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

The factory manual covers vehicle-wide service and repair. The ATSG booklet adds focused AW-4 troubleshooting charts and illustrated subassembly work for applicable transmission configurations.

Application limits: The ATSG booklet also describes Power/Comfort shift controls and four-cylinder transmission specifications; its applications should not be treated as identical to the factory manual’s 1995 coverage. Full DRB operation and some PCM/ABS diagnostic procedures require separate Powertrain or chassis/body diagnostic publications, which are not included. Operating instructions and theory of operation belong to separate owner and training material.

PDF Search, Bookmarks, and Diagram Detail

Text search and diagram viewing: The factory PDF is partially searchable and has embedded bookmarks covering its service groups and many individual topics. Numerous wiring sheets lack searchable circuit text. The ATSG PDF has neither usable text search nor embedded bookmarks. Small wiring and connector labels in the factory file, and dense chart labels in the ATSG booklet, are best read with zoom.

The ZIP contains two printable PDFs totaling 2,295 pages, including the main file’s added cover and tab locator (2 pages), 55 blank separator pages, and 13 revised wiring/body pages.

Engine Overhaul, Drivetrain Service, and Electrical Diagnosis

The following selected coverage highlights outline major workshop tasks rather than the complete contents. Other topics include propeller-shaft service and emission-control checks.

• Engine repair: Compression and leakage diagnosis, engine removal and installation, cylinder-head and valvetrain service, timing-chain and camshaft work, oil-pump inspection, and piston, connecting-rod, crankshaft, and main-bearing repair.

• Transmission overhaul: AX4/AX5, AX15, 30RH, 32RH, and AW-4 diagnosis, removal, adjustment, internal disassembly, inspection, overhaul, and assembly procedures.

• Transfer cases: NP231 Command-Trac removal and overhaul for XJ/YJ applications, plus XJ-specific NP242 full- and part-time transfer-case service.

• Axles and suspension: Model 30 front axle and 2WD tube-axle service, Model 35 and 8-1/4 rear axle repair, Trac-Lok work, ring-and-pinion setup, alignment, and ball-joint replacement.

• Brakes and steering: Brake bleeding, disc and drum repair, ABS component service, steering-gear repair, and related inspection and adjustment procedures.

• Electrical and drivability: Multi-port fuel-injection diagnosis, PCM inputs and outputs, ignition and charging tests, transmission-control circuits, ABS wiring, connector pin-outs, and connector/splice locations.

• ATSG AW-4 procedures: Preliminary diagnosis, hydraulic-pressure, stall, and time-lag tests, transmission and torque-converter removal, case and subassembly overhaul, valve-body teardown, reassembly, and neutral-safety-switch adjustment.

The factory manual was written for professional automotive technicians; its overhaul procedures also suit experienced owners with the required measuring skills, diagnostic equipment, and workshop tools.

Engine Service and Maintenance

Step-by-step procedures cover major engine work, with separate XJ and YJ removal and installation instructions. Internal inspection includes cylinder bores, bearing clearances, valve components, and crankshaft condition.

Normal- and severe-use maintenance schedules accompany lubrication instructions, approved-fluid specifications, and capacity tables. Component-specific torque values, wear limits, and adjustment data appear in the relevant service groups.

Transmission Applications and Axle Setup

Application notes help prevent parts and procedure mix-ups. The AX4/AX5 section serves the smaller gasoline engine, while AX15 coverage serves the inline-six. Automatic-transmission sections distinguish XJ and YJ applications before diagnosis or overhaul procedures are selected.

Differential setup: Bearing and gear-noise diagnosis leads into pinion-depth measurement, bearing-preload and backlash adjustment, and tooth-contact pattern analysis. Axle-shaft, U-joint, and Command-Trac vacuum-disconnect procedures are also included.

Named equipment includes axle spreader W-129-B, dial indicator C-3339, flange wrench C-3281, AW-4 overhaul Tool Kit 6294, and pressure-test adapter 7554.

Repair cautions: The 30RH/32RH removal section identifies crankshaft-position-sensor damage as a risk during transmission handling. Model 35 differential instructions warn that excessive collapsible-spacer preload cannot be corrected by loosening the pinion nut, leaving an incorrect bearing setting.

Diagnostic Charts and System Schematics

The Disconnect Axle/Shift Motor Diagnosis chart supports vacuum-disconnect fault isolation. Electrical references include fuel/ignition diagrams, AW-4 TCM and solenoid circuits, ABS brake-line and wiring layouts, heating schematics, and connector pin-out views.

These references connect symptoms, component tests, circuit paths, and physical connector locations, allowing faults to be investigated before assemblies are removed.

Cooling, HVAC, and Body Repair

Cooling coverage includes system diagnosis and radiator, fan, thermostat, and water-pump service. HVAC sections add refrigerant performance tests, compressor procedures, and model-specific heater components.

Body instructions cover XJ/YJ doors, glass, and interior/exterior hardware, along with YJ top and windshield-frame work.

Because the repair sections include vehicle lifting, brake hydraulics, pressurized fuel, and refrigerant service, use rated support equipment and the specified test or recovery tools before opening those systems.

A Preview of Compression and Oil-Pressure Specifications

Compression testing: The engine-performance section gives a minimum of 689 kPa (100 psi) and a maximum cylinder-to-cylinder variation of 172 kPa (25 psi), with the engine at normal operating temperature and the throttle fully open. These readings are diagnostic guidance rather than an automatic reason for teardown.

Oil pressure: For the 4.0L engine, the oil-pump section lists a minimum pressure of 89.6 kPa (13 psi) at 600 rpm.