Jeep Cherokee XJ 1995 Service & Repair Manual (P/N 81-370-5146)

• Coverage and document set: 2,295 PDF pages total—one 2,183-page compiled service-manual file for the 1995 Jeep Cherokee XJ and Wrangler YJ, plus a separate 112-page ATSG Jeep AW-4 service booklet. Included Chrysler revision pages identify Publication No. 81-370-5146.
• Engine and fuel-system repair: Covers XJ/YJ removal and installation of the 2.5L and 4.0L engines, internal cylinder-head, valve-train, timing, camshaft, lubrication, piston, crankshaft, bearing, rear-main-seal, and cylinder-block work, plus MFI/PCM and OBD coverage, fuel-pressure testing, injector, sensor, and relay checks, and DTC access and descriptions.
• Transmission and transfer-case service: Documents AX-4/AX-5 and AX-15 manual transmission overhaul; 30RH/32RH and AW-4 automatic diagnosis, operational testing, valve-body and clutch repair, adjustment, removal, reassembly, and cooler service; and NP231/NP242 transfer-case overhaul.
• Axles, suspension, and driveline: Details XJ coil-spring and YJ leaf-spring front suspension, Model 30 and 2WD front axles, Model 35 and Chrysler 8¼ rear axles, Trac-Lok service, differential and pinion setup, hub and axle-shaft repair, and single- and double-Cardan propeller-shaft work.
• Brake, steering, cooling, and HVAC procedures: Breaks down ABS and non-ABS service, HCU/ECU and wheel-sensor work, brake bleeding, steering-pump pressure tests and gear overhaul, cooling-system diagnosis, and refrigerant recovery, evacuation, leak testing, and A/C component replacement.
• Dedicated XJ and YJ electrical documentation: Includes Power Distribution, Ground Distribution, 2.5L/4.0L Fuel/Ignition, Transmission Controls, Anti-Lock Brakes, and Connector Pin-Outs, supported by circuit-testing, connector-location, splice-location, and wiring-repair information.
• Specifications and service tools: Supplies component-specific torque tables, fluid-capacity and lubricant data, pressure-test specifications, clearances, wear limits, adjustment data, and tool callouts including differential Spreader W-129-B, 8¼ axle Gauge Set 6575, AW-4 Tool Kit 6294, and Pressure Test Port Adapter 7554.

Model and Configuration Coverage

This set is for the 1995 Cherokee XJ and Wrangler YJ; it is not a Grand Cherokee ZJ manual. Identification and code-plate information helps match the engine, transmission, transfer case, axle, and vehicle-specific section before repair begins. The procedures distinguish XJ and YJ suspension layouts, linkages, steering columns, propeller shafts, wiring, cooling equipment, and body hardware rather than treating the platforms as interchangeable.

The 2.5L and 4.0L chapters are full repair sections, not maintenance summaries. They cover engine assembly removal and installation, cylinder-head and valve service, valve timing, timing-chain and sprocket work, camshaft and bearing service, oil-pressure diagnosis and oil-pump repair, piston and connecting-rod inspection, crankshaft and main-bearing fitting, rear-main-seal replacement, block disassembly, bore inspection and honing, and assembly specifications. Fuel-system material adds pump, module, tank, line, and injector service; pressure, capacity, and leak-down tests; PCM inputs and outputs; OBD access; sensor and relay checks; and DTC descriptions.

Drivetrain Diagnosis and Overhaul

The manual transmission chapters take the AX-4/AX-5 and AX-15 through gear-train and case disassembly, shaft and bearing service, synchronizer inspection, shift-rail and fork work, reassembly, and adjustment. Automatic coverage includes road, hydraulic-pressure, stall, air-pressure, and time-lag testing as applicable; cable, linkage, and band adjustments; cooler-flow testing and reverse flushing; valve-body service; torque-converter removal; internal clutch, brake, servo, planetary, pump, governor, and park-lock repair; and full assembly. NP231 and NP242 chapters cover diagnosis, removal, overhaul, and installation.

The separate ATSG AW-4 booklet adds TCU, sensor, neutral-safety-switch, and solenoid diagnosis, manual-shifting checks, troubleshooting flowcharts, transmission and torque-converter removal, subassembly overhaul, valve-body teardown, and final assembly. It is an ATSG service publication, not a second Chrysler factory manual.

Chassis, Electrical, and Body Work

Axle repair goes through final setup. The Model 30 front-axle material includes YJ vacuum-disconnect diagnosis, shift-motor work, hub bearings, axle shafts, Cardan joints, steering knuckles, ball studs, inner seals, differential removal, pinion-depth selection, preload and backlash adjustment, and tooth-contact checks. Rear coverage includes Model 35 and Chrysler 8¼ axle shafts, bearings, seals, differentials, pinion service, and Trac-Lok limited-slip repair. Suspension chapters cover control arms, track bars, bushings, springs, shocks, ride height, and alignment for the differing XJ and YJ layouts.

Brake coverage includes front-disc/rear-drum repair, master-cylinder and booster work, parking brakes, bleeding, and optional all-wheel ABS hardware. Steering ranges from pump-pressure diagnosis to recirculating-ball gear overhaul and adjustment, manual steering-gear service, XJ/YJ columns, and right-hand-drive configurations. Cooling and HVAC sections cover system testing and flushing; radiator, pump, thermostat, fan, and transmission-cooler service; and refrigerant recovery, evacuation, charging, pressure diagnosis, compressor/clutch, heater-core, evaporator, expansion-valve, and control work.

Separate XJ and YJ wiring blocks provide system schematics, connector pin-outs, connector and splice locations, ground and power distribution, and circuit-specific fault tracing for engine and transmission controls, ABS, HVAC, instruments, lighting, wipers, power accessories, restraints, and speed control. The electrical introduction covers voltage, continuity, short-to-ground, and voltage-drop testing, plus terminal, connector, diode, and harness repair.

Body and structural sections include frame dimensions and straightening, bumpers, tow hooks and skid plates, XJ doors, regulators, liftgate and stationary glass, and YJ hard top, soft top, sport bar, tailgate, full and half doors, windshield frame, and glass. Lubrication schedules, wheel and tire service, vibration diagnosis, exhaust and intake repair, emissions controls, and a rear alphabetical index are also included.

Repair Cautions and Scope

The axle chapters warn that over-spreading a differential housing can permanently distort or damage it. A collapsible pinion-preload spacer cannot be corrected by backing off the nut after preload has been exceeded; the repair calls for a new spacer. During AW-4 assembly, forcing the oil pump into the case can damage the stator-shaft seal rings if they bind in the direct-clutch drum.

Brake, airbag, refrigerant, and heavy drivetrain work should be performed with the vehicle properly supported and the manual's isolation, lifting, pressure-release, and refrigerant-handling precautions followed.

The set contains OBD access, DTC descriptions, component tests, wiring, and DRB references, but several DRB-guided fault trees direct the technician to separate Powertrain Diagnostic Procedures or chassis/body diagnostic manuals. Those companion diagnostic books are not part of this two-PDF set. The main foreword also assigns theory of operation and equipment use to separate service-training and owner's-manual material.