Vehicle Segment:
Compact Sport Utility Vehicle (SUV) / Off-Road Vehicle
Brand Heritage:
Direct descendant of the original Willys Jeep, known for extreme off-road capability and ruggedness.
Key Competitors:
Toyota 4Runner, Ford Bronco (earlier generations), Chevrolet Blazer
Design Philosophy:
Body-on-frame construction, solid axles (rear), removable doors and tops, robust off-road drivetrain
Target Demographic:
Off-road enthusiasts, outdoor adventurers, individuals seeking durable and capable vehicles.
Engine Service:
Engine overhaul, diagnostics, fuel system, ignition system, cooling system, lubrication system, emission control systems
Transmission Service:
Manual transmission (AX-5, NV3550), automatic transmission (30RH), clutch system, transfer case (NP231, NP242)
Drivetrain Service:
Front and rear axles (Dana 30, Dana 35), propeller shafts, CV joints, differential service
Suspension Steering Brakes:
Front and rear suspension (leaf springs, shock absorbers), steering system (steering box, tie rods, drag links), brake system (front disc, rear drum, ABS components)
Electrical System:
Wiring diagrams, charging system, starting system, lighting, instrumentation, power windows, power locks, audio system
Body Chassis:
Body panel removal and installation, doors, hood, tailgate, interior trim, frame components, weatherstripping
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication
Repair:
Component diagnosis, disassembly, reassembly, replacement procedures for all major systems
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting for common issues
Specifications:
Torque specifications, clearances, fluid capacities, electrical specifications
Diagnostic Procedures:
Detailed diagnostic procedures using OEM methods, including scan tool data interpretation where applicable
Rebuild Procedures:
Comprehensive rebuild procedures for engines, transmissions, and differentials
Wiring Diagrams:
Full-color, detailed wiring diagrams for all electrical systems
Engine Code:
4.0L Inline-6 (OHV)
Engine Displacement:
3960 cc (242 cu in)
Bore X Stroke:
3.875 in x 3.562 in (98.4 mm x 90.5 mm)
Horsepower:
180 hp @ 4500 rpm (approx.)
Torque:
220 lb-ft @ 2400 rpm (approx.)
Fuel Type:
Unleaded Gasoline
Fuel Delivery:
Multi-port Electronic Fuel Injection (MPI)
Ignition System:
Distributorless Ignition System (DIS) with coil-on-plug or distributor-based systems depending on specific build date
Block Material:
Cast Iron
Cylinder Head Material:
Cast Iron
Catalytic Converter:
Equipped with a catalytic converter for emissions control
Transmission Type:
5-Speed Manual Transmission
Standard Transmission Model:
AX-5 (early models) / NV3550 (later models)
Transmission Type:
3-Speed Automatic Transmission
Automatic Transmission Model:
30RH
Transfer Case:
2-speed part-time 4WD (Command-Trac)
Transfer Case Model:
New Process NP231 (standard) / NP242 (optional Selec-Trac with full-time 4WD option)
Clutch Type:
Dry single plate, hydraulically actuated (for manual transmission)
Wheelbase:
93.4 inches (2372 mm)
Length:
150.3 inches (3818 mm)
Width:
66.5 inches (1689 mm)
Height:
65.8 inches (1671 mm)
Ground Clearance:
Approx. 8.5 inches (216 mm)
Curb Weight:
3300 - 3500 lbs (1497 - 1588 kg) depending on configuration
Gross Vehicle Weight Rating:
4600 lbs (2087 kg)
Cargo Volume:
Approximately 12.8 cu ft with rear seats up, expandable by removing rear seats and top.
NHTSA Rollover Rating:
3-star (typical for vehicles of this era and design)
ABS:
Available on some models/trims (often rear-wheel only for part-time 4WD systems)
Airbags:
Driver and passenger airbags (standard for these model years)
Seatbelts:
Front seat belts with shoulder belts, rear seat belts
Frame Type:
Body-on-frame
Oil Change Interval:
Every 3,000 miles (4,800 km) or 3 months, whichever comes first.
Transmission Fluid Change:
Manual: Every 30,000 - 60,000 miles (48,000 - 96,000 km). Automatic: Every 30,000 miles (48,000 km).
Differential Fluid Change:
Every 30,000 miles (48,000 km) or more frequently for severe off-road use.
Engine Oil:
API SG or higher, SAE 10W-30 (check owner's manual for specific temperature ranges)
Engine Oil Capacity:
5 US quarts (4.7 L) with filter
Coolant:
Mopar Antifreeze/Coolant (50/50 mix with distilled water) or equivalent ethylene glycol-based coolant
Power Steering Fluid:
ATF+3 or equivalent
Manual Transmission Fluid:
AX-5: SAE 75W-90 API GL-3 or GL-4. NV3550: SAE 75W-90 API GL-3 or GL-4 (specific Mopar fluid recommended)
Automatic Transmission Fluid:
Mopar ATF+3 or equivalent
Common Wear Items:
Clutch wear, U-joints, ball joints, leaf spring bushings, aging rubber components (hoses, seals), exhaust system corrosion.
Engine Issues:
Cracked cylinder heads (less common than later generations but possible), oil leaks from valve cover and oil pan gaskets, radiator issues, CPS (Crankshaft Position Sensor) failure.
Transmission Issues:
AX-5 internal synchro wear, NV3550 throw-out bearing noise, clutch hydraulic system leaks.
Electrical Issues:
Corroded grounds, faulty instrument cluster components, intermittent sensor failures.
Part Number Format:
The manual often provides OEM part numbers for reference.
