the instru- ment panel.
  • Page 49 2001 JEEP WRANGLER 8Js - 14 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) ASSEMBLY TRIP ODOMETER RESET KNOB BOOT (1) Position the trip odometer reset knob boot to WARNING: ON VEHICLES EQUIPPED WITH AIR- the mounting hole from the back of the cluster lens BAGS, DISABLE THE AIRBAG SYSTEM BEFORE (Fig.

  • Page 50: Abs Indicator

    2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 15 INSTRUMENT CLUSTER (Continued) INSTALLATION overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber lens behind the cutout in the...
  • Page 51 2001 JEEP WRANGLER 8Js - 16 INSTRUMENT CLUSTER ABS INDICATOR (Continued) and retention, connector pin-out information and AIRBAG INDICATOR location views for the various wire harness connec- tors, splices and grounds. DESCRIPTION An airbag indicator is standard equipment on all...

  • Page 52: Description

    2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 17 AIRBAG INDICATOR (Continued) OPERATION remains illuminated for about twelve seconds or until the cluster receives a single lamp-off message from The brake indicator gives an indication to the vehi- the ACM, whichever is longer.

  • Page 53: Operation

    2001 JEEP WRANGLER 8Js - 18 INSTRUMENT CLUSTER BRAKE/PARK BRAKE INDICATOR (Continued) INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES bulb check portion of the test to confirm the function- NOT WHEN PARK BRAKE APPLIED ality of the LED and the cluster control circuitry.
  • Page 54 2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 19 BRAKE/PARK BRAKE INDICATOR (Continued) (4) Check for continuity between the terminal of 127° C or higher (about 261° F or higher), the check the park brake switch and a good ground. There gauges indicator will be illuminated.
  • Page 55 2001 JEEP WRANGLER 8Js - 20 INSTRUMENT CLUSTER • Actuator Test - Each time the cluster is put CRUISE INDICATOR through the actuator test, the cruise indicator will be turned on, then off again during the bulb check por- DESCRIPTION...
  • Page 56 2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 21 ENGINE TEMPERATURE GAUGE (Continued) OPERATION tone feature will occur only once per ignition cycle. The gauge needle remains in the center of the red The engine coolant temperature gauge gives an zone and the check gauges indicator remains illumi-...
  • Page 57 2001 JEEP WRANGLER 8Js - 22 INSTRUMENT CLUSTER DIAGNOSIS AND TESTING - FRONT/REAR FOG FOG LAMP INDICATOR LAMP INDICATOR DESCRIPTION The diagnosis found here addresses an inoperative A fog lamp indicator is standard equipment on all front/rear fog lamp indicator condition. Before begin-...
  • Page 58 2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 23 FUEL GAUGE proper position on the gauge scale. The algorithm is used to dampen gauge needle movement against the negative effect that fuel sloshing within the fuel tank DESCRIPTION can have on accurate inputs from the fuel tank send- A fuel gauge is standard equipment on all instru- ing unit to the PCM.
  • Page 59 2001 JEEP WRANGLER 8Js - 24 INSTRUMENT CLUSTER FUEL GAUGE (Continued) • Beam Select Switch Input - Each time the The PCM continually monitors the fuel tank send- ing unit, then sends the proper messages to the cluster detects battery current on the beam select instrument cluster.
  • Page 60 2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 25 HIGH BEAM INDICATOR (Continued) replace the indicator bulb and bulb holder with a near the lower edge of the instrument cluster overlay, known good unit and repeat the test. If the indicator...
  • Page 61 2001 JEEP WRANGLER 8Js - 26 INSTRUMENT CLUSTER LOW FUEL INDICATOR (Continued) • Less Than Empty Percent Tank Full Mes- tic Trouble Code (DTC) for an On-Board Diagnostics sage - Each time the cluster receives a message from II (OBDII) emissions-related circuit or component the PCM indicating the percent tank full is less than malfunction.
  • Page 62 2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 27 MALFUNCTION INDICATOR LAMP MIL (Continued) require service. For proper diagnosis of the fuel and reset knob boot on the outside of the cluster lens is emissions systems, the PCM, the PCI data bus, or available for separate service replacement.

  • Page 63: Engine

    2001 JEEP WRANGLER 8Js - 28 INSTRUMENT CLUSTER ODOMETER (Continued) vehicle speed sensor, the PCM, the PCI data bus, or (4 psi) and about 6.7 kg/cm (95 psi), the cluster the message inputs to the instrument cluster that moves the gauge needle to the appropriate linear...
  • Page 64 2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 29 SEATBELT WARNING On positions, the seatbelt indicator will be illumi- nated. The seatbelt indicator remains illuminated INDICATOR until the seat belt switch sense input to the cluster is an open circuit (seatbelt switch open = seatbelt buck-...

  • Page 65: Transmission

    2001 JEEP WRANGLER 8Js - 30 INSTRUMENT CLUSTER SHIFT INDICATOR (TRANSFER CASE) (Continued) cil-like cutout of the words “FULL TIME” in the The transfer case switch is connected in series opaque layer of the instrument cluster overlay. The between ground and the 4WD switch sense (part- dark outer layer of the overlay prevents the indicator time) input to the instrument cluster.
  • Page 66 2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 31 SHIFT INDICATOR (TRANSFER CASE) (Continued) information on the transfer case switch. For further harness connector for the transfer case switch and a diagnosis of the part time indicator or the instrument good ground. There should be continuity. If OK, go to cluster circuitry that controls the LED, (Refer to 8 - Step 2.
  • Page 67 2001 JEEP WRANGLER 8Js - 32 INSTRUMENT CLUSTER SHIFT INDICATOR (TRANSFER CASE) (Continued) test, confirm the functionality of the full time indica- (3) Turn the ignition switch to the Off position. tor Light Emitting Diode (LED) and the cluster con- Disconnect and isolate the battery negative cable.
  • Page 68 2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 33 SPEEDOMETER (Continued) • Actuator Test - Each time the cluster is put equivalent opposite units from the primary scale. A label on the cluster overlay beneath the hub of the through the actuator test, the gauge needle will be...
  • Page 69 2001 JEEP WRANGLER 8Js - 34 INSTRUMENT CLUSTER TACHOMETER (Continued) munications Interface (PCI) data bus. The tachome- indicator consists of a stencil-like cutout of the Inter- ter is an air core magnetic unit that receives battery national Control and Display Symbol icon for “Turn current on the instrument cluster electronic circuit Warning”...
  • Page 70 2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 35 TURN SIGNAL INDICATORS (Continued) to diagnose or repair the turn signal indicators. is located near the right upper edge of the instru- (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - ment cluster overlay, just above the oil pressure EXTERIOR - DIAGNOSIS AND TESTING - TURN gauge.
  • Page 71 2001 JEEP WRANGLER 8Js - 36 INSTRUMENT CLUSTER UPSHIFT INDICATOR (Continued) accelerating and is brought back into the range of tronic circuit board based upon cluster programming indicator operation, or until the transmission is and electronic messages received by the cluster from shifted into another gear.
  • Page 72 2001 JEEP WRANGLER INSTRUMENT CLUSTER 8Js - 37 VOLTAGE GAUGE (Continued) • Actuator Test - Each time the cluster is put MENT CLUSTER - DIAGNOSIS AND TESTING). If through the actuator test, the gauge needle will be the instrument cluster turns on the check gauges...
  • Page 73 2001 JEEP WRANGLER...

  • Page 74: This Service Manual Supplement Includes Only The Information That Is New Or Updated For

    2001 JEEP WRANGLER RESTRAINTS 8Os - 1 RESTRAINTS TABLE OF CONTENTS page page RESTRAINTS FRONT SEAT BELT & RETRACTOR DESCRIPTION ......1 REMOVAL .
  • Page 75 2001 JEEP WRANGLER 8Os - 2 RESTRAINTS RESTRAINTS (Continued) DESCRIPTION ger airbag door on the instrument panel above the glove box on the passenger side of the vehicle. A dual front airbag system is standard factory-in- • Passenger Airbag On/Off Switch - The pas- stalled safety equipment on this model.
  • Page 76 2001 JEEP WRANGLER RESTRAINTS 8Os - 3 RESTRAINTS (Continued) chanical Instrument Cluster (EMIC) lights for about depending upon the vehicle speed, impact angle, seven seconds as a bulb test each time the ignition severity of the impact, and the type of collision.
  • Page 77 2001 JEEP WRANGLER 8Os - 4 RESTRAINTS RESTRAINTS (Continued) STANDARD PROCEDURE - HANDLING OF WARNING: REPLACE AIRBAG SYSTEM COMPO- NENTS ONLY WITH PARTS SPECIFIED IN THE NON-DEPLOYED AIRBAGS DAIMLERCHRYSLER MOPAR PARTS CATALOG. At no time should any source of electricity be per-...
  • Page 78 2001 JEEP WRANGLER RESTRAINTS 8Os - 5 RESTRAINTS (Continued) CLEANUP PROCEDURE Following an airbag deployment, the vehicle interior will contain a powdery residue. This residue consists primarily of harmless particulate by-products of the small pyrotechnic charge used to initiate the propellant used to deploy the airbags.

  • Page 79: On-Board Diagnostics (Obd)

    2001 JEEP WRANGLER 8Os - 6 RESTRAINTS RESTRAINTS (Continued) AIRBAG CONTROL MODULE DESCRIPTION Fig. 5 Airbag Control Module 1 - SCREW (4) Fig. 4 16-Way Data Link Connector - Typical 2 - AIRBAG CONTROL MODULE 1 - 16–WAY DATA LINK CONNECTOR...
  • Page 80 2001 JEEP WRANGLER RESTRAINTS 8Os - 7 AIRBAG CONTROL MODULE (Continued) OPERATION). The ACM microprocessor continuously vides verification of the direction and severity of an monitors all of the airbag system electrical circuits to impact. A pre-programmed decision algorithm in the determine the system readiness.
  • Page 81 2001 JEEP WRANGLER 8Os - 8 RESTRAINTS AIRBAG CONTROL MODULE (Continued) enough to access the Airbag Control Module (ACM), which is forward of the floor console. (3) If the vehicle is equipped with the optional Anti-lock Brake System (ABS), remove the accelera- tion switch from the left side of the mounting bracket on the floor panel transmission tunnel.

  • Page 82: Standard Procedure

    2001 JEEP WRANGLER RESTRAINTS 8Os - 9 AIRBAG CONTROL MODULE (Continued) WARNING: THE AIRBAG CONTROL MODULE CON- TAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION.
  • Page 83 2001 JEEP WRANGLER 8Os - 10 RESTRAINTS CLOCKSPRING (Continued) DARD PROCEDURE CLOCKSPRING STRAINTS/CLOCKSPRING - STANDARD PROCE- CENTERING). DURE - CLOCKSPRING CENTERING). The clockspring cannot be repaired. If the clock- STANDARD PROCEDURE - CLOCKSPRING spring is faulty, damaged, or if the driver airbag has been deployed, the clockspring must be replaced.
  • Page 84 2001 JEEP WRANGLER RESTRAINTS 8Os - 11 CLOCKSPRING (Continued) STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON- NECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE.
  • Page 85 2001 JEEP WRANGLER 8Os - 12 RESTRAINTS CLOCKSPRING (Continued) (11) Using a small screwdriver, gently pry both plastic latches of the clockspring assembly to release them from the steering column upper housing. NOTE: If the clockspring plastic latches are broken, be certain to remove the broken pieces from the steering column upper housing.
  • Page 86 2001 JEEP WRANGLER RESTRAINTS 8Os - 13 CLOCKSPRING (Continued) NOTE: Before starting this procedure, be certain DRIVER AIRBAG that the front wheels are still in the straight-ahead position. DESCRIPTION (1) If the removed clockspring is being reinstalled, remove the wire from the index hole that is locking the clockspring rotor to the clockspring case to main- tain clockspring centering.
  • Page 87 2001 JEEP WRANGLER 8Os - 14 RESTRAINTS DRIVER AIRBAG (Continued) that is captured on the upper left inflator mounting STEERING COLUMN, OR INSTRUMENT PANEL stud between the inflator and the upper trim cover COMPONENT DIAGNOSIS OR SERVICE. DISCON- retainer. The other horn switch pigtail wire is routed...
  • Page 88 2001 JEEP WRANGLER RESTRAINTS 8Os - 15 DRIVER AIRBAG (Continued) CAUTION: Do not pull on the clockspring wire har- (3) Remove the plastic horn switch pigtail wire ness to disengage the connector from the driver retainer from the stud on the back of the driver air- airbag inflator connector receptacle.
  • Page 89 2001 JEEP WRANGLER 8Os - 16 RESTRAINTS DRIVER AIRBAG (Continued) (6) Remove the horn switch ground pigtail wire DEALER SERVICE TECHNICIANS. FAILURE TO eyelet terminal connector from the upper left airbag TAKE THE PROPER PRECAUTIONS OR TO FOL- housing stud.
  • Page 90 2001 JEEP WRANGLER RESTRAINTS 8Os - 17 DRIVER AIRBAG (Continued) WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT.
  • Page 91 2001 JEEP WRANGLER 8Os - 18 RESTRAINTS FRONT SEAT BELT & (4) Remove the shoulder belt turning loop and the support/guide washer from the adjuster. RETRACTOR (5) Remove the screw that secures the retractor and lower seat belt anchor plate to the sport bar near REMOVAL its base (Fig.
  • Page 92 2001 JEEP WRANGLER RESTRAINTS 8Os - 19 FRONT SEAT BELT & RETRACTOR (Continued) (3) Position the support/guide washer and the shoulder belt turning loop onto the height adjuster near the top of the sport bar (Fig. 18). (4) Install and tighten the screw that secures the shoulder belt turning loop to the adjuster.
  • Page 93 2001 JEEP WRANGLER 8Os - 20 RESTRAINTS PASSENGER AIRBAG (Continued) (or squib) circuits. The hybrid-type inflator assembly includes a small canister of highly compressed argon gas. When the ACM sends the proper electrical signal to the airbag inflator, the electrical energy generates enough heat to ignite chemical pellets within the inflator.
  • Page 94 2001 JEEP WRANGLER RESTRAINTS 8Os - 21 PASSENGER AIRBAG (Continued) WARNING: WHEN REMOVING A DEPLOYED AIR- THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BAG, RUBBER GLOVES, EYE PROTECTION, AND A BEFORE PERFORMING FURTHER DIAGNOSIS OR LONG-SLEEVED SHIRT SHOULD BE WORN. THERE SERVICE.
  • Page 95 2001 JEEP WRANGLER 8Os - 22 RESTRAINTS PASSENGER AIRBAG ON / OFF The passenger airbag on-off switch housing is con- structed of molded plastic and has three integral SWITCH mounting tabs. These mounting tabs are used to secure the switch to the back of the molded plastic DESCRIPTION console switch bezel with three small screws.
  • Page 96 2001 JEEP WRANGLER RESTRAINTS 8Os - 23 PASSENGER AIRBAG ON / OFF SWITCH (Continued) driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the Off indicator of the switch. The ACM will also illuminate the Off indica- tor of the switch for about seven seconds each time the ignition switch is turned to the On position as a bulb test.
  • Page 97 2001 JEEP WRANGLER 8Os - 24 RESTRAINTS REAR SEAT BELT & RETRACTOR REMOVAL WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED.
  • Page 98 2001 JEEP WRANGLER RESTRAINTS 8Os - 25 REAR SEAT BELT & RETRACTOR (Continued) INSTALLATION REAR SEAT BELT BUCKLE WARNING: DURING AND FOLLOWING ANY SEAT REMOVAL BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND WARNING: DURING AND FOLLOWING ANY SEAT...
  • Page 99 2001 JEEP WRANGLER 8Os - 26 RESTRAINTS REAR SEAT BELT BUCKLE (Continued) INSTALLATION WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED.
  • Page 100 2001 JEEP WRANGLER RESTRAINTS 8Os - 27 SEAT BELT SWITCH (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- (1) Unsnap and lift the shoulder belt turning loop BAGS, DISABLE THE AIRBAG SYSTEM BEFORE cover to access the screw that secures the turning ATTEMPTING ANY STEERING WHEEL, STEERING loop to the adjuster (Fig.
  • Page 101 2001 JEEP WRANGLER 8Os - 28 RESTRAINTS SEAT BELT TURNING LOOP ADJUSTER (Continued) (1) Position the turning loop adjuster onto the (4) Position the support/guide washer and the sport bar (Fig. 29). Be certain that the word “Up” shoulder belt turning loop onto the adjuster.

  • Page 102: Table Of Contents

    2001 JEEP WRANGLER WIRING 8Wa - 1 WIRING TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION..8Wa-01-1 AIR CONDITIONING-HEATER ..8Wa-42-1 COMPONENT INDEX ....8Wa-02-1 AIRBAG SYSTEM .
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  • Page 104 2001 JEEP WRANGLER 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 1 8W-01 WIRING DIAGRAM INFORMATION TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION CONNECTOR - MOLEX DESCRIPTION ......1 REMOVAL .
  • Page 105 2001 JEEP WRANGLER 8Wa - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 1 WIRING DIAGRAM EXAMPLE 1...
  • Page 106 2001 JEEP WRANGLER 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 3 WIRING DIAGRAM INFORMATION (Continued) Fig. 2 WIRING DIAGRAM EXAMPLE 2...
  • Page 107 2001 JEEP WRANGLER 8Wa - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 3 WIRING DIAGRAM SYMBOLS...

  • Page 108: Diagnosis And Testing

    2001 JEEP WRANGLER 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 5 WIRING DIAGRAM INFORMATION (Continued) TERMINOLOGY TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA- LYTIC CONVERTER AND MUFFLER. This is a list of terms and definitions used in the wiring diagrams.
  • Page 109 2001 JEEP WRANGLER 8Wa - 01 - 6 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) • Probing Tools - These tools are used for probing disconnect them to verify these add-on items are not terminals in connectors (Fig. 4)Select the proper size the cause of the problem.
  • Page 110 2001 JEEP WRANGLER 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 7 WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING FOR STANDARD PROCEDURE - TESTING FOR CONTINUITY SHORT TO GROUND ON FUSES POWERING (1) Remove the fuse for the circuit being checked SEVERAL LOADS or, disconnect the battery.

  • Page 111: Special Tools

    2001 JEEP WRANGLER 8Wa - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) SPECIAL TOOLS CONNECTOR - AUGAT SPECIAL TOOLS - WIRING/TERMINAL REMOVAL (1) Disconnect battery. (2) Disconnect the connector from its mating half/ component. (3) Push down on the yellow connector locking tab to release the terminals (Fig.
  • Page 112 2001 JEEP WRANGLER 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 9 CONNECTOR - AUGAT (Continued) INSTALLATION (1) Reset the terminal locking tang. (2) Insert the removed wire in the same cavity on the repair connector. (3) Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities.
  • Page 113 2001 JEEP WRANGLER 8Wa - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION CONNECTOR - THOMAS AND BETTS (Continued) (4) Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). Fig. 14 SINGLE LOCK TAB 1 - SINGLE LOCK TAB Fig.

  • Page 114: Table Of Contents

    2001 JEEP WRANGLER 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 11 TERMINAL REMOVAL (1) Disconnect battery. (2) Disconnect the connector being repaired from its mating half/component. (3) Remove connector locking wedge, required (Fig. 16). Fig. 18 TERMINAL REMOVAL USING SPECIAL TOOL...
  • Page 115 2001 JEEP WRANGLER 8Wa - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION WIRE (5) Solder the connection together using rosin core type solder only (Fig. 21). CAUTION: DO NOT USE ACID CORE SOLDER. STANDARD PROCEDURE STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the cor- rect gage be used as shown in the wiring diagrams.
  • Page 116 2001 JEEP WRANGLER 8W-02 COMPONENT INDEX 8Wa - 02 - 1 8W-02 COMPONENT INDEX Component Page Component Page 4WD Indicator ..... . . 8Wa-31 Grounds .
  • Page 117 2001 JEEP WRANGLER 8Wa - 02 - 2 8W-02 COMPONENT INDEX Component Page Component Page Speed Control Servo ....8Wa-30 Transmission Range Indicator Illumination . 8Wa-44 Speed Control Switch Pod .
  • Page 118 2001 JEEP WRANGLER 8W-10 POWER DISTRIBUTION 8Wa - 10 - 1 8W-10 POWER DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8Wa-10-16 Fuse 8 (PDC) ....8Wa-10-7, 10 A/C Compressor Clutch Relay .
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  • Page 136 2001 JEEP WRANGLER 8W-11 FUSE BLOCK 8Wa - 11 - 1 8W-11 FUSE BLOCK Component Page Component Page A/C Compressor Clutch Relay ..8Wa-11-8 Fuse 12 (FB) ..... . . 8Wa-11-7 A/C-Heater Control .
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  • Page 146 2001 JEEP WRANGLER 8W-15 GROUND DISTRIBUTION 8Wa - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page Component Page A/C Compressor Clutch ..8Wa-15-11, 12, 13 Instrument Cluster ....8Wa-15-6, 7 A/C-Heater Control .
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  • Page 160 2001 JEEP WRANGLER 8W-18 BUS COMMUNICATION 8Wa - 18 - 1 8W-18 BUS COMMUNICATION Component Page Component Page Airbag Control Module ....8Wa-18-2 Instrument Cluster ....8Wa-18-2 Controller Antilock Brake .
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  • Page 162 2001 JEEP WRANGLER 8W-20 CHARGING SYSTEM 8Wa - 20 - 1 8W-20 CHARGING SYSTEM Component Page Component Page Automatic Shut Down Relay ... 8Wa-20-2 Fusible Link ..... . . 8Wa-20-2 Battery .
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  • Page 166 2001 JEEP WRANGLER 8W-21 STARTING SYSTEM 8Wa - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Battery ......8Wa-21-2, 3 Fuse Block .
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  • Page 170 2001 JEEP WRANGLER 8W-30 FUEL/IGNITION SYSTEM 8Wa - 30 - 1 8W-30 FUEL/IGNITION SYSTEM Component Page Component Page A/C Compressor Clutch Relay ..8Wa-30-3 G100 ......8Wa-30-20 A/C High Pressure Switch .
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  • Page 190 2001 JEEP WRANGLER 8W-31 TRANSMISSION CONTROL SYSTEM 8Wa - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Component Page Component Page Brake Lamp Switch ....8Wa-31-2 G105 .
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  • Page 192 2001 JEEP WRANGLER 8W-35 ANTILOCK BRAKES 8Wa - 35 - 1 8W-35 ANTILOCK BRAKES Component Page Component Page Antilock Brake Relay ....8Wa-35-2 Fuse Block ..... . . 8Wa-35-2, 3 Brake Lamp Switch .
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  • Page 196 2001 JEEP WRANGLER 8W-40 INSTRUMENT CLUSTER 8Wa - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Component Page Airbag Control Module ....8Wa-40-4 G300 ......8Wa-40-7 Antilock Brake Relay .
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  • Page 206 2001 JEEP WRANGLER 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8Wa - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET Component Page Component Page Cigar Lighter/Power Outlet ... . 8Wa-41-2 G200 ......8Wa-41-2 Clockspring .
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  • Page 210 2001 JEEP WRANGLER 8W-42 AIR CONDITIONING-HEATER 8Wa - 42 - 1 8W-42 AIR CONDITIONING-HEATER Component Page Component Page A/C Compressor Clutch ....8Wa-42-4 Fuse 11 (FB) ..... . . 8Wa-42-4 A/C Compressor Clutch Relay .
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  • Page 214 2001 JEEP WRANGLER 8W-43 AIRBAG SYSTEM 8Wa - 43 - 1 8W-43 AIRBAG SYSTEM Component Page Component Page Airbag Control Module ... . . 8Wa-43-2, 3 Fuse 9 (FB) ......8Wa-43-2 Brake Transmission Shift Interlock Fuse 10 (FB) .
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  • Page 218 2001 JEEP WRANGLER 8W-44 INTERIOR LIGHTING 8Wa - 44 - 1 8W-44 INTERIOR LIGHTING Component Page Component Page A/C-Heater Control ....8Wa-44-7 Instrument Cluster ....8Wa-44-5, 6, 7 Dome Lamp .
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  • Page 226 2001 JEEP WRANGLER 8W-47 AUDIO SYSTEM 8Wa - 47 - 1 8W-47 AUDIO SYSTEM Component Page Component Page Brake Lamp Switch ....8Wa-47-2 Left Rear Speaker ....8Wa-47-3, 4 Fuse 3 (FB) .
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  • Page 230 2001 JEEP WRANGLER 8W-48 REAR WINDOW DEFOGGER 8Wa - 48 - 1 8W-48 REAR WINDOW DEFOGGER Component Page Component Page Fuse 7 (FB) ......8Wa-48-2 Instrument Cluster .
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  • Page 232 2001 JEEP WRANGLER 8W-50 FRONT LIGHTING 8Wa - 50 - 1 8W-50 FRONT LIGHTING Component Page Component Page Beam Select Switch ....8Wa-50-2 Left Fog Lamp .
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  • Page 242 2001 JEEP WRANGLER 8W-51 REAR LIGHTING 8Wa - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Back-Up Lamp Switch ....8Wa-51-2, 4 Left License Lamp ....8Wa-51-8, 9 Brake Lamp Switch .
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  • Page 252 2001 JEEP WRANGLER 8W-52 TURN SIGNALS 8Wa - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page Brake Lamp Switch ....8Wa-52-2, 3 Left Side Marker Lamp ....8Wa-52-4 Fuse 13 (FB) .
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  • Page 258 2001 JEEP WRANGLER 8W-53 WIPERS 8Wa - 53 - 1 8W-53 WIPERS Component Page Component Page Front Washer Pump ....8Wa-53-2 G300 ......8Wa-53-2 Front Wiper Motor .
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  • Page 270 2001 JEEP WRANGLER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 1 8W-80 CONNECTOR PINOUTS Component Page Component Page A/C Compressor Clutch ....8Wa-80-3 C323 (RHD) (Except 2 Speaker Soft Top) .
  • Page 271 2001 JEEP WRANGLER 8Wa - 80 - 2 8W-80 CONNECTOR PINOUTS Component Page Component Page Intake Air Temperature Sensor ..8Wa-80-30 Radio Choke And Relay ....8Wa-80-39 Rear Fog Lamp (Built-Up-Export) .
  • Page 272 2001 JEEP WRANGLER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 3 A/C COMPRESSOR CLUTCH - BLACK 2 WAY CIRCUIT FUNCTION C3 20DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT Z1 20BK GROUND A/C-HEATER CONTROL C1 - 5 WAY CIRCUIT FUNCTION C7 12BR/TN...
  • Page 273 2001 JEEP WRANGLER 8Wa - 80 - 4 8W-80 CONNECTOR PINOUTS A/C LOW PRESSURE SWITCH - 2 WAY CIRCUIT FUNCTION C22 20DB/WT (4 CYL) A/C LOW PRESSURE SWITCH SENSE C21 20DB/OR (4 CYL) A/C SWITCH SENSE C21 20DB/OR (6 CYL)
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  • Page 283 2001 JEEP WRANGLER 8Wa - 80 - 14 8W-80 CONNECTOR PINOUTS C202 - GRAY (CROSSBODY SIDE) CIRCUIT Z12 20BK/LB Z12 20BK/LB G34 14RD/GY F38 16LB G5 20DB/WT G5 20DB/WT C203 - GREEN (I/P SIDE) CIRCUIT L60 18TN L61 18GY G26 20LB...
  • Page 284 2001 JEEP WRANGLER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 15 C203 - GREEN (CROSSBODY SIDE) CIRCUIT D25 2OVT/YL D25 18VT/YL C204 - RED (I/P SIDE) CIRCUIT X16 20LG V13 18BR/LG (HARD TOP) G10 20LG/RD Z12 20BK/TN M2 20YL V23 18BR/PK...
  • Page 285 2001 JEEP WRANGLER 8Wa - 80 - 16 8W-80 CONNECTOR PINOUTS C205 - LT. GREEN (I/P SIDE) CIRCUIT Z11 20BK/WT C4 18TN C5 16LG/LB C6 14LB F24 20RD/DG F24 20RD/DG C36 20DB/RD C7 12BR/TN A111 12RD/LB F24 20RD/DG Z1 20BK...
  • Page 286 2001 JEEP WRANGLER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 17 C322 (LHD) - BLACK (CROSSBODY SIDE) CIRCUIT L7 18BK/YL L62 18BR/RD L1 20VT/BK L63 18DG/RD Z1 12BK G10 20LG/RD L50 18WT/TN L50 18WT/TN G9 20GY/BK V23 18BR/PK C322 (RHD) - BLACK (REAR BODY SIDE)
  • Page 287 2001 JEEP WRANGLER 8Wa - 80 - 18 8W-80 CONNECTOR PINOUTS C323 (LHD) (EXCEPT 2 SPEAKER SOFT TOP) - RED (REAR BODY SIDE) CIRCUIT C15 12BK/WT (HARD TOP) M1 20PK/WT M2 20YL V23 18BR/PK (HARD TOP) V13 18BR/LG (HARD TOP)
  • Page 288 2001 JEEP WRANGLER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 19 C323 (RHD) (EXCEPT 2 SPEAKER SOFT TOP) - GRAY (CROSSBODY SIDE) CIRCUIT C15 12BK/WT (HARD TOP) M1 20PK/WT M2 20YL V23 18BR/PK (HARD TOP) V13 18BR/LG (HARD TOP) V20 18VT/OR (HARD TOP)
  • Page 289 2001 JEEP WRANGLER 8Wa - 80 - 20 8W-80 CONNECTOR PINOUTS C326 (HARD TOP) - (REAR BODY SIDE) CIRCUIT M2 20YL C326 (HARD TOP) - BLACK (HARD TOP SIDE) CIRCUIT C15 12BK/WT V13 18BR/LG V23 18BR/PK V23 18BR/PK Z1 12BK...
  • Page 290 2001 JEEP WRANGLER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 21 C330 (4 SPKR SYS) - WHITE (SOUND BAR JUMPER SIDE) CIRCUIT X57 18BR/LB X51 18BR/YL M1 20PK/WT M2 20YL X58 18DB/PK X52 18DB/WT C330 (4 SPKR SYS) - BLACK (SOUND BAR...
  • Page 291 2001 JEEP WRANGLER 8Wa - 80 - 22 8W-80 CONNECTOR PINOUTS CAMSHAFT POSITION SENSOR - 3 WAY CIRCUIT FUNCTION K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL K4 20BK/LB SENSOR GROUND K7 20OR 5V SUPPLY CIGAR LIGHTER/POWER OUTLET - RED 3 WAY...
  • Page 292 2001 JEEP WRANGLER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 23 CLUTCH PEDAL POSITION SWITCH (M/T) - BLACK 2 WAY CIRCUIT FUNCTION T141 14YL/RD FUSED IGNITION SWITCH OUTPUT (START) A41 14YL FUSED IGNITION SWITCH OUTPUT (START) CONTROLLER ANTILOCK BRAKE - 25 WAY...
  • Page 293 2001 JEEP WRANGLER 8Wa - 80 - 24 8W-80 CONNECTOR PINOUTS DATA LINK CONNECTOR - BLACK 16 WAY CIRCUIT FUNCTION Z12 20BK/LB GROUND Z12 20BK/TN GROUND D32 20LG SCI RECEIVE D21 20PK SCI TRANSMIT M1 20PK/WT FUSED B(+) DAYTIME RUNNING LAMP MODULE (EXCEPT BUILT-UP-EXPORT) - BLACK 10 WAY...
  • Page 294 2001 JEEP WRANGLER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 25 ENGINE COOLANT TEMPERATURE SENSOR - BLACK 2 WAY CIRCUIT FUNCTION K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL K4 20BK/LB SENSOR GROUND FRONT FOG LAMP SWITCH - BLACK 4 WAY...
  • Page 295 2001 JEEP WRANGLER 8Wa - 80 - 26 8W-80 CONNECTOR PINOUTS FUEL INJECTOR NO. 1 (2.5L) - 2 WAY CIRCUIT FUNCTION F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER FUEL INJECTOR NO. 1 (4.0L) - 2 WAY...
  • Page 296 2001 JEEP WRANGLER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 27 FUEL INJECTOR NO. 4 (2.5L) - 2 WAY CIRCUIT FUNCTION F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT K14 18LB/BR FUEL INJECTOR NO. 4 DRIVER FUEL INJECTOR NO. 4 (4.0L) - 2 WAY...
  • Page 297 2001 JEEP WRANGLER 8Wa - 80 - 28 8W-80 CONNECTOR PINOUTS GENERATOR - BLACK 2 WAY CIRCUIT FUNCTION K125 18WT/DB GENERATOR SOURCE K20 18DG GENERATOR FIELD HEADLAMP LEVELING SWITCH (BUILT-UP-EXPORT) - 6 WAY CIRCUIT FUNCTION L22 20LG/DG FUSED HEADLAMP SWITCH OUTPUT...
  • Page 298 2001 JEEP WRANGLER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 29 IGNITION COIL PACK (4.0L) - BLACK 4 WAY CIRCUIT FUNCTION K19 18GY IGNITION COIL NO.1 DRIVER F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT K17 18DB/TN IGNITION COIL NO.2 DRIVER K18 18RD/YL IGNITION COIL NO.3 DRIVER...
  • Page 299 2001 JEEP WRANGLER 8Wa - 80 - 30 8W-80 CONNECTOR PINOUTS INSTRUMENT CLUSTER C2 - 16 WAY CIRCUIT FUNCTION C81 20LB/WT (EXCEPT LHD EXCEPT REAR WINDOW DEFFOGER RELAY CONTROL BUILT-UP-EXPORT) G19 20LG/OR ABS WARNING INDICATOR DRIVER G99 20GY/WT BRAKE WARNING INDICATOR DRIVER...
  • Page 300 2001 JEEP WRANGLER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 31 LEFT FRONT PARK/ TURN SIGNAL LAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 W CIRCUIT FUNCTION L61 18GY LEFT TURN SIGNAL L7 18BK/YL HEADLAMP SWITCH OUTPUT Z1 18BK GROUND LEFT FRONT POSITION LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY...
  • Page 301 2001 JEEP WRANGLER 8Wa - 80 - 32 8W-80 CONNECTOR PINOUTS LEFT HEADLAMP LEVELING MOTOR (BUILT-UP-EXPORT) - BLACK 3 WAY CIRCUIT FUNCTION L22 20LG/DG FUSED HEADLAMP SWITCH OUTPUT L13 20BR/YL HEADLAMP ADJUST SIGNAL Z1 20BK GROUND LEFT LICENSE LAMP (BUILT-UP-EXPORT) - GRAY 2 WAY...
  • Page 302 2001 JEEP WRANGLER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 33 LEFT REAR WHEEL SPEED SENSOR - 2 WAY CIRCUIT FUNCTION B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR (-) B4 18LG LEFT REAR WHEEL SPEED SENSOR (+) LEFT SIDE MARKER LAMP (EXCEPT BUILT-UP-EXPORT) - GRAY 2 WAY...
  • Page 303 2001 JEEP WRANGLER 8Wa - 80 - 34 8W-80 CONNECTOR PINOUTS MULTI-FUNCTION SWITCH - GRAY 20 WAY CIRCUIT FUNCTION L50 18WT/TN BRAKE LAMP SWITCH OUTPUT L61 18GY LEFT TURN SIGNAL L5 20BK/GY FUSED IGNITION SWITCH OUTPUT (RUN-ACC) L63 18DG/RD LEFT TURN/STOP SIGNAL...
  • Page 304 2001 JEEP WRANGLER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 35 OXYGEN SENSOR 2/1 UPSTREAM (4.0L CALIFORNIA/EUROPEAN III) - 4 WAY CIRCUIT FUNCTION F142 18OR/DG OXYGEN SENSOR UPSTREAM HEATER RELAY OUT- K299 18BR/WT GROUND K4 20BK/LB SENSOR GROUND K241 18LG/RD OXYGEN SENSOR 2/1 SIGNAL OXYGEN SENSOR 2/2 DOWNSTREAM (4.0L CALIFORNIA/EUROPEAN III) - 4 WAY...
  • Page 305 2001 JEEP WRANGLER 8Wa - 80 - 36 8W-80 CONNECTOR PINOUTS PASSENGER DOOR AJAR SWITCH - BLACK 3 WAY CIRCUIT FUNCTION M23 20YL/BK DOOR AJAR SWITCH OUTPUT G76 20TN/YL DRIVER DOOR AJAR SWITCH SENSE POWER STEERING PRESSURE SWITCH (2.5L) - BLACK 2 WAY...
  • Page 306 2001 JEEP WRANGLER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 37 POWERTRAIN CONTROL MODULE C2 - WHITE 32 WAY CIRCUIT FUNCTION K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER K38 18GY (4.0L) FUEL INJECTOR NO. 5 DRIVER K15 18PK/BK (LHD 4.0L CALIFORNIA)
  • Page 307 2001 JEEP WRANGLER 8Wa - 80 - 38 8W-80 CONNECTOR PINOUTS POWERTRAIN CONTROL MODULE C3 - GRAY 32 WAY CIRCUIT FUNCTION V32 18YL/RD (SPEED CONTROL) SPEED CONTROL ON/OFF SWITCH SENSE A142 14DG/PK AUTOMATIC SHUT DOWN RELAY OUTPUT K107 18OR (CANADA)
  • Page 308 2001 JEEP WRANGLER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 39 RADIO CHOKE AND RELAY - BLACK 4 WAY CIRCUIT FUNCTION X60 16DG/RD FUSED B(+) X13 16BK/RD SUBWOOFER RELAY X16 20LG ANTENNA Z1 20BK GROUND REAR FOG LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY...
  • Page 309 2001 JEEP WRANGLER 8Wa - 80 - 40 8W-80 CONNECTOR PINOUTS REAR WIPER/WASHER SWITCH (HARD TOP) - WHITE 6 WAY CIRCUIT FUNCTION Z1 18BK/WT GROUND V20 18VT/OR REAR WASHER MOTOR CONTROL E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL V13 18BR/LG...
  • Page 310 2001 JEEP WRANGLER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 41 RIGHT FRONT TURN SIGNAL LAMP (BUILT-UP-EXPORT) - BLACK 3 WAY CIRCUIT FUNCTION L60 18TN RIGHT TURN SIGNAL Z1 18BK GROUND RIGHT FRONT WHEEL SPEED SENSOR - BLACK 2 WAY...
  • Page 311 2001 JEEP WRANGLER 8Wa - 80 - 42 8W-80 CONNECTOR PINOUTS RIGHT REAR LAMP ASSEMBLY (BUILT-UP-EXPORT) - BLACK 4 WAY CIRCUIT FUNCTION L62 18BR/RD RIGHT TURN/STOP SIGNAL L1 20BR/RD BACK-UP LAMP FEED L50 18WT/TN BRAKE LAMP SWITCH FEED L7 18BK/YL...
  • Page 312 2001 JEEP WRANGLER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 43 RIGHT SIDE REPEATER LAMP (BUILT-UP-EXPORT) - GRAY 2 WAY CIRCUIT FUNCTION L60 18TN RIGHT TURN SIGNAL Z1 18BK GROUND SEAT BELT SWITCH (RHD BUILT-UP-EXPORT) - BLACK 2 WAY CIRCUIT...
  • Page 313 2001 JEEP WRANGLER 8Wa - 80 - 44 8W-80 CONNECTOR PINOUTS SUBWOOFER - LT. GRAY 6 WAY CIRCUIT FUNCTION X51 18BR/YL LEFT REAR SPEAKER (+) X57 18BR/LB LEFT REAR SPEAKER (-) X13 16BK/RD SUBWOOFER RELAY POWER X52 18DB/WT RIGHT REAR SPEAKER (+)
  • Page 314 2001 JEEP WRANGLER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 45 UNDERHOOD LAMP - BLACK 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND M1 20PK/WT FUSED B(+) VEHICLE SPEED SENSOR - BLACK 3 WAY CIRCUIT FUNCTION K6 20VT/OR 5V SUPPLY K4 20BK/LB...
  • Page 315 2001 JEEP WRANGLER...
  • Page 316 2001 JEEP WRANGLER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 1 8W-90 CONNECTOR/GROUND LOCATIONS TABLE OF CONTENTS page CONNECTOR/GROUND LOCATIONS DESCRIPTION ......1 tor and ground index is provided.
  • Page 317 2001 JEEP WRANGLER 8Wa - 90 - 2 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. C110 Left Fender Side Shield 1, 3, 4 C154 Top Right Side of Transmission 20, 21, 22, 23, 24 C170 (LHD)

  • Page 318: Table Of Contents

    2001 JEEP WRANGLER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 3 CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Fuel Injector NO.4 At Injector 17, 18 Fuel Injector NO.5 At Injector Fuel Injector NO.6 At Injector Fuel Pump Module Above Fuel Tank...
  • Page 319 2001 JEEP WRANGLER 8Wa - 90 - 4 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Left Fog Lamp (Except At Lamp Built-Up-Export) Left Front Park/Turn Signal At Lamp Lamp (Except Built-Up- Export) Left Front Position Lamp...
  • Page 320 2001 JEEP WRANGLER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 5 CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Power Steering Pressure Near Power Steering Pump Switch (2.5L) Powertrain Control Module - Right Rear of Engine Compartment C1 (LHD) Powertrain Control Module -...
  • Page 321 2001 JEEP WRANGLER 8Wa - 90 - 6 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Right Rear Wheel Speed Near Vehicle Speed Sensor T/O Sensor Right Side Marker Lamp At Lamp (Except Built-Up-Export) Right Side Repeater Lamp...
  • Page 322 2001 JEEP WRANGLER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 7 CONNECTOR/GROUND LOCATIONS (Continued)
  • Page 323 2001 JEEP WRANGLER 8Wa - 90 - 8 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
  • Page 324 2001 JEEP WRANGLER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 9 CONNECTOR/GROUND LOCATIONS (Continued)
  • Page 325 2001 JEEP WRANGLER 8Wa - 90 - 10 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
  • Page 326 2001 JEEP WRANGLER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 11 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 5 POWERTRAIN CONTROL MODULE Fig. 6 FRONT WIPER MOTOR...
  • Page 327 2001 JEEP WRANGLER 8Wa - 90 - 12 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
  • Page 328 2001 JEEP WRANGLER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 13 CONNECTOR/GROUND LOCATIONS (Continued)
  • Page 329 2001 JEEP WRANGLER 8Wa - 90 - 14 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
  • Page 330 2001 JEEP WRANGLER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 15 CONNECTOR/GROUND LOCATIONS (Continued)
  • Page 331 2001 JEEP WRANGLER 8Wa - 90 - 16 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 11 RIGHT SIDE INSTRUMENT PANEL LHD...
  • Page 332 2001 JEEP WRANGLER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 17 CONNECTOR/GROUND LOCATIONS (Continued)
  • Page 333 2001 JEEP WRANGLER 8Wa - 90 - 18 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
  • Page 334 2001 JEEP WRANGLER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 19 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 14 LEFT COWL PANEL LHD...
  • Page 335 2001 JEEP WRANGLER 8Wa - 90 - 20 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
  • Page 336 2001 JEEP WRANGLER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 21 CONNECTOR/GROUND LOCATIONS (Continued)
  • Page 337 2001 JEEP WRANGLER 8Wa - 90 - 22 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
  • Page 338 2001 JEEP WRANGLER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 23 CONNECTOR/GROUND LOCATIONS (Continued)
  • Page 339 2001 JEEP WRANGLER 8Wa - 90 - 24 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 19 TRANSFER CASE Fig. 20 MANUAL TRANSMISSION BUX...
  • Page 340 2001 JEEP WRANGLER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 25 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 21 MANUAL TRANSMISSION Fig. 22 AUTOMATIC TRANSMISSION BUX...
  • Page 341 2001 JEEP WRANGLER 8Wa - 90 - 26 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 23 4.0 LITER ENGINE AND TRANSMISSION RHD Fig. 24 2.5 LITER ENGINE AND TRANSMISSION...
  • Page 342 2001 JEEP WRANGLER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 27 CONNECTOR/GROUND LOCATIONS (Continued)
  • Page 343 2001 JEEP WRANGLER 8Wa - 90 - 28 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 26 FUEL PUMP Fig. 27 REAR LAMPS BUX...
  • Page 344 2001 JEEP WRANGLER 8W-95 SPLICE LOCATIONS 8Wa - 95 - 1 8W-95 SPLICE LOCATIONS TABLE OF CONTENTS page SPLICE LOCATIONS DESCRIPTION ......1 index is provided.
  • Page 345 2001 JEEP WRANGLER 8Wa - 95 - 2 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued) Splice Number Location Fig. S137 Near T/O for Throttle Position Sensor S138 Middle of Radiator Closure Panel S140 Near T/O for C104 S141 Near T/O for Left Front Turn Signal Lamp...
  • Page 346 2001 JEEP WRANGLER 8W-95 SPLICE LOCATIONS 8Wa - 95 - 3 SPLICE LOCATIONS (Continued) Splice Number Location Fig. S336 (LHD) Near T/O for Airbag Control Module S336 (RHD) Near T/O for 100 way Connector S400 Near T/O for Rear Window Defogger Feed...
  • Page 347 2001 JEEP WRANGLER 8Wa - 95 - 4 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
  • Page 348 2001 JEEP WRANGLER 8W-95 SPLICE LOCATIONS 8Wa - 95 - 5 SPLICE LOCATIONS (Continued)
  • Page 349 2001 JEEP WRANGLER 8Wa - 95 - 6 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
  • Page 350 2001 JEEP WRANGLER 8W-95 SPLICE LOCATIONS 8Wa - 95 - 7 SPLICE LOCATIONS (Continued)
  • Page 351 2001 JEEP WRANGLER 8Wa - 95 - 8 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued) Fig. 5 2.5 LITER ENGINE REAR Fig. 6 4.0 LITER ENGINE REAR...
  • Page 352 2001 JEEP WRANGLER 8W-95 SPLICE LOCATIONS 8Wa - 95 - 9 SPLICE LOCATIONS (Continued) Fig. 7 4.0 LITER ENGINE Fig. 8 4.0 LITER ENGINE RIGHT SIDE...
  • Page 353 2001 JEEP WRANGLER 8Wa - 95 - 10 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued) Fig. 9 4.0 LITER ENGINE AND TRANSMISSION Fig. 10 2.5 LITER ENGINE...
  • Page 354 2001 JEEP WRANGLER 8W-95 SPLICE LOCATIONS 8Wa - 95 - 11 SPLICE LOCATIONS (Continued) Fig. 11 2.5 LITER ENGINE AND TRANSMISSION Fig. 12 INSTRUMENT PANEL LHD...
  • Page 355 2001 JEEP WRANGLER 8Wa - 95 - 12 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
  • Page 356 2001 JEEP WRANGLER 8W-95 SPLICE LOCATIONS 8Wa - 95 - 13 SPLICE LOCATIONS (Continued)
  • Page 357 2001 JEEP WRANGLER 8Wa - 95 - 14 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
  • Page 358 2001 JEEP WRANGLER 8W-95 SPLICE LOCATIONS 8Wa - 95 - 15 SPLICE LOCATIONS (Continued)
  • Page 359 2001 JEEP WRANGLER 8Wa - 95 - 16 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued) Fig. 17 REAR LAMPS...

  • Page 360: Specifications

    2001 JEEP WRANGLER FUEL SYSTEM 14s - 1 FUEL SYSTEM TABLE OF CONTENTS page page FUEL DELIVERY ......1 FUEL INJECTION .
  • Page 361 2001 JEEP WRANGLER 14s - 2 FUEL DELIVERY ROLLOVER VALVE DESCRIPTION The fuel tank is equipped with 2 rollover valves. The valves are located on the top of the fuel tank (Fig. 1) . Fig. 1 Rollover Valve Location 1 - FUEL PUMP MODULE...
  • Page 362 2001 JEEP WRANGLER FUEL INJECTION 14s - 3 FUEL INJECTION TABLE OF CONTENTS page page FUEL INJECTION O2 HEATER RELAY SPECIFICATIONS ......3 DESCRIPTION .

  • Page 363: Crankshaft Position Sensor

    2001 JEEP WRANGLER 14s - 4 FUEL INJECTION CRANKSHAFT POSITION SENSOR REMOVAL The crankshaft position (CKP) sensor is mounted to the transmission bellhousing at the left/rear side of the engine block. The sensor may be mounted to the transmission with one of the following three different configura- tions: •...
  • Page 364 2001 JEEP WRANGLER FUEL INJECTION 14s - 5 CRANKSHAFT POSITION SENSOR (Continued) OPERATION - PCM OUTPUT The nozzle ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.).
  • Page 365 2001 JEEP WRANGLER 14s - 6 FUEL INJECTION O2 HEATER RELAY Four wires (circuits) are used on each O2 sensor: a 12–volt feed circuit for the sensor heating element; a ground circuit for the heater element; a low-noise DESCRIPTION sensor return circuit to the PCM, and an input cir-...
  • Page 366 2001 JEEP WRANGLER FUEL INJECTION 14s - 7 O2 SENSOR (Continued) Downstream Sensor - Engine Equipped With convertor efficiency is not calculated with this pack- 2 Sensors: The downstream oxygen sensor (1/2) is age. also used to determine the correct air-fuel ratio. As...
  • Page 367 2001 JEEP WRANGLER...
  • Page 368 2001 JEEP WRANGLER TRANSMISSION/TRANSAXLE 21s - 1 TRANSMISSION/TRANSAXLE TABLE OF CONTENTS page page TRANSMISSION/TRANSAXLE AUTOMATIC - 30RH ..... . 77 DESCRIPTION .
  • Page 369 2001 JEEP WRANGLER 21s - 2 MANUAL-AX5 MANUAL-AX5 (5) Remove shift tower bolts and remove tower from transmission (Fig. 2). DISASSEMBLY ADAPTER/EXTENSION HOUSING (1) Drain transmission lubricant, if necessary. (2) Remove release bearing and lever. (3) Remove clutch housing bolts and remove hous- ing (Fig.
  • Page 370 2001 JEEP WRANGLER MANUAL-AX5 21s - 3 MANUAL-AX5 (Continued) (7) Remove detent ball plug (Fig. 4). Fig. 6 Detent Ball Fig. 4 Detent Ball Plug 1 - PENCIL MAGNET 1 - TORX BIT 2 - SHIFT DETENT BALL 2 - DETENT BALL PLUG (9) Remove shift arm retainer bolt (Fig.
  • Page 371 2001 JEEP WRANGLER 21s - 4 MANUAL-AX5 MANUAL-AX5 (Continued) (10) Remove shift arm restrictor pins (Fig. 8). (12) Remove shifter shaft with large magnet (Fig. 10). NOTE: Restrictor pins are not interchangeable, they (13) Remove shift arm from the adapter housing.
  • Page 372 2001 JEEP WRANGLER MANUAL-AX5 21s - 5 MANUAL-AX5 (Continued) (16) Remove adapter/extension housing (Fig. 12). (19) Remove bearing retainer from transmission case (Fig. 14). Fig. 12 Adapter/Extension Housing-Typical 1 - ADAPTER HOUSING Fig. 14 Front Bearing Retainer 2 - INTERMEDIATE PLATE...
  • Page 373 2001 JEEP WRANGLER 21s - 6 MANUAL-AX5 MANUAL-AX5 (Continued) (22) Separate intermediate plate and transmission case by tapping them loose with rawhide/rubber hammer (Fig. 16). Fig. 16 Intermediate Plate and Transmission Case 1 - INTERMEDIATE PLATE 2 - RUBBER HAMMER...
  • Page 374 2001 JEEP WRANGLER MANUAL-AX5 21s - 7 MANUAL-AX5 (Continued) (3) Remove bolt holding fifth gear shift fork to (5) Remove fifth gear synchro ring (Fig. 22). shift rail (Fig. 20). Fig. 22 Fifth Gear Synchro Ring 1 - FIFTH GEAR SYNCHRO RING (6) Remove countershaft fifth gear assembly from Fig.
  • Page 375 2001 JEEP WRANGLER 21s - 8 MANUAL-AX5 MANUAL-AX5 (Continued) (7) Remove fifth gear thrust ring from counter- (9) Remove bolt holding reverse idler gear shaft shaft (Fig. 24). lock plate to the intermediate plate. (10) Remove reverse idler gear shaft and reverse idler gear assembly (Fig.
  • Page 376 2001 JEEP WRANGLER MANUAL-AX5 21s - 9 MANUAL-AX5 (Continued) (12) Remove bolts holding 1-2 and 3-4 shift forks to the shift rails (Fig. 28) and discard bolts. Fig. 30 Output Shaft Rear Bearing Snap-ring 1 - OUTPUT SHAFT BEARING SNAP-RING 2 - COUNTERSHAFT BEARING SNAP-RING Fig.
  • Page 377 2001 JEEP WRANGLER 21s - 10 MANUAL-AX5 MANUAL-AX5 (Continued) Fig. 34 1-2 Shift Fork Fig. 32 Mainshaft 1 - 1-2 SHIFT FORK 1 - SHIFT FORKS 2 - 3-4 SHIFT RAIL 2 - MAINSHAFT 3 - 1-2 SHIFT RAIL (18) Remove 3-4 shift fork from the 3-4 shift rail NOTE: The bottom spring is shorter in length than (Fig.
  • Page 378 2001 JEEP WRANGLER MANUAL-AX5 21s - 11 MANUAL-AX5 (Continued) (22) Remove intermediate plate from the vise, (25) Remove reverse shift head and rail assembly rotate the plate 180°, and reinstall plate in the vise (Fig. 38). using the same bolt and washer mounting set-up.
  • Page 379 2001 JEEP WRANGLER 21s - 12 MANUAL-AX5 MANUAL-AX5 (Continued) (28) Remove interlock pin from reverse shift rail (32) Remove interlock pin from 1-2 shift rail (Fig. (Fig. 40). 42). Fig. 40 Reverse Interlock Pin 1 - REVERSE SHIFT RAIL Fig. 42 1-2 SHIFT RAIL...
  • Page 380 2001 JEEP WRANGLER MANUAL-AX5 21s - 13 MANUAL-AX5 (Continued) Fig. 44 Shift Rail Components 1 - 3-4 FORK 5 - FIFTH GEAR FORK 2 - 3-4 SHIFT RAIL 6 - FIFTH GEAR SHIFT RAIL 3 - 1-2 FORK 7 - 1-2 SHIFT RAIL...
  • Page 381 2001 JEEP WRANGLER 21s - 14 MANUAL-AX5 MANUAL-AX5 (Continued) (2) Install 1-2 elongated check ball into the inter- (5) Install snap-ring onto 3-4 shift rail. mediate plate (Fig. 45). (6) Install reverse check ball into the intermediate plate (Fig. 47).
  • Page 382 2001 JEEP WRANGLER MANUAL-AX5 21s - 15 MANUAL-AX5 (Continued) (8) Assemble reverse arm bracket to the reverse (10) Install snap-ring onto reverse shift rail (Fig. fork (Fig. 49). 51). Fig. 49 Reverse Arm Bracket And Fork Fig. 51 Reverse Snap-ring...
  • Page 383 2001 JEEP WRANGLER 21s - 16 MANUAL-AX5 MANUAL-AX5 (Continued) (13) Install fifth gear shift rail (Fig. 53). (19) Install snap-ring onto the 1-2 shift rail. (20) Install 3-4 shift fork onto the 3-4 shift rail (Fig. 55). Fig. 53 Fifth Gear Shift Rail...
  • Page 384 2001 JEEP WRANGLER MANUAL-AX5 21s - 17 MANUAL-AX5 (Continued) (27) Install new bolts to hold the shift forks to the shift rails (Fig. 56). Fig. 57 Reverse Shift Arm Position 1 - REVERSE SHIFT ARM 2 - INTERMEDIATE PLATE Fig. 56 Shift Fork Bolts...
  • Page 385 2001 JEEP WRANGLER 21s - 18 MANUAL-AX5 MANUAL-AX5 (Continued) (34) Align pin with the alignment notch in the (36) Install reverse idler gear shaft the remainder reverse idler gear assembly (Fig. 60). Alignment of the way through the reverse idler gear assembly.
  • Page 386 2001 JEEP WRANGLER MANUAL-AX5 21s - 19 MANUAL-AX5 (Continued) (41) Install fifth gear shift fork to the countershaft (2) Apply a 1/8 to 3/16 inch wide bead of Threeb- fifth gear assembly. Liquid Gasket TB1281. Make sure to keep (42) Install countershaft fifth gear bearings into sealer bead to inside of bolt holes (Fig.
  • Page 387 2001 JEEP WRANGLER 21s - 20 MANUAL-AX5 MANUAL-AX5 (Continued) (4) Install new front bearing snap rings (Fig. 67). Fig. 69 Speedometer Drive Gear 1 - SNAP RING 2 - LOCK BALL 3 - SNAP RING 4 - OUTPUT SHAFT GROOVES...
  • Page 388 2001 JEEP WRANGLER MANUAL-AX5 21s - 21 MANUAL-AX5 (Continued) (12) Rotate shifter arm shaft until the hole in the shift arm is aligned with the hole in the shaft. (13) Install shift arm retainer bolt and tighten to 38 N·m (28 ft. lbs.) (Fig. 73).
  • Page 389 2001 JEEP WRANGLER 21s - 22 MANUAL-AX5 MANUAL-AX5 (Continued) (15) Install shift restrictor pins in shift tower and (17) Install detent spring in case (Fig. 77). tighten to 27 N·m (20 ft. lbs.) (Fig. 75). CAUTION: Restrictor pins are not interchangeable and are color coded.
  • Page 390 2001 JEEP WRANGLER MANUAL-AX5 21s - 23 MANUAL-AX5 (Continued) (19) Install shift tower gasket onto shift tower. (23) Install new metal o-ring onto the backup (20) Install shift tower oil deflector and gasket lamp switch. onto the adapter or extension housing.
  • Page 391 2001 JEEP WRANGLER 21s - 24 MANUAL-AX5 MANUAL-AX5 (Continued) SPECIFICATIONS SPECIFICATIONS - MANUAL - AX5 TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Plugs, Access Bolts, Adapter Housing Switch, Back-up Light 32.5 Plugs, Drain and Fill 32.5 Bolts, Front Bearing...
  • Page 392 2001 JEEP WRANGLER MANUAL-AX5 21s - 25 MANUAL-AX5 (Continued) SPECIAL TOOLS TRANSMISSION Installer 8212 Dial Indicator C-3339 Installer 8208 Installer C-3995-A Splitter P-334 Handle C-4171 Installer 8109 Tube Driver L-4507 Installer 8211...

  • Page 393: Bearing Retainer

    2001 JEEP WRANGLER 21s - 26 MANUAL-AX5 MANUAL-AX5 (Continued) Adapter 6747-1A Installer MD-998805 BEARING RETAINER Fig. 81 Front Bearing Retainer Seal REMOVAL 1 - HANDLE (1) Remove release bearing and lever from the 2 - INSTALLER transmission. (2) Remove the bolts holding the front bearing retainer to the transmission case.
  • Page 394 2001 JEEP WRANGLER MANUAL-AX5 21s - 27 INPUT SHAFT (Continued) (3) Remove output shaft pilot bearing rollers from the input shaft and the output shaft. (4) Remove fourth gear synchronizer ring from the input shaft (Fig. 83). Fig. 83 Input Shaft Components...

  • Page 395: Output Shaft

    2001 JEEP WRANGLER 21s - 28 MANUAL-AX5 INPUT SHAFT (Continued) (5) Install output shaft pilot bearing rollers in input shaft bore (Fig. 85). Ensure to use sufficient petroleum jelly to hold rollers in position. Fig. 86 Output Shaft Gear Fig. 85 Install Output Shaft Pilot Bearing Rollers...
  • Page 396 2001 JEEP WRANGLER MANUAL-AX5 21s - 29 OUTPUT SHAFT (Continued) Fig. 90 Second Gear, Reverse Gear And 1-2 Fig. 88 Fifth Gear, First Gear Bearing And Race Synchronizer 1 - PRESS RAM 1 - PRESS RAM 2 - OUTPUT SHAFT...
  • Page 397 2001 JEEP WRANGLER 21s - 30 MANUAL-AX5 OUTPUT SHAFT (Continued) (11) With Bearing Splitter P-334 or press plates positioned under third gear, press the 3-4 synchro- nizer and third gear from output shaft (Fig. 92). Fig. 93 Geartrain Components 1 - SNAP RING 2 - FIFTH GEAR Fig.
  • Page 398 2001 JEEP WRANGLER MANUAL-AX5 21s - 31 OUTPUT SHAFT (Continued) Fig. 96 Third Gear 1 - FEELER GAUGE 2 - THIRD GEAR Fig. 94 Synchronizer Identification 1 - SLEEVES 2 - HUBS I.D. Mark Snap Ring Thickness mm (in.) 1.75-1.80 (0.0689-0.0709) 1.80-1.85 (0.0709-0.0728)
  • Page 399 2001 JEEP WRANGLER 21s - 32 MANUAL-AX5 OUTPUT SHAFT (Continued) (18) Install first gear needle bearing onto output (24) Check first-second gear thrust clearance (Fig. shaft (Fig. 98). 99). Standard clearance is 0.10 - 0.25 mm (0.004 - (19) Install first gear onto output shaft and over 0.010 in.).
  • Page 400 2001 JEEP WRANGLER MANUAL-AX5 21s - 33 OUTPUT SHAFT (Continued) I.D. Mark Snap Ring Thickness mm (in.) 2.67-2.72 (0.1051-0.1071) 2.73-2.78 (0.1075-0.1094) 2.79-2.84 (0.1098-0.1118) 2.85-2.90 (0.1122-0.1142) 2.91-2.96 (0.1146-0.1165) 2.97-3.02 (0.1169-0.1189) 3.03-3.08 (0.1193-0.1213) 3.09-3.14 (0.1217-0.1236) 3.15-3.20 (0.1240-0.1260) 3.21-3.26 (0.1264-0.1283) 3.27-3.32 (0.1287-0.1307) Fig. 100 Select/Install Fifth Gear Snap Ring...
  • Page 401 2001 JEEP WRANGLER 21s - 34 MANUAL-NV3550 MANUAL-NV3550 TABLE OF CONTENTS page page MANUAL-NV3550 OPERATION......74 REMOVAL .
  • Page 402 2001 JEEP WRANGLER MANUAL-NV3550 21s - 35 MANUAL-NV3550 (Continued) (27) Disconnect rear cushion and bracket from transmission. (28) Remove rear crossmember. (29) Remove clutch housing-to-engine bolts. (30) Pull transmission jack rearward until input shaft clears clutch. Then slide transmission out from under vehicle.
  • Page 403 2001 JEEP WRANGLER 21s - 36 MANUAL-NV3550 MANUAL-NV3550 (Continued) DISASSEMBLY (6) Remove shift shaft lock bolt (Fig. 7) located on top of the housing just forward of shift tower. FRONT HOUSING (1) Shift transmission into Neutral. (2) Remove drain plug and drain lubricant.
  • Page 404 2001 JEEP WRANGLER MANUAL-NV3550 21s - 37 MANUAL-NV3550 (Continued) Fig. 11 BEARING RETAINER 1 - PRY TOOL 2 - INPUT SHAFT BEARING RETAINER Fig. 9 PULL DETENT PLUG 1 - NUT 2 - REMOVER (8) Remove shift shaft detent plunger and spring (Fig.
  • Page 405 2001 JEEP WRANGLER 21s - 38 MANUAL-NV3550 MANUAL-NV3550 (Continued) (12) Remove bolts that attach front housing to rear housing (Fig. 14). Three bolts at extreme rear of housing are actually for the output shaft bearing retainer. It is not necessary to remove all three bolts at this time.
  • Page 406 2001 JEEP WRANGLER MANUAL-NV3550 21s - 39 MANUAL-NV3550 (Continued) (15) Remove screw from reverse blocker and remove blocker (Fig. 17) from case. Fig. 17 REVERSE BLOCKER 1 - REVERSE BLOCKER 2 - SHIFTER SHAFT BUSHING Fig. 18 GEARTRAIN AND SHIFT COMPONENT...
  • Page 407 2001 JEEP WRANGLER 21s - 40 MANUAL-NV3550 MANUAL-NV3550 (Continued) (2) With a hammer and punch drive out roll pin that secures shift bushing and lever to shift shaft (Fig. 20). NOTE: Use proper size punch to avoid bending the shift shaft.
  • Page 408 2001 JEEP WRANGLER MANUAL-NV3550 21s - 41 MANUAL-NV3550 (Continued) (7) Remove the reverse idler shaft support bolt (d) Stand geartrain and rear housing upright on (front bolt) (Fig. 25). fixture (Fig. 28). Have helper hold fixture tool in (8) Loosen rear reverse idler shaft bolt (rear bolt) place while housing and geartrain is being rotated (Fig.
  • Page 409 2001 JEEP WRANGLER 21s - 42 MANUAL-NV3550 MANUAL-NV3550 (Continued) REAR HOUSING - 2WD (1) On 2-wheel drive transmission, remove three bolts that attach output shaft bearing retainer to rear case (Fig. 29). Bolts are rear of shift tower open- ing.
  • Page 410 2001 JEEP WRANGLER MANUAL-NV3550 21s - 43 MANUAL-NV3550 (Continued) Fig. 32 COUNTERSHAFT REAR BEARING Fig. 34 REAR SEAL - 4WD 1 - COUNTERSHAFT REAR BEARING 1 - SLIDE HAMMER 2 - OUTPUT SHAFT 2 - REMOVER TOOL 3 - COUNTER SHAFT...
  • Page 411 2001 JEEP WRANGLER 21s - 44 MANUAL-NV3550 MANUAL-NV3550 (Continued) GEARTRAIN FROM FIXTURE (3) Lift rear adapter housing upward and off geartrain (Fig. 36). (1) Remove reverse idler gear assembly from assembly fixture cup. (2) Remove 1-2 and fifth-reverse forks from syn- chro sleeves.
  • Page 412 2001 JEEP WRANGLER MANUAL-NV3550 21s - 45 MANUAL-NV3550 (Continued) (4) Remove retaining ring that secures two-piece (6) Remove second gear and needle bearing (Fig. thrust washer on shaft (Fig. 39). Use a small pry tool 41). to remove retaining ring.
  • Page 413 2001 JEEP WRANGLER 21s - 46 MANUAL-NV3550 MANUAL-NV3550 (Continued) (10) Remove 1-2 synchro hub and sleeve and first gear from output shaft with press and Bearing Split- ter 1130 (Fig. 43). Position splitter between first and reverse gears. Fig. 45 OUTPUT SHAFT BEARING SNAP RING 1 - OUTPUT SHAFT BEARING Fig.
  • Page 414 2001 JEEP WRANGLER MANUAL-NV3550 21s - 47 MANUAL-NV3550 (Continued) (17) Remove fifth-reverse synchro hub and sleeve with a press (Fig. 49). Fig. 47 FIFTH GEAR NEEDLE BEARING 1 - FIFTH GEAR NEEDLE BEARING (SPREAD BEARING TO CLEAR SHOULDER ON SHAFT) (16) Remove fifth-reverse synchro hub snap ring (Fig.
  • Page 415 2001 JEEP WRANGLER 21s - 48 MANUAL-NV3550 MANUAL-NV3550 (Continued) Fig. 51 REVERSE IDLER COMPONENTS 1 - SNAP RING 6 - IDLER GEAR BEARING 2 - FLAT WASHER 7 - IDLER SHAFT 3 - WAVE WASHER 8 - THRUST WASHER 4 - THRUST WASHER...
  • Page 416 2001 JEEP WRANGLER MANUAL-NV3550 21s - 49 MANUAL-NV3550 (Continued) OUTPUT SHAFT Lubricate shaft, gears and bearings with recom- mended lubricant during assembly. Petroleum jelly can be used to hold parts in place. Check bearing surfaces of output shaft for nicks or scratches.
  • Page 417 2001 JEEP WRANGLER 21s - 50 MANUAL-NV3550 MANUAL-NV3550 (Continued) (6) Install new fifth-reverse hub snap ring (Fig. (8) Install fifth gear bearing, spreading bearing 57) and verify the snap ring is seated. only enough to clear shoulder on output shaft (Fig.
  • Page 418 2001 JEEP WRANGLER MANUAL-NV3550 21s - 51 MANUAL-NV3550 (Continued) (10) Invert output shaft and set the shaft in Cup 6310-1 so that fifth gear is seated on the tool (Fig. 61). (11) Install first gear bearing on output shaft (Fig.
  • Page 419 2001 JEEP WRANGLER 21s - 52 MANUAL-NV3550 MANUAL-NV3550 (Continued) (17) Install interm ring. (18) Install new 1-2 synchro hub snap ring (Fig. 66) and verfiy the snap ring is seated. NOTE: Snap rings are available in thicknesses from 1.80 mm to 2.00 mm (0.070 to 0.078 in.). Install thickest snap ring that will fit in shaft groove.
  • Page 420 2001 JEEP WRANGLER MANUAL-NV3550 21s - 53 MANUAL-NV3550 (Continued) (21) Install second gear needle bearing on shaft (23) Install two-piece thrust washer (Fig. 70). (Fig. 68). Ensure washer halves are seated in shaft groove and that washer lugs are seated in shaft lug bores. Verify i.d.
  • Page 421 2001 JEEP WRANGLER 21s - 54 MANUAL-NV3550 MANUAL-NV3550 (Continued) (24) Start retaining ring around two-piece thrust (26) Install third gear needle bearing on shaft (Fig. washer (Fig. 71). Ensure locating dimple is between 73). the thrust washer halves. Fig. 73 THIRD GEAR BEARING 1 - THIRD GEAR BEARING Fig.
  • Page 422 2001 JEEP WRANGLER MANUAL-NV3550 21s - 55 MANUAL-NV3550 (Continued) (28) Install third speed synchro ring on third gear (Fig. 75). Fig. 75 THIRD SPEED SYNCHRO RING 1 - THIRD SPEED SYNCHRO RING 2 - THIRD GEAR (29) Assemble 3-4 synchro hub, sleeve, springs, struts and detent balls.
  • Page 423 2001 JEEP WRANGLER 21s - 56 MANUAL-NV3550 MANUAL-NV3550 (Continued) (33) Install output shaft bearing. (34) Install output shaft bearing snap ring, spread- ing it just enough to install it (Fig. 79). Verify snap ring is seated in shaft groove. (35) Verify position of synchro sleeves before pro- ceeding with assembly operations (Fig.
  • Page 424 2001 JEEP WRANGLER MANUAL-NV3550 21s - 57 MANUAL-NV3550 (Continued) REVERSE IDLER ASSEMBLY (7) Install lock ball in dimple at front of shaft. Hold ball in place with petroleum jelly. (1) Lubricate idler components with gear lube. (8) Install front thrust washer on shaft and slide (2) Slide idler gear bearing on shaft (Fig.
  • Page 425 2001 JEEP WRANGLER 21s - 58 MANUAL-NV3550 MANUAL-NV3550 (Continued) (8) Attach a slide hammer or suitable puller to the bolt and remove the bearing. (9) Use the short end of Installer 8119 to install the new bearing. (10) The bearing is correctly installed if the bear- ing is flush with the transmission case.
  • Page 426 2001 JEEP WRANGLER MANUAL-NV3550 21s - 59 MANUAL-NV3550 (Continued) (4) Install fourth gear synchro ring on input shaft (6) Install assembled output shaft and geartrain in (Fig. 86). input shaft (Fig. 88). Carefully rotate output shaft until the 3-4 synchro ring seats in synchro hub and sleeve.
  • Page 427 2001 JEEP WRANGLER 21s - 60 MANUAL-NV3550 MANUAL-NV3550 (Continued) Fig. 90 REVERSE IDLER ASSEMBLY POSITION 1 - OUTPUT SHAFT AND GEARTRAIN 2 - COUNTERSHAFT 3 - REVERSE IDLER ASSEMBLY 4 - PEDESTAL Fig. 89 COUNTERSHAFT ON FIXTURE 1 - OUTPUT SHAFT AND GEARTRAIN...
  • Page 428 2001 JEEP WRANGLER MANUAL-NV3550 21s - 61 MANUAL-NV3550 (Continued) Fig. 92 1-2 AND FIFTH-REVERSE 1 - INSERT ARM THROUGH 1–2 FORK 2 - 1–2 FORK 3 - FIFTH-REVERSE FORK Fig. 94 REAR HOUSING DOWELS 1 - HOUSING ALIGNMENT DOWELS 2 - REAR HOUSING 3 - DOWEL FLUSH WITH SURFACE Fig.
  • Page 429 2001 JEEP WRANGLER 21s - 62 MANUAL-NV3550 MANUAL-NV3550 (Continued) CAUTION: Be sure the large diameter side of the roller retainer faces the countershaft and the small diameter side faces the race and housing (Fig. 96). (4) Apply extra petroleum jelly to hold counter- shaft rear bearing in place when housing is installed.
  • Page 430 2001 JEEP WRANGLER MANUAL-NV3550 21s - 63 MANUAL-NV3550 (Continued) (10) Start first two bolts in retainer (Fig. 99). It may be necessary to move retainer rearward (with pilot stud) in order to start bolts in retainer. (11) Remove Alignment Pin 8120 and install last retainer bolt (Fig.
  • Page 431 2001 JEEP WRANGLER 21s - 64 MANUAL-NV3550 MANUAL-NV3550 (Continued) (10) Lubricate lip of new rear seal (Fig. 102) with Mopar Door Ease or transmission fluid. (11) Install new rear seal in adapter housing bore with Installer C-3860-A. Verify seal is seated in hous- ing bore (Fig.
  • Page 432 2001 JEEP WRANGLER MANUAL-NV3550 21s - 65 MANUAL-NV3550 (Continued) Fig. 107 SHIFT SOCKET Fig. 105 LEVER AND BUSHING ASSENBLY 1 - SHIFT SOCKET 1 - SHIFT SHAFT 2 - SHIFT SHAFT 2 - SHAFT LEVER AND BUSHING 3 - 3–4 FORK Fig.
  • Page 433 2001 JEEP WRANGLER 21s - 66 MANUAL-NV3550 MANUAL-NV3550 (Continued) (11) Seat shaft lever roll pin with pin punch (Fig. (14) Seat roll pin in shift socket with pin punch. 110). Roll pin must be flush with socket (Fig. 112). CAUTION: The shaft lever roll pin must be flush with the surface of the lever.
  • Page 434 2001 JEEP WRANGLER MANUAL-NV3550 21s - 67 MANUAL-NV3550 (Continued) Fig. 113 INPUT SHAFT AND COUNTERSHAFT FRONT BEARING 1 - INPUT SHAFT BEARING 2 - COUNTERSHAFT FRONT BEARING 3 - SHIFT SHAFT BUSHING Fig. 115 SEAL FRONT/REAR HOUSINGS 1 - HOUSING FLANGE SURFACE...
  • Page 435 2001 JEEP WRANGLER 21s - 68 MANUAL-NV3550 MANUAL-NV3550 (Continued) Fig. 116 HOUSING BOLTS Fig. 118 SHIFT SHAFT DETENT PLUNGER 1 - HOUSING ATTACHING BOLTS (APPLY SEALER BEFOREHAND) 1 - FRONT HOUSING 2 - PLUG 3 - SPRING 4 - PLUNGER Fig.
  • Page 436 2001 JEEP WRANGLER MANUAL-NV3550 21s - 69 MANUAL-NV3550 (Continued) (19) Install new oil seal in front bearing retainer (21) Align and install front bearing retainer over with Installer 6448 (Fig. 121). input shaft and onto housing mounting surface (Fig. 123). Although retainer is one-way fit on housing, be sure bolt holes are aligned before seating retainer.
  • Page 437 2001 JEEP WRANGLER 21s - 70 MANUAL-NV3550 MANUAL-NV3550 (Continued) SHIFT TOWER AND LEVER INSTALLATION - TRANSMISSION (1) Apply petroleum jelly to ball end of shift lever (1) Install clutch housing on transmission and and interior of shift socket. tighten housing bolts to 46 N·m (34 ft. lbs.).
  • Page 438 2001 JEEP WRANGLER MANUAL-NV3550 21s - 71 MANUAL-NV3550 (Continued) (25) Align marks on front propeller shaft, axle and transfer case yokes, if equipped. (26) Install and tighten propeller shaft U-joint clamp bolts to 19 N·m (170 in. lbs.). (27) Install slave cylinder in clutch housing.
  • Page 439 2001 JEEP WRANGLER 21s - 72 MANUAL-NV3550 MANUAL-NV3550 (Continued) SPECIAL TOOLS NV3550 MANUAL TRANSMISSION Remover C-3985-B Handle C-4171 Installer C-3972-A Remover 8117 Remover Bushing 6957 Remover/Installer 6858 Installer Bushing 6951 Fixture 6747...
  • Page 440 2001 JEEP WRANGLER MANUAL-NV3550 21s - 73 MANUAL-NV3550 (Continued) Adapter 6747-1A Remover/Installer 8119 Adapter 6747-2B Pin Alignment 8120 Cup 8115 Installer C-3860-A Splitter Bearing 1130 Installer 8123 Tube 6310-1 Installer Bearing Cone 6448 Installer 8118...
  • Page 441 2001 JEEP WRANGLER 21s - 74 MANUAL-NV3550 VEHICLE SPEED SENSOR DESCRIPTION The 3-wire Vehicle Speed Sensor (VSS) is located on the speedometer pinion gear adapter. If equipped with 4WD, this adapter is located on the extension housing of the transfer case (drivers side). If equipped with 2WD, this adapter is located on the left side of the transmission extension housing.
  • Page 442 2001 JEEP WRANGLER MANUAL-NV3550 21s - 75 VEHICLE SPEED SENSOR (Continued) INSTALLATION (1) Clean inside speedometer pinion gear adapter before installing speed sensor. (2) Install sensor into speedometer gear adapter and install mounting bolt. Before tightening bolt, ver- ify speed sensor is fully seated (mounted flush) to speedometer pinion gear adapter.
  • Page 443 2001 JEEP WRANGLER 21s - 76 MANUAL-NV3550 EXTENSION HOUSING (Continued) INSTALLATION (1) Align bushing oil hole with oil slot in rear housing. (2) Tap bushing into place with Installer 6951 and Handle C-4171. (3) Install new oil seal in housing using Installer C-3972-A (Fig.
  • Page 444 2001 JEEP WRANGLER AUTOMATIC - 30RH 21s - 77 AUTOMATIC - 30RH TABLE OF CONTENTS page AUTOMATIC - 30RH DISASSEMBLY......77...
  • Page 445 2001 JEEP WRANGLER 21s - 78 AUTOMATIC - 30RH AUTOMATIC - 30RH (Continued) (d) Position the dial indicator plunger against a (17) Loosen front band adjusting screw until band flat spot on the oil pump and zero the dial indica- is completely loose (Fig.
  • Page 446 2001 JEEP WRANGLER AUTOMATIC - 30RH 21s - 79 AUTOMATIC - 30RH (Continued) (20) Lift front clutch off rear clutch (Fig. 9). Set clutch units aside for overhaul. Fig. 7 Front Band Strut 1 - BAND LEVER 2 - BAND STRUT...
  • Page 447 2001 JEEP WRANGLER 21s - 80 AUTOMATIC - 30RH AUTOMATIC - 30RH (Continued) (23) Remove front band from case (Fig. 11). (27) Loosen rear band adjusting screw 4-5 turns (24) Remove extension housing from transmission (Fig. 13). case. (28) Remove snap-ring that secures low-reverse...
  • Page 448 2001 JEEP WRANGLER AUTOMATIC - 30RH 21s - 81 AUTOMATIC - 30RH (Continued) Fig. 17 Rear Band and Link 1 - LINK 2 - REAR BAND Fig. 15 Rear Support 1 - OIL PAN FACE 2 - TRANSMISSION HOUSING 3 - REAR SUPPORT Fig.

  • Page 449: Table Of Contents

    2001 JEEP WRANGLER 21s - 82 AUTOMATIC - 30RH AUTOMATIC - 30RH (Continued) (37) Remove compressor tools and remove front servo rod guide, spring and servo piston. (38) Compress rear servo spring retainer about 1/16 in. with C-clamp and Tool C-4470 or SP-5560 (Fig.
  • Page 450 2001 JEEP WRANGLER AUTOMATIC - 32RH 21s - 83 AUTOMATIC - 32RH TABLE OF CONTENTS page page AUTOMATIC - 32RH DISASSEMBLY ......111 DESCRIPTION .
  • Page 451 2001 JEEP WRANGLER 21s - 84 AUTOMATIC - 32RH AUTOMATIC - 32RH (Continued) PARK POWERFLOW NEUTRAL POWERFLOW As the engine is running and the crankshaft is With the gear selector in the neutral position (Fig. rotating, the flexplate and torque converter, which...
  • Page 452 2001 JEEP WRANGLER AUTOMATIC - 32RH 21s - 85 AUTOMATIC - 32RH (Continued) REVERSE POWERFLOW ions is transferred to the rear annulus gear, which is splined to the output shaft. The output shaft in turn When the gear selector is moved into the reverse rotates with the annulus gear in a counterclockwise position (Fig.
  • Page 453 2001 JEEP WRANGLER 21s - 86 AUTOMATIC - 32RH AUTOMATIC - 32RH (Continued) FIRST GEAR POWERFLOW planets which rotate back in a clockwise direction. With the rear annulus gear stationary, the rear When the gearshift lever is moved into the drive planet rotation on the annulus gear causes the rear position the transmission goes into first gear (Fig.
  • Page 454 2001 JEEP WRANGLER AUTOMATIC - 32RH 21s - 87 AUTOMATIC - 32RH (Continued) SECOND GEAR POWERFLOW Now that the front band is holding the sun gear sta- tionary, the annulus rotation causes the front planets In drive-second (Fig. 5), the same elements are to rotate in a clockwise direction.
  • Page 455 2001 JEEP WRANGLER 21s - 88 AUTOMATIC - 32RH AUTOMATIC - 32RH (Continued) DIRECT DRIVE POWERFLOW annulus gear. If two members of the same planetary set are driven, direct drive results. Therefore, when The vehicle has accelerated and reached the shift two members are rotating at the same speed and in point for the 2-3 upshift into direct drive (Fig.
  • Page 456 2001 JEEP WRANGLER AUTOMATIC - 32RH 21s - 89 AUTOMATIC - 32RH (Continued) DIAGNOSIS AND TESTING - PRELIMINARY Two basic procedures are required. One procedure for vehicles that are drivable and an alternate proce- dure for disabled vehicles (will not back up or move forward).
  • Page 457 2001 JEEP WRANGLER 21s - 90 AUTOMATIC - 32RH AUTOMATIC - 32RH (Continued) (12) Remove front band reaction pin access plug (Fig. 11). Plug is accessible through converter hous- ing. Use 1/4 inch drive extension to remove plug as shown.
  • Page 458 2001 JEEP WRANGLER AUTOMATIC - 32RH 21s - 91 AUTOMATIC - 32RH (Continued) (18) Squeeze front band together and remove band strut (Fig. 14). (19) Remove front band reaction pin with pencil magnet. Pin is accessible from converter housing side of case (Fig.
  • Page 459 2001 JEEP WRANGLER 21s - 92 AUTOMATIC - 32RH AUTOMATIC - 32RH (Continued) (21) Slide front band rearward and onto driving shell. Band will not be removed until after front/rear clutch removal. (22) Remove front and rear clutch units as assem- bly.
  • Page 460 2001 JEEP WRANGLER AUTOMATIC - 32RH 21s - 93 AUTOMATIC - 32RH (Continued) (34) Remove rear support bolts and remove sup- port from low-reverse drum and case (Fig. 26). Keep rear support bolts together for assembly reference. (35) Remove bolts attaching overrunning clutch cam to case (Fig.
  • Page 461 2001 JEEP WRANGLER 21s - 94 AUTOMATIC - 32RH AUTOMATIC - 32RH (Continued) Fig. 26 Rear Support 1 - OIL PAN FACE 2 - TRANSMISSION HOUSING 3 - REAR SUPPORT Fig. 24 Rear Band Pivot And Reaction Pins 1 - PARALLEL JAW SNAP-RING PLIERS 2 - REAR BAND PIVOT AND REACTION PINS Fig.
  • Page 462 2001 JEEP WRANGLER AUTOMATIC - 32RH 21s - 95 AUTOMATIC - 32RH (Continued) OVERRUNNING CLUTCH (36) Remove low-reverse drum and overrunning clutch as assembly. Slide drum and clutch through (1) Examine bolt holes in overrunning clutch cam. rear band and out of case. Set drum and clutch Note that one hole is not threaded (Fig.
  • Page 463 2001 JEEP WRANGLER 21s - 96 AUTOMATIC - 32RH AUTOMATIC - 32RH (Continued) Fig. 32 Rear Band Components Fig. 30 Location Of Blank Area In Clutch Cam Seat 1 - ADJUSTING SCREW Of Case 2 - LOCKNUT 1 - CLUTCH CAM SEAT (IN CASE)
  • Page 464 2001 JEEP WRANGLER AUTOMATIC - 32RH 21s - 97 AUTOMATIC - 32RH (Continued) REAR SUPPORT AND LOW-REVERSE DRUM (1) Hold low-reverse drum in position and install rear support (Fig. 36). (2) Align support with punch marks made during disassembly. (3) Install and tighten rear support bolts to 17 N·m (150 in.
  • Page 465 2001 JEEP WRANGLER 21s - 98 AUTOMATIC - 32RH AUTOMATIC - 32RH (Continued) PLANETARY GEARTRAIN AND OUTPUT SHAFT GOVERNOR AND PARK GEAR (1) Lubricate output shaft, rear support bore and (1) Lubricate governor components and park gear low-reverse drum hub with transmission fluid.
  • Page 466 2001 JEEP WRANGLER AUTOMATIC - 32RH 21s - 99 AUTOMATIC - 32RH (Continued) Fig. 40 Governor Valve And Output Shaft Spotface Fig. 42 Governor Valve And Shaft Alignment 1 - E-CLIP (2 REQ’D) 1 - OUTPUT SHAFT 2 - GOVERNOR VALVE SHAFT...
  • Page 467 2001 JEEP WRANGLER 21s - 100 AUTOMATIC - 32RH AUTOMATIC - 32RH (Continued) Fig. 45 Output Shaft Thrust Plate 1 - OUTPUT SHAFT HUB 2 - OUTPUT SHAFT THRUST PLATE Fig. 44 Governor Body/Park Gear Retaining Snap-Rings And Thrust Washer Position...
  • Page 468 2001 JEEP WRANGLER AUTOMATIC - 32RH 21s - 101 AUTOMATIC - 32RH (Continued) (9) Carefully work assembled clutches back and forth to engage and seat rear clutch discs on front annulus gear. Verify that front clutch drive lugs are fully engaged in slots of driving shell after installa- tion.
  • Page 469 2001 JEEP WRANGLER 21s - 102 AUTOMATIC - 32RH AUTOMATIC - 32RH (Continued) Fig. 52 Installing Front Band Pivot Pin Access Plug 1 - 1/4'' DRIVE EXTENSION 2 - FRONT BAND REACTION PIN ACCESS PLUG Fig. 50 Installing Front Band And Reaction Pin...
  • Page 470 2001 JEEP WRANGLER AUTOMATIC - 32RH 21s - 103 AUTOMATIC - 32RH (Continued) (8) Thread two Pilot Stud Tools C-3288-B into bolt holes in oil pump flange (Fig. 55). (9) Align and install oil pump gasket (Fig. 55). (10) Lubricate oil pump seals with Mopar Door- Ease, or Ru-Glyde, Door Eze, or ATF Plus 4.
  • Page 471 2001 JEEP WRANGLER 21s - 104 AUTOMATIC - 32RH AUTOMATIC - 32RH (Continued) (9) Install and tighten valve body-to-case bolts alternately and evenly to 12 N·m (105 in. lbs.) torque. Start at center and work outward when tight- ening bolts. Do not overtighten valve body bolts.
  • Page 472 2001 JEEP WRANGLER AUTOMATIC - 32RH 21s - 105 AUTOMATIC - 32RH (Continued) (2) Position new extension housing gasket on transmission case. Use petroleum jelly to hold gasket in place. (3) Install new rear seal in extension housing if required.
  • Page 473 2001 JEEP WRANGLER 21s - 106 AUTOMATIC - 32RH AUTOMATIC - 32RH (Continued) THRUST WASHER/SPACER/SNAP-RING DIMENSIONS COMPONENT METRIC INCH Front clutch thrust washer (reaction shaft support hub) 1.55 mm 0.061 in. Rear clutch thrust washer (clutch retainer) 1.55 mm 0.061 in.
  • Page 474 2001 JEEP WRANGLER AUTOMATIC - 32RH 21s - 107 AUTOMATIC - 32RH (Continued) TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Bolt/nut, crossmember Bolt, driveplate to crankshaft Plug, front band reaction Locknut, front band adj. Switch, park/neutral Bolt, fluid pan...
  • Page 475 2001 JEEP WRANGLER 21s - 108 AUTOMATIC - 32RH BANDS (Continued) Fig. 62 Front Band Adjusting Screw Lock Nut 1 - LOCK-NUT 2 - FRONT BAND ADJUSTER ADJUSTMENTS - REAR BAND The transmission oil pan must be removed for access to the rear band adjusting screw.
  • Page 476 2001 JEEP WRANGLER AUTOMATIC - 32RH 21s - 109 FLUID AND FILTER (Continued) ers as well. The torque converter should also be (b) Correct maximum level is to MAX arrow replaced whenever a failure generates sludge and mark. debris. This is necessary because normal converter (c) Incorrect level is at or below MIN line.

  • Page 477: Maintenance

    2001 JEEP WRANGLER 21s - 110 AUTOMATIC - 32RH FLUID AND FILTER (Continued) CAUTION: Do not overfill transmission, fluid foam- ing and shifting problems can result. (9) Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube.
  • Page 478 2001 JEEP WRANGLER AUTOMATIC - 32RH 21s - 111 DISASSEMBLY FRONT CLUTCH (1) Remove waved snap-ring and remove pressure OPERATION plate, clutch plates and clutch discs (Fig. 67). (2) Compress clutch piston spring with Compressor To apply the clutch, pressure is applied between Tool C-3575-A (Fig.
  • Page 479 2001 JEEP WRANGLER 21s - 112 AUTOMATIC - 32RH FRONT CLUTCH (Continued) Fig. 67 Front Clutch Components - Typical 1 - SNAP-RING (WAVE) 7 - SEAL 2 - REACTION PLATE 8 - PISTON 3 - CLUTCH DISC 9 - SPRING...
  • Page 480 2001 JEEP WRANGLER AUTOMATIC - 32RH 21s - 113 FRONT CLUTCH (Continued) Fig. 70 Clutch Piston Spring Installation 1 - RETAINER 2 - CLUTCH SPRING 3 - PISTON Clearance should be 1.70 to 3.40 mm (0.067 to 0.134 in.). If clearance is incorrect, clutch discs, plates, pressure plates and snap ring may have to be Fig.
  • Page 481 2001 JEEP WRANGLER 21s - 114 AUTOMATIC - 32RH GEAR SHIFT CABLE (Continued) (8) Install any floor console components removed previously. (Refer to 23 - BODY/INTERIOR/FLOOR CONSOLE - INSTALLATION) ADJUSTMENT - GEARSHIFT CABLE Check adjustment by starting the engine in PARK and NEUTRAL.
  • Page 482 2001 JEEP WRANGLER AUTOMATIC - 32RH 21s - 115 GOVERNOR AND PARK GEAR (Continued) Fig. 75 Intermediate and Inner Governor Weights 1 - INTERMEDIATE WEIGHT Fig. 73 Snap-Ring, Washer, and Outer Weight 2 - INNER WEIGHT 3 - SNAP-RING 1 - SNAP-RING...
  • Page 483 2001 JEEP WRANGLER 21s - 116 AUTOMATIC - 32RH PARK/NEUTRAL POSITION REAR SERVO SWITCH DISASSEMBLY (1) Remove small snap-ring and remove plug and DESCRIPTION spring from servo piston (Fig. 77). The park/neutral position switch (Fig. 76) is (2) Remove and discard servo piston seal ring.
  • Page 484 2001 JEEP WRANGLER AUTOMATIC - 32RH 21s - 117 ADJUSTMENT VERIFICATION SHIFT MECHANISM (1) Turn ignition key to OFF position. (2) Remove air cleaner. DESCRIPTION (3) Verify that lever on throttle body is at curb idle The shift mechanism is cable operated and pro- position (Fig.
  • Page 485 2001 JEEP WRANGLER 21s - 118 AUTOMATIC - 32RH THROTTLE VALVE CABLE (Continued) (3) Disconnect cable end from attachment stud. Carefully slide cable off stud. Do not pry or pull cable off. (4) Verify that transmission throttle lever is in fully closed position.
  • Page 486 2001 JEEP WRANGLER TRANSFER CASE-NV231 21s - 119 TRANSFER CASE-NV231 TABLE OF CONTENTS page page TRANSFER CASE-NV231 SPEED SENSOR DISASSEMBLY ......119 REMOVAL .
  • Page 487 2001 JEEP WRANGLER 21s - 120 TRANSFER CASE-NV231 TRANSFER CASE-NV231 (Continued) (12) Disengage oil pickup tube from oil pump and remove oil pump assembly. Remove oil pump by tilt- ing the edge of the oil pump from under the edge of the rear case half and sliding the pump (Fig.
  • Page 488 2001 JEEP WRANGLER TRANSFER CASE-NV231 21s - 121 TRANSFER CASE-NV231 (Continued) YOKE AND RANGE LEVER (5) Remove nut and washer that attach range lever to sector shaft. Then move sector to neutral (1) Remove transfer case indicator switch. position and remove range lever from shaft (Fig. 9).
  • Page 489 2001 JEEP WRANGLER 21s - 122 TRANSFER CASE-NV231 TRANSFER CASE-NV231 (Continued) Fig. 13 Mode Fork Spring Removal Fig. 11 Loosening Rear Case 1 - MODE SPRING 1 - REAR CASE 2 - PRY TOOL (IN CASE SLOT) 3 - FRONT CASE (5) Remove oil pickup tube from rear case (Fig.
  • Page 490 2001 JEEP WRANGLER TRANSFER CASE-NV231 21s - 123 TRANSFER CASE-NV231 (Continued) SHIFT FORKS AND MAINSHAFT (1) Remove detent plug, O-ring, detent spring and detent plunger (Fig. 15). (2) Remove mainshaft from mode sleeve and input gear pilot bearing. Fig. 17 Range Fork And Hub Removal...
  • Page 491 2001 JEEP WRANGLER 21s - 124 TRANSFER CASE-NV231 TRANSFER CASE-NV231 (Continued) Fig. 21 Mode Hub Removal Fig. 19 Sector Bushing And O-Ring Removal 1 - MAINSHAFT 1 - SEAL RETAINER 2 - MODE HUB 2 - SECTOR SHAFT BORE 3 - O-RING SEAL...
  • Page 492 2001 JEEP WRANGLER TRANSFER CASE-NV231 21s - 125 TRANSFER CASE-NV231 (Continued) INPUT GEAR AND LOW RANGE GEAR (3) Remove front bearing retainer seal. Tap seal out with drift and hammer. (1) Remove front bearing retainer attaching bolts (4) Remove input gear retaining ring with heavy (Fig.
  • Page 493 2001 JEEP WRANGLER 21s - 126 TRANSFER CASE-NV231 TRANSFER CASE-NV231 (Continued) INPUT AND LOW RANGE GEAR (1) Remove snap-ring that retains input gear in low range gear (Fig. 27). (2) Remove retainer (Fig. 28). (3) Remove front tabbed thrust washer (Fig. 29).
  • Page 494 2001 JEEP WRANGLER TRANSFER CASE-NV231 21s - 127 TRANSFER CASE-NV231 (Continued) Fig. 31 Rear Tabbed Thrust Washer Removal 1 - LOW RANGE GEAR Fig. 33 Front Output Shaft Bearing Retaining Ring 2 - REAR TABBED THRUST WASHER Removal 1 - SCREWDRIVERS...
  • Page 495 2001 JEEP WRANGLER 21s - 128 TRANSFER CASE-NV231 TRANSFER CASE-NV231 (Continued) Fig. 35 Front Output Shaft Bearing Installation Fig. 37 Front Output Seal Installation 1 - SPECIAL TOOL C-4171 1 - INSTALLER 8143-A 2 - SPECIAL TOOL 5064 2 - TRANSFER CASE...
  • Page 496 2001 JEEP WRANGLER TRANSFER CASE-NV231 21s - 129 TRANSFER CASE-NV231 (Continued) Fig. 41 Input Shaft Bearing Removal 1 - SPECIAL TOOL C-4171 2 - SPECIAL TOOL C-4210 (12) Using Remover C-4210 and Handle C-4171, drive input shaft bearing into case. The bearing Fig.
  • Page 497 2001 JEEP WRANGLER 21s - 130 TRANSFER CASE-NV231 TRANSFER CASE-NV231 (Continued) (13) Remove input gear pilot bearing by inserting a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer (Fig.
  • Page 498 2001 JEEP WRANGLER TRANSFER CASE-NV231 21s - 131 TRANSFER CASE-NV231 (Continued) Fig. 46 Oil Pump Seal Installation 1 - HOUSING SEAL 2 - SPECIAL TOOL 7888 3 - OIL PUMP FEED HOUSING Fig. 48 Input/Low Range Gear Components 1 - SNAP-RING...
  • Page 499 2001 JEEP WRANGLER 21s - 132 TRANSFER CASE-NV231 TRANSFER CASE-NV231 (Continued) MAINSHAFT (1) Lubricate mainshaft splines with recommended transmission fluid. (2) Slide drive sprocket onto mainshaft. (3) Slide mode hub onto mainshaft. (4) Install mode hub retaining ring. Verify that the retaining ring is fully seated in mainshaft groove.
  • Page 500 2001 JEEP WRANGLER TRANSFER CASE-NV231 21s - 133 TRANSFER CASE-NV231 (Continued) Fig. 56 Mainshaft Assembly Installation 1 - DRIVE SPROCKET 2 - MODE HUB 3 - MAINSHAFT Fig. 53 Shift Sector Installation 1 - SHIFT SECTOR Fig. 54 Range Lever Installation Fig.
  • Page 501 2001 JEEP WRANGLER 21s - 134 TRANSFER CASE-NV231 TRANSFER CASE-NV231 (Continued) Fig. 58 Mode Fork And Sleeve Installation 1 - MODE SLEEVE 2 - MODE FORK AND RAIL Fig. 60 Installing Drive Chain And Front Output Shaft 1 - FRONT OUTPUT SHAFT...
  • Page 502 2001 JEEP WRANGLER TRANSFER CASE-NV231 21s - 135 TRANSFER CASE-NV231 (Continued) OIL PUMP AND REAR CASE (1) Install magnet in front case pocket (Fig. 62). (2) Assemble oil pickup screen, connecting hose, and tube. (3) Install new pickup tube O-ring in oil pump (Fig.
  • Page 503 2001 JEEP WRANGLER 21s - 136 TRANSFER CASE-NV231 TRANSFER CASE-NV231 (Continued) Fig. 68 Yoke Seal Washer Installation 1 - YOKE SEAL WASHER REAR RETAINER (1) Apply bead of Mopar Sealer P/N 82300234, or Fig. 66 Range Lever Installation Loctite™ Ultra Gray, to mating surface of rear retainer.
  • Page 504 2001 JEEP WRANGLER TRANSFER CASE-NV231 21s - 137 TRANSFER CASE-NV231 (Continued) Fig. 70 Rear Seal Installation Fig. 71 Position Damper on Output Shaft 1 - SPECIAL TOOL C-4076-B 2 - SPECIAL TOOL MD-998323 1 - Transfer Case 3 - TRANSFER CASE...

  • Page 505: Speed Sensor

    2001 JEEP WRANGLER 21s - 138 TRANSFER CASE-NV231 TRANSFER CASE-NV231 (Continued) SPEED SENSOR REMOVAL The Vehicle Speed Sensor (VSS) is located on the speedometer pinion gear adapter. If equipped with 4WD, this adapter is located on the transfer case extension (left side) (Fig. 75). If equipped with 2WD, this adapter is located on the extension housing of the transmission (left side).
  • Page 506 2001 JEEP WRANGLER TRANSFER CASE-NV231 21s - 139 SPEED SENSOR (Continued) INSTALLATION (1) Clean inside speedometer pinion gear adapter before installing speed sensor. (2) Install sensor into speedometer gear adapter and install mounting bolt. Before tightening bolt, ver- ify speed sensor is fully seated (mounted flush) to speedometer pinion gear adapter.
  • Page 507 SERVICE MANUAL COMMENTS What features do you find most useful? ______________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ What errors have you found? Please include page number. ___________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ What topics are hard to locate, confusing, or not covered completely? ________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________...
  • Page 508 DaimlerChrysler International Operations Attn. Publications Dept. CIMS 486-02-70 800 Chrysler Drive Auburn Hills, MI 48326-2757...

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