Jeep Grand Cherokee ZJ 1996 Service Manual Set (P/N 81-370-6147)

The supplement adds updated fluid capacities and dedicated service procedures for the aluminum Model 44 rear axle and NV242 transfer case. Use the supplement for those assemblies and the base manual for the related vehicle systems.

For some scan-tool and chassis fault-isolation procedures, Chrysler refers technicians to the Powertrain Diagnostic Procedures, Body Diagnostic Procedures, or Chassis Diagnostic manuals. Those companion publications are separate from this set.

Search, Bookmarks, and Wiring Detail

Finding text and diagrams: Text search works in the service chapters. Embedded bookmarks take you to groups and individual procedures. Many wiring diagrams and pinout tables are image-based, and small wire codes and pin numbers are easiest to read with zoom.

The ZIP contains one 1,546-page printable PDF, including both publications, a shared cover, a shared group locator, and 38 separator pages. The base manual includes Chrysler service bulletin replacement pages dated through December 1996.

Powertrain, Chassis, and Electrical Service

These selected topics cover part of the set. The factory chapters also include headlamp aiming and overhead-console compass calibration.

• Engine, fuel, and cooling: Compression, combustion-leak and oil-pressure tests, cylinder-head and valve repair, timing-chain and camshaft service, and fuel and cooling-system pressure tests.

• 42RE and 44RE automatics: Road-test analysis, hydraulic-pressure, air and converter-stall tests, valve-body and overdrive overhaul, and band and cable adjustments.

• Suspension and propeller shafts: Wheel alignment, link-and-coil suspension service, hub and bearing replacement, control arms, track bars, and single- and double-Cardan propeller shafts.

• Axles and transfer cases: Selec-Trac and Model 30 front axle service, Model 35 and Model 44 rear axle repair, Trac-Lok differentials, and NV231, NV242, and NV249 transfer cases.

• Brakes and steering: Four-wheel disc and parking-brake service, ABS hydraulic and wheel-speed sensor checks, and steering-gear overhaul.

• Electrical and emissions: Starting and charging checks, wiring diagrams, connector pinouts, PCM sensor and actuator tests, and EVAP and OBD trouble-code references.

• Body and climate control: Door, glass, sunroof, and liftgate repair, automatic temperature control (ATC) diagnosis, and refrigerant recovery, evacuation, and charging.

Chrysler prepared this service material for automotive technicians who perform day-to-day shop repairs.

Differential Setup and Transfer Case Overhaul

Axle diagnosis covers gear and bearing noise, vibration, and driveline snap. Setup procedures include pinion-depth measurement, shim selection, bearing preload, ring gear backlash, and tooth-contact patterns. The aluminum Model 44 chapter adds Trac-Lok testing and disassembly, axle shaft bearing and seal service, and dedicated torque tables.

The transfer case chapters distinguish the part-time NV231, the selectable full- and part-time NV242, and the full-time NV249 so you can match the procedure to the installed unit. Each covers symptom diagnosis, removal, internal disassembly and reassembly, inspection, sealing, and shift-linkage adjustment.

Special-tool callouts identify pinion-depth sets 6774 and 6955, the W-129-B axle spreader, and Trac-Lok service tools. Over-crushing the collapsible spacer can compromise pinion-bearing preload, and the aluminum Model 44 procedure calls for new ring gear bolts.

Engine and Transmission Repair

Engine repair extends to engine removal, piston and bearing inspection, and oil pump service. Fuel-system diagnosis includes pressure and leak-down checks, with separate 5.2L procedures for fuel rails with and without a pressure test port.

The automatic transmission section pairs hydraulic schematics with pressure-test analysis and identifies gauges C-3292 and C-3293SP. Overhaul procedures cover the clutch packs and planetary geartrain, plus removal and installation of the transmission and torque converter.

Wiring, Brake Hydraulics, and Climate Controls

Group 8W includes power distribution, fuel and ignition, transmission control, ABS, A/C and heater, and body control module circuits. The diagrams let you trace a suspect circuit through its power feed, grounds, and splices to the connector on the vehicle. The section also covers terminal repair.

Brake work includes master cylinder and caliper repair, rotor machining, manual bleeding, and ABS hydraulic control unit service and bleeding. The steering-gear section covers the pitman shaft, spool valve, rack piston, and worm shaft.

Body diagnosis covers water leaks and wind noise, along with stationary glass repair. The climate section includes ATC fault-code and circuit tests, plus heater core and evaporator service.

Striking the permanent-magnet starter, clamping its field frame, or reversing test polarity can damage the magnets. Use rated lifting equipment where required and follow the manual’s pressure-release, electrical-isolation, and component-handling warnings.

Fuel and Transmission Pressure Test Preview

The 4.0L and 5.2L fuel pressure tests specify 49 ± 2 psi (338 ± 14 kPa) at idle. The warm-engine leak-down test sets a minimum of 24 psi for five minutes after shutdown.

For the 42RE and 44RE, the manual-second pressure test specifies 54–60 psi (372–414 kPa) at the accumulator port at 1,000 rpm with the transmission throttle lever fully forward.