Jeep Commander 2006 2010 Workshop Manual

Introduction

Restraints

Lubrication and Maintenance

Speed Control

Suspension

Vehicle Theft Security

Differential & Driveline

Wipers/Washers

Vehicle Quick Reference

Navigation/Telecommunication

Brakes

Wiring

Cooling

Engine

Audio/Video

Exhaust System

Chime/Buzzer

Frame & Bumpers

Electronic Control Modules

Fuel System

Engine Systems

Steering

Heated Systems

Transmission and Transfer Case

Horn

Tires/Wheels

Ignition Control

Body

Instrument Cluster

Heating & Air Conditioning

Lamps

Emission Control

Message Systems

Component and System Index

Power Systems

DTC Index

Note: The manual is referenced to year 2006, which is the Jeep Commander XK platform. This is applicable for the base model years 2006-2010 North America

Edition. Please be aware that there may be some slight differences of your actual model due to year by year body trim and electrical updates by the manufacturer.

INDEX

For more Workshop Manual, please visit our website at: http://stores.ebay.com/postdoc526

XK INTRODUCTION 1

INTRODUCTION

TABLE OF CONTENTS

page page

VEHICLE IDENTIFICATION NUMBER

DESCRIPTION .................................2

VEHICLE EMISSION CONTROL INFORMATION

(VECI)

DESCRIPTION .................................3

VEHICLE CERTIFICATION LABEL

DESCRIPTION .................................4

FASTENER IDENTIFICATION

DESCRIPTION .................................5

FASTENER USAGE

DESCRIPTION

FASTENER USAGE ..........................7

THREADED HOLE REPAIR

DESCRIPTION

THREADED HOLE REPAIR ...................8

INTERNATIONAL SYMBOLS

DESCRIPTION - INTERNATIONAL SYMBOLS .....9

METRIC SYSTEM

DESCRIPTION ................................10

TORQUE REFERENCES

DESCRIPTION ................................11

2 INTRODUCTION XK

VEHICLE IDENTIFICATION NUMBER

DESCRIPTION

The Vehicle Identification Number (VIN) plate is
attached to the top left side of the instrument panel.
The VIN contains 17 characters that provide data con­cerning the vehicle. Refer to the decoding chart to
determine the identification of a vehicle.

To protect the consumer from theft and possible fraud
the manufacturer is required to include a Check Digit
at the ninth position of the Vehicle Identification Num­ber. The check digit is used by the manufacturer and
government agencies to verify the authenticity of the
vehicle and official documentation. The formula to use
the check digit is not released to the general public.

VEHICLE IDENTIFICATION NUMBER DECODING CHART

POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin 1 = Manufactured By DaimlerChrysler

Corporation
2 Make J = Jeep
3 Vehicle Type 4 = MPV Less Side Air Bags

8 = MPV With Side Air Bags
4 Gross Vehicle Weight Rating G = 5001-6000 lbs.
5 Vehicle Line (XK) G = Commander Left Hand Drive (4X4)

H = Commander Left Hand Drive (4X2)

5 Vehicle Line (XH) 3 = Grand Cherokee Left Hand Drive (4X4)

1 = Grand Cherokee Right Hand Drive (4X4)

6 Series 4 = Commander

5 = Commander Limited
7 Body Style 8 = Sport Utility 4 Door
8 Engine K = 3.7K 6 cyl. MPI Gasoline

N = 4.7L 8 cyl. MPI Gasoline

2 = 5.7L 8 cyl. HEMI Multiple Displacement

Gasoline

M = 3.0L 6 cyl. Turbo Diesel

9 Check Digit 0 through 9 or X

10 Model Year 6=2006
11 Assembly Plant C = Jefferson North Assembly

Y = Chrysler Steyer Assembly

12 thru 17 Vehicle Build Sequence

XK INTRODUCTION 3

VEHICLE EMISSION CONTROL INFORMATION (VECI)

DESCRIPTION

All vehicles are equipped with a combined vehicle emission control information (VECI) label(s). The label is located
in the engine compartment on the vehicle hood. Two labels are used for vehicles built for sale in the country of
Canada.

The VECI label(s) contain the following:

• Engine family and displacement

• Evaporative family

• Emission control system schematic

• Certification application

• Spark plug and gap

The label also contains an engine vacuum schematic.
There are unique labels for vehicles built for sale in
the state of California and the country of Canada.
Canadian labels are written in both the English and
French languages. These labels are permanently
attached and cannot be removed without defacing
information and destroying label.

4 INTRODUCTION XK

VEHICLE CERTIFICATION LABEL

DESCRIPTION

A vehicle certification label is attached to every
DaimlerChrysler Corporation vehicle. The label certi­fies that the vehicle conforms to all applicable Federal
Motor Vehicle Standards. The label also lists:

• Month and year of vehicle manufacture.

• Gross Vehicle Weight Rating (GVWR). The gross

front and rear axle weight ratings (GAWRs) are
based on a minimum rim size and maximum cold
tire inflation pressure.

• Vehicle Identification Number (VIN).

• Type of vehicle.

• Type of rear wheels.

• Bar code.

• Month, Day and Hour (MDH) of final assembly.

• Paint and Trim codes.

• Country of origin.

The label is located on the driver-side door shut-face.

XK INTRODUCTION 5

FASTENER IDENTIFICATION

DESCRIPTION

The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt
strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade
corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and

10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class
number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut
face. Refer to the Fastener Identification and Fastener Strength Charts.

Bolt Markings and Torques - Metric

Bolt Markings 8.8/8.9 10.9 12.9

Bolt Dia. N·m Ft. Lbs. N·m Ft. Lbs. N·m Ft. Lbs.

6 12 105* 14 120* 16 12

8 25 250* 32 23 38 28
10 54 40 60 45 74 55
12 95 70 108 80 135 100
14 155 115 175 130 216 160
16 243 180 324 210 324 240

* Inch Lbs.

Bolt Markings and Torques - U. S. Customary

Bolt Markings Grade 5 Grade 8

Bolt Dia. N·m Ft. Lbs N·m Ft. Lbs

1/4 - 20 10 95* 14 125*

1/4 - 28 10 95* 17 150*
5/16 - 18 22 200* 30 270*
5/16 - 24 26 240* 33 300*

3/8-1640305540

3/8-2447356045
7/16-1468508865
7/16-2074559570

1/2 - 13 101 75 135 100

1/2 -20 115 85 150 110
9/16 - 12 135 105 182 135
9/16 - 18 155 115 202 150

5/8 - 11 202 150 263 195
5/8 - 18 215 160 284 210
3/4 - 10 230 170 297 220
3/4 - 16 236 175 304 225
7/8 - 14 405 300 540 400

* Inch Lbs.

6 INTRODUCTION XK

XK INTRODUCTION 7

FASTENER USAGE

DESCRIPTION
FASTENER USAGE

WARNING: Use of an incorrect fastener may result in component damage or personal injury.

Fasteners and torque specifications references in this Service Manual are identified in metric and SAE format.
During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassem-

bly. If the fastener is not salvageable, a fastener of equivalent specification must be used.

8 INTRODUCTION XK

THREADED HOLE REPAIR

DESCRIPTION
THREADED HOLE REPAIR

Most stripped threaded holes can be repaired using a HelicoilT. Follow the vehicle or HelicoilT recommendations for
application and repair procedures.

XK INTRODUCTION 9

INTERNATIONAL SYMBOLS

DESCRIPTION - INTERNATIONAL SYMBOLS

The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify
various instrument controls. The symbols correspond to the controls and displays that are located on the instrument
panel.

10 INTRODUCTION XK

METRIC SYSTEM

DESCRIPTION

The metric system is based on quantities of one, ten, one hundred, one thousand and one million.
The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa.

CONVERSION FORMULAS AND EQUIVALENT VALUES

MULTIPLY BY TO GET MULTIPLY BY TO GET

in-lbs x

0.11298

ft-lbs x

1.3558

Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x

psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x

Feet x

0.3048

Yards x

0.9144

mph x

1.6093

Feet/Sec x

0.3048

mph x

0.4470

Kilometers/Hr. (Km/h) x

0.27778

= Newton Meters
(N·m)

= Newton Meters
(N·m)

= Meters (M) M x 3.281 = Feet

= Meters M x

= Kilometers/Hr.
(Km/h)

= Meters/Sec (M/S) M/S x 3.281 = Feet/Sec

= Meters/Sec (M/S) M/S x 2.237 = mph

= Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)

N·m x 8.851 = in-lbs

N·m x

0.7376

0.2961

0.03937

1.0936

Km/h x

0.6214

= ft-lbs

= Inches Hg

= Inches

= Yards

= mph

COMMON METRIC EQUIVALENTS

1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters
1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers

Refer to the Metric Conversion Chart to convert torque values listed in metric Newton-meters (N·m). Also, use the
chart to convert between millimeters (mm) and inches (in.).

XK INTRODUCTION 11

TORQUE REFERENCES

DESCRIPTION

Individual Torque Charts appear within many of the Groups. Refer to the Standard Torque Specifications Chart for
torque references not listed in the individual torque charts.

12 INTRODUCTION XK

XK LUBRICATION & MAINTENANCE 0 - 1

LUBRICATION & MAINTENANCE

TABLE OF CONTENTS

page page

INTERNATIONAL SYMBOLS

DESCRIPTION .................................2

PARTS & LUBRICANT RECOMMENDATION

DESCRIPTION

LUBRICANT RECOMMENDATIONS ............3

FLUID TYPES ...............................3

FLUID TYPES

DESCRIPTION

ENGINE OIL - GASOLINE ENGINES ...........4

ENGINE COOLANT ..........................5

HOAT COOLANT .............................6

AXLE .......................................7

TRANSFER CASE ............................7

AUTOMATIC TRANSMISSION FLUID ...........7

POWER STEERING FLUID ....................8

BRAKE FLUID ...............................8

DIESEL FUEL ................................8

OPERATION - AUTOMATIC TRANSMISSION

FLUID .......................................8

FLUID CAPACITIES

SPECIFICATIONS - FLUID CAPACITIES ..........9

FLUID FILL/CHECK LOCATIONS

INSPECTION - FLUID FILL/CHECK

LOCATIONS ................................10

MAINTENANCE SCHEDULES

DESCRIPTION

MAINTENANCE SCHEDULES ................11

LIFT POINTS

STANDARD PROCEDURE - HOISTING AND

JACKING RECOMMENDATIONS ..............17

JUMP STARTING

STANDARD PROCEDURE - JUMP STARTING .. . 18

EMERGENCY TOW HOOKS

DESCRIPTION ................................20

TOWING

STANDARD PROCEDURE - TOWING

RECOMMENDATIONS .......................21

0 - 2 LUBRICATION & MAINTENANCE XK

INTERNATIONAL SYMBOLS

DESCRIPTION

DaimlerChrysler Corporation uses international sym­bols to identify engine compartment lubricant and fluid
inspection and fill locations.

XK LUBRICATION & MAINTENANCE 0 - 3

PARTS & LUBRICANT RECOMMENDATION

DESCRIPTION
LUBRICANT RECOMMENDATIONS

Chassis

Component Fluid, Lubricant, or Genuine Part

Steering Gear & Linkage, Ball
Joints, Prop Shafts & Yokes,
Wheel Bearings

Body

Component Fluid, Lubricant, and Genuine Part

Hinges:

Door & Hood MoparT Engine Oil

Swing Gate MoparT Multi-Purpose Lube NLGI Grade 2 EP, GC-LB

Latches: Door, Hood/Safety
Catch, Swing Gate

Seat Regulator & Track MoparT Multi-Purpose Lube NLGI Grade 2 EP, GC-LB
Lock Cylinders MoparT Lock Cylinder Lube

MoparT Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB

MoparT Multi-Purpose Lube NLGI Grade 2 EP, GC-LB

FLUID TYPES

When service is required, DaimlerChrysler Corporation recommends that only MoparT brand parts, lubricants and
chemicals be used. MoparT provides the best engineered products for servicing DaimlerChrysler Corporation vehi­cles.

Only lubricants bearing designations defined by the following organization should be used to service a
DaimlerChrysler Corporation vehicle.

• Society of Automotive Engineers (SAE)

• American Petroleum Institute (API)

• National Lubricating Grease Institute (NLGI)

API QUALITY CLASSIFICATION

This symbol on the front of an oil container means
that the oil has been certified by the American Petro­leum Institute (API) to meet all the lubrication require­ments specified by DaimlerChrysler Corporation.

GEAR LUBRICANTS

SAE ratings also apply to multigrade gear lubricants. In addition, API classification defines the lubricants usage.
Such as API GL-5 and SAE 75W-90.

0 - 4 LUBRICATION & MAINTENANCE XK

FLUID TYPES

DESCRIPTION
ENGINE OIL - GASOLINE ENGINES

WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact
with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your
health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel,
thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact
your dealer or government agency for location of collection center in your area.

When service is required, DaimlerChrysler Corporation recommends that only MoparT brand parts, lubricants and
chemicals be used. MoparT provides the best engineered products for servicing DaimlerChrysler Corporation vehi­cles.

Only lubricants bearing designations defined by the following organization should be used.

• Society of Automotive Engineers (SAE)

• American Petroleum Institute (API)

• National Lubricating Grease Institute (NLGI)

• Association des Constructeurs Européens d’ Automobiles (European Automobile Manufacturers Association)

(ACEA)

API SERVICE GRADE CERTIFIED

Use an engine oil that is API Certified. MOPART provides engine oils, that meet or exceed this requirement.

SAE VISCOSITY

An SAE viscosity grade is used to specify the viscosity
of engine oil. Use only engine oils with multiple viscos­ities such as 5W-30 or 10W-30. These are specified
with a dual SAE viscosity grade which indicates the
cold-to-hot temperature viscosity range. For 3.7L/4.7L

engines SAE 5W-30 engine oil is recommended for
all operating temperatures. For 5.7L engines, SAE
5W-20 engine oil is recommended for all operating
temperatures. Vehicles with 5.7L engines equipped
with Multiple Displacement System, (MDS), must
use SAE 5W-20 oil. Failure to do so may result in
improper operation of the Multiple Displacement
System (MDS).These engine oils improve low tem­perature starting and vehicle fuel economy. Refer
to your engine oil filler cap for the recommended engine oil viscosity for your vehicle.

ACEA Categories

For countries that use the ACEA European Oil Categories for Service Fill Oils, use engine oils that meet the require­ments of ACEA A1/B1, A2/B2, or A3/B3.

ENERGY CONSERVING OIL

An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING
is located on the label of an engine oil container.

XK LUBRICATION & MAINTENANCE 0 - 5

CONTAINER IDENTIFICATION

Standard engine oil identification notations have been
adopted to aid in the proper selection of engine oil.
The identifying notations are located on the front label
of engine oil plastic bottles and the top of engine oil
cans.

This symbol means that the oil has been certified by
the American Petroleum Institute (API). Diamler­Chrysler only recommends API Certified engine oils.
Use MoparT engine oil or equivalent.

SYNTHETIC ENGINE OILS

There are a number of engine oils being promoted as either synthetic or semi-synthetic. If you chose to use such
a product, use only those oils that meet the American Petroleum Institute (API) and SAE viscosity standard. Follow
the service schedule that describes your driving type.

ENGINE OIL ADDITIVES/SUPPLEMENTS

The manufacturer does not recommend the addition of any engine oil additives/supplements to the specified
engine oil. Engine oil additives/supplements should not be used to enhance engine oil performance. Engine oil addi­tives/supplements should not be used to extend engine oil change intervals. No additive is known to be safe for
engine durability and can degrade emission components. Additives can contain undesirable materials that harm the
long term durability of engines by:

• Doubling the level of phosphorus in the engine oil. The ILSAC (International Lubricant Standard Approval Com­mittee) GF-2 and GF-3 standards require that engine oil contain no more than 0.10% phosphorus to protect
the vehicles emissions performance. Addition of engine oil additives/supplements can poison, from the added
sulfur and phosphorus, catalysts and hinder efforts to guarantee emissions performance to 80,000 miles.

• Altering the viscosity characteristics of the engine oil so that it no longer meets the requirements of the spec­ified viscosity grade.

• Creating potential for an undesirable additive compatibility interaction in the engine crankcase. Generally it is
not desirable to mix additive packages from different suppliers in the crankcase; there have been reports of
low temperature engine failures caused by additive package incompatibility with such mixtures.

ENGINE COOLANT

ETHYLENE-GLYCOL MIXTURES

CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause prob­lems associated with 100 percent ethylene-glycol.

The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating condi­tions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37°
C (-35° F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If

percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system com­ponents may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68

percent antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze
at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the
specific heat of antifreeze is lower than that of water.

Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive
additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing tem­peratures to rise to as high as 149° C (300° F). This temperature is hot enough to melt plastic and soften solder.
The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22°
C(-8°F).

0 - 6 LUBRICATION & MAINTENANCE XK

PROPYLENE-GLYCOL MIXTURES

It’s overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene­glycol and water is -32° C (-26° F). 5° C higher than ethylene-glycol’s freeze point. The boiling point (protection
against summer boil-over) of propylene-glycol is 125° C (257°F)at96.5 kPa (14 psi), compared to 128° C (263°
F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up on a cooling system designed for
ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can
increase cylinder head temperatures under certain conditions.

Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing dam­age to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are
mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index
and specific gravity differ between ethylene glycol and propylene glycol.

HOAT COOLANT

WARNING: Antifreeze is an ethylene-glycol base coolant and is harmful if swallowed or inhaled. If swal­lowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. seek medical
attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly
after coming in contact with ethylene-glycol. Keep out of reach of children. Dispose of glycol base coolant
properly, contact your dealer or government agency for location of collection center in your area. Do not
open a cooling system when the engine is at operating temperature or hot under pressure, personal injury
can result. Avoid radiator cooling fan when engine compartment related service is performed, personal
injury can result.

CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze pro­tection and less corrosion protection.

The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder
head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/
fin radiator can transfer the heat to the air.

The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection.
MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant
with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This cool­ant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to
obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh
properly mixed coolant solution.

CAUTION: MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any
other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in
engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protec­tion.

COOLANT PERFORMANCE

The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions.
The coolant performance of various mixtures follows:

Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat
transfer only. Water also freezes at a higher temperature and allows corrosion.

100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to
dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as
high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature
can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F).

50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C
(-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If per­centage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a
68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will

XK LUBRICATION & MAINTENANCE 0 - 7

freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because
specific heat of antifreeze is lower than that of water.

CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause prob­lems associated with 100 percent ethylene-glycol.

COOLANT SELECTION AND ADDITIVES

The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only
MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT,
for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without cor­rosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37°C (-35°F). If it loses color or
becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution.

CAUTION: Do not use coolant additives that are claimed to improve engine cooling.

AXLE

NOTE: DaimlerChrysler recommends using MoparT lubricants or lubricants of equal quality.

FRONT AXLE

• 200MM - MoparT Synthetic Gear Lubricant 75W-140

REAR AXLE

• 213MM - MoparT Synthetic Gear Lubricant 75W-140

NOTE: ELSD equipped axles require 118 ml (4 ounces) of Limited Slip Additive be added to the lubricant.

TRANSFER CASE

Recommended lubricant for the NV140 transfer case is MoparT ATF+4, Automatic Transmission Fluid. Recom­mended lubricant for the NV245 transfer case is MoparT NV245/247 Transfer Case Fluid.

AUTOMATIC TRANSMISSION FLUID

NOTE: Refer to Service Procedures in this group for fluid level checking procedures.

MoparT ATF +4, Automatic Transmission Fluid is the recommended fluid for DaimlerChrysler automatic transmis­sions.

Dexron II fluid IS NOT recommended. Clutch chatter can result from the use of improper fluid.

MoparT ATF +4, Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified
from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an
indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually
become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and
color cannot be used to indicate the fluid condition or the need for a fluid change.

FLUID ADDITIVES

DaimlerChrysler strongly recommends against the addition of any fluids to the transmission, other than those auto­matic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid
leaks.

Various “special” additives and supplements exist that claim to improve shift feel and/or quality. These additives and
others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge.
These claims have not been supported to the satisfaction of DaimlerChrysler and these additives must not be
used. The use of transmission “sealers” should also be avoided, since they may adversely affect the integrity of
transmission seals.

0 - 8 LUBRICATION & MAINTENANCE XK

POWER STEERING FLUID

This system requires the use of hydraulic system/power steering fluid which meets DaimlerChrysler specification
MS-10838, or equivalent, DO NOT MIX POWER STEERING FLUID TYPES. Damage may result to the power steer­ing pump and system if any other fluid is used, and DO NOT OVERFILL.

BRAKE FLUID

The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type
of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an
equivalent from a tightly sealed container.

CAUTION: Never use reclaimed brake fluid or fluid from an container which has been left open. An open
container of brake fluid will absorb moisture from the air and contaminate the fluid.

CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type
fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake
system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid,
etc.

DIESEL FUEL

Diesel fuels are available from most reputable fuel marketers. Fuel with a calculated Cetane Index of 45 or higher
must be used. See your authorized dealer or distributor for further information regarding fuels availability.

In areas where diesel fuel is below the recommended quality levels (high levels of sulfur and water) it is critical to
monitor the fuel filter for contamination and the “Water-In-Fuel” message in the Electronic Vehicle Information Center
(EVIC). Failure to properly service the fuel system for these items can significantly reduce engine life and lead to
major engine repair. More frequent service intervals of the fuel filter/water separator unit may be required under
these conditions than those shown in “Maintenance Schedule A or B.”

OPERATION - AUTOMATIC TRANSMISSION FLUID

The automatic transmission fluid is selected based upon several qualities. The fluid must provide a high level of
protection for the internal components by providing a lubricating film between adjacent metal components. The fluid
must also be thermally stable so that it can maintain a consistent viscosity through a large temperature range. If the
viscosity stays constant through the temperature range of operation, transmission operation and shift feel will remain
consistent. Transmission fluid must also be a good conductor of heat. The fluid must absorb heat from the internal
transmission components and transfer that heat to the transmission case.

XK LUBRICATION & MAINTENANCE 0 - 9

FLUID CAPACITIES

SPECIFICATIONS - FLUID CAPACITIES

DESCRIPTION SPECIFICATION

FUEL TANK 20 U.S. Gallons (76 Liters)****
Engine Oil - with Filter - 3.7 L 4.7 L (5.0 qts.)
Engine Oil - with Filter - 4.7 L 5.6 L (6.0 qts.)
Engine Oil - with Filter - 5.7 L 6.6 L (7.0 qts.)

Engine Oil - with Filter - 3.0 L Diesel 9.5 L (10.0 qts.)

Cooling System - 3.0 L Diesel 13.2 L (14.0 qts.)

Cooling System - 3.7 L 10.0 L (9 qts.)***
Cooling System - 4.7 L 13.7 L (14.5 qts.)***
Cooling System - 5.7 L 13.7 L (14.5 qts.)***

POWER STEERING SYSTEM

Power steering fluid capacities are dependent on engine/chassis options as well as steering gear/cooler options.

Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary

cooler, these capacities may vary. Refer to 19, Steering for proper fill and bleed procedures.

AUTOMATIC TRANSMISSION

Service Fill - 545RFE

Service Fill - NAG1 5.0 L (10.6 pts.)

Overhaul Fill - 545RFE 13.33 L (28.0 pts.)L

Overhaul Fill - NAG1 7.7 L (16.3 pts)L

LDry fill capacity. Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use

of an auxiliary cooler, these figures may vary. (Refer to appropriate 21 - TRANSMISSION/AUTOMATIC/FLUID -

STANDARD PROCEDURE).

TRANSFER CASE
NV140 0.65L (1.4 pts.)
NV245 1.8L (3.8 pts.)

FRONT AXLE ± 0.3 L (2 oz.)

C200F 1.7 L (57.5 oz.)

C200FE 1.7 L (57.5 oz.)*

REAR AXLE ± 0.3 L (2 oz.)

C213R 2.07 L (70 oz.)

C213RE 2.24L (75.5 oz.)*
*ELSD, add 118 ml (4 oz.) of Friction Modifier.
*** Includes 0.9L (1.0 qts.) for coolant reservoir.
****Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due to manufacturing

tolerance and refill procedure.

2WD - 5.2 L (11 pts.)
4WD - 6.2 L (13 pts.)

0 - 10 LUBRICATION & MAINTENANCE XK

FLUID FILL/CHECK LOCATIONS

INSPECTION - FLUID FILL/CHECK LOCATIONS

The fluid fill/check locations and lubrication points are located in each applicable group.

XK LUBRICATION & MAINTENANCE 0 - 11

MAINTENANCE SCHEDULES

DESCRIPTION
MAINTENANCE SCHEDULES

There are two maintenance schedules that show the required service for your vehicle.
First is Schedule (B(. It is for vehicles that are operated under the conditions that are listed below and at the begin-

ning of the schedule.

• Day or night temperatures are below 32°F (0°C)

• Stop and go driving

• Excessive engine idling

• Driving in dusty conditions

• Short trips of less than 10 miles (16.2 km)

• More than 50% of your driving is at sustained high speeds during hot weather, above 90°F (32°C)

• Trailer towing

• Taxi, police, or delivery service (commercial service)

• Off-road or desert driving

• If equipped for and operated with E-85 (ethanol) fuel.

NOTE: Most vehicles are operated under the conditions listed for Schedule “B.”

NOTE: If ANY of these apply to you, change your engine oil every 3,000 miles (5 000 km) or 3 months,
whichever comes first, and follow the maintenance recommendations in “Maintenance Schedule B.”

NOTE: If ANY of these apply to you then flush and replace your engine coolant every 102,000 miles (163 000
km) or 60 months, whichever comes first, and follow “Schedule B” of the “Maintenance Schedules” section
of this manual.

Second is Schedule “A”. It is for vehicles that are not operated under any of the conditions listed under Schedule
“B.”

Use the schedule that best describes your driving conditions. Where time and mileage are listed, follow the interval
that occurs first.

CAUTION: Failure to perform the required maintenance items may result in damage to the vehicle.

At Each Stop for Fuel

• Check the engine oil level about 5 minutes after a fully warmed engine is shut off. Checking the oil level while
the vehicle is on level ground will improve the accuracy of the oil level reading. Add oil only when the level is
at or below the ADD or MIN mark.

• Check the windshield washer solvent, add as required.

Once a Month

• Check the tire pressure and look for unusual wear or damage.

• Inspect the battery and clean and tighten the terminals as required.

• Check the fluid levels of the coolant reservoir, brake master cylinder, and transmission, and add as needed.

• Check all lights and all other electrical items for correct operation.

At Each Oil Change

• Change the engine oil filter.

• Inspect the exhaust system.

• Inspect brake hoses.

• Check the engine coolant/anti-freeze level, hoses, and clamps.

0 - 12 LUBRICATION & MAINTENANCE XK

• After completion of off-road operation, the underside of the vehicle should be thoroughly inspected. Examine
threaded fasteners for looseness.

Schedule “B”

Follow this schedule if you usually operate your vehicle under one or more of the following conditions.

• Day or night temperatures are below 32°F (0°C)

• Stop and go driving

• Excessive engine idling

• Driving in dusty conditions

• Short trips of less than 10 miles (16.2 km)

• More than 50% of your driving is at sustained high speeds during hot weather, above 90°F (32°C)

• Trailer towing

• Taxi, police, or delivery service (commercial service)

• Off-road or desert driving

• If equipped for and operated with E-85 (ethanol) fuel.

NOTE: If ANY of these apply to you, change your engine oil every 3,000 miles (5 000 km) or 3 months,
whichever comes first, and follow the maintenance recommendations in “Maintenance Schedule B.”

NOTE: If ANY of these apply to you then flush and replace your engine coolant every 102,000 miles (163 000
km) or 60 months, whichever comes first, and follow “Schedule B” of the “Maintenance Schedules” section
of this manual.

Miles 3,000 6,000 9,000 12,000 15,000
(Kilometers) (5 000) (10 000) (15 000) (20 000) (25 000)

Change the engine oil and engine oil filter, if not
replaced at 3 months.

Rotate the tires. X X

Inspect the engine air cleaner filter, replace if
necessary.

Drain and refill the front and rear axles. X
Inspect the brake linings. X

Miles 18,000 21,000 24,000 27,000 30,000
(Kilometers) (30 000) (35 000) (40 000) (45 000) (50 000)

Change the engine oil and engine oil filter, if not
replaced at 3 months.

Rotate the tires. X X X

Inspect the engine air cleaner filter, replace if
necessary.

Inspect the PCV Valve, replace if necessary.L X
Replace the spark plugs. X

Drain and refill the front and rear axles. X
Inspect the brake linings. X
Drain the transfer case and refill. X

XXXXX

X

XXXXX

X

XK LUBRICATION & MAINTENANCE 0 - 13

Miles 33,000 36,000 39,000 42,000 45,000
(Kilometers) (55 000) (60 000) (65 000) (70 000) (75 000)

Change the engine oil and engine oil filter, if not
replaced at 3 months.

Rotate the tires. X X

Inspect the engine air cleaner filter, replace if
necessary.

Drain and refill the front and rear axles. X
Inspect the brake linings. X

Miles 48,000 51,000 54,000 57,000 60,000
(Kilometers) (80 000) (85 000) (90 000) (95 000) (100

Change the engine oil and engine oil filter, if not
replaced at 3 months.

Rotate the tires. X X X

Inspect the engine air cleaner filter, replace if
necessary.

Inspect the PCV Valve, replace if necessary.L X
Replace the spark plugs. X

Inspect drive belt, replace if necessary. X
Inspect the brake linings. X X
Drain and refill the front and rear axles. X
Drain and refill the automatic transmission fluid, and

replace main sump filter (4.7L/5.7L Only).‡
Drain and refill the transfer case fluid. X
Flush and replace engine coolant/anti-freeze. X

XXXXX

X

000)

XXXXX

X

X

‡ Applies only if vehicle is used for frequent trailer towing, or fleet/commercial service.

Miles 63,000 66,000 69,000 72,000 75,000
(Kilometers) (105

000)

Change the engine oil and engine oil filter, if not
replaced at 3 months.

Rotate the tires. X X

Inspect the engine air cleaner filter, replace if
necessary.

Inspect the drive belt, replace if necessary. X
Inspect the brake linings. X
Drain and refill the front and rear axle fluid. X

Miles 78,000 81,000 84,000 87,000 90,000
(Kilometers) (130

Change the engine oil and engine oil filter, if not
replaced at 3 months.

Rotate the tires. X X X

XXXXX

000)

XXXXX

(110 000) (115

000)

(135 000) (140

000)

(120

000)

(145

000)

(125

000)

X

(150

000)

0 - 14 LUBRICATION & MAINTENANCE XK

Miles 78,000 81,000 84,000 87,000 90,000
(Kilometers) (130

000)

Inspect the engine air cleaner filter, replace if
necessary.

Inspect the PCV Valve, replace if necessary.L X
Replace the spark plugs. X

Inspect the drive belt, replace if necessary.* X
Drain and refill the transfer case fluid. X
Inspect the brake linings. X
Drain and refill the front and rear axle fluid. X

Miles 93,000 96,000 99,000 102,000 105,000
(Kilometers) (155

000)

Change the engine oil and engine oil filter, if not
replaced at 3 months.

Rotate the tires. X X

Inspect the engine air cleaner filter, replace if
necessary.

Inspect the drive belt, replace if necessary.* X
Inspect the brake linings. X
Drain and refill the front and rear axle fluid. X
Flush and replace the engine coolant/anti-freeze, if

not done at 60 months.

XXXXX

(135 000) (140

000)

(160 000) (165

000)

(145

000)

(170

000)

X

(150

000)

X

(175

000)

X

Miles 108,000 111,000 114,000 117,000 120,000
(Kilometers) (180

000)

Change the engine oil and engine oil filter, if not
replaced at 3 months.

Rotate the tires. X X X

Inspect the engine air cleaner filter, replace if
necessary.

Inspect the PCV Valve, replace if necessary.L X
Replace the spark plugs. X

Inspect the drive belt, replace if necessary.* X
Inspect the brake linings. X X
Drain and refill the front and rear axle fluid. X
Drain and refill the automatic transmission fluid,

replace main sump filter, and spin-on cooler return
filter (if equipped). (4.7L/5.7L Only).‡

Drain and refill the transfer case fluid. X
Flush and replace the engine coolant/anti-freeze at

120 months, if not replaced at 102,000 miles (170
000 km).

XXXXX

(185 000) (190

000)

(195

000)

(200

000)

X

X

X

NOTE: ‡ Applies only if vehicle is used for frequent trailer towing, or fleet/commercial service.

XK LUBRICATION & MAINTENANCE 0 - 15

Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all
receipts.

L This maintenance is recommended by the manufacturer to the owner, but is not required to maintain emissions
warranty.

* This maintenance is not required if the belt was previously replaced.

Schedule “A”

Miles 6,000 12,000 18,000 24,000 30,000
(Kilometers) (10 000) (20 000) (30 000) (40 000) (50 000)
[Months] [6] [12] [18] [24] [30]

Change the engine oil and engine oil filter. X X X X X
Rotate the tires. X X X X X

Inspect the engine air cleaner filter, and replace if
necessary.

Replace the spark plugs. X

Inspect the brake linings. X
Drain the transfer case and refill. X

X

Miles 36,000 42,000 48,000 54, 000
(Kilometers) (60 000) (70 000) (80 000) (90 000)
[Months] [36] [42] [48] [54]

Change the engine oil and engine oil filter. X X X X
Rotate the tires. X X X X
Inspect the brake linings. X X

Miles 60,000 66,000 72,000 78,000
(Kilometers) (100 000) (110 000) (120 000) (130 000)
[Months] [60] [66] [72] [78]

Change the engine oil and engine oil filter. X X X X
Rotate the tires. X X X X

Inspect the engine air cleaner filter, and replace if
necessary.

Inspect the PCV Valve, replace if necessary.L X
Replace the spark plugs. X

Inspect the drive belt, replace if necessary. X
Flush and replace the engine coolant/anti-freeze at 60

months, if not replaced at 102,000 miles (170 000 km).
Inspect the brake linings. X
Drain the transfer case and refill. X

X

X

Miles 84,000 90,000 96,000 102, 000
(Kilometers) (140 000) (150 000) (160 000) (170 000)
[Months] [84] [90] [96] [102]

Change the engine oil and engine oil filter. X X X X
Rotate the tires. X X X X

0 - 16 LUBRICATION & MAINTENANCE XK

Miles 84,000 90,000 96,000 102, 000
(Kilometers) (140 000) (150 000) (160 000) (170 000)
[Months] [84] [90] [96] [102]

Inspect the engine air cleaner filter, and replace if
necessary.

Inspect the PCV Valve, replace if necessary.L X
Replace the spark plugs. X

Inspect the drive belt, replace if necessary.* X
Inspect the brake linings. X
Flush and replace the engine coolant/anti-freeze if not

replaced at 60 months.
Drain the transfer case and refill. X

Miles 108,000 114,000 120,000
(Kilometers) (180 000) (190 000) (200 000)
[Months] [108] [114] [120]

Change the engine oil and engine oil filter. X X X
Rotate the tires. X X X

Inspect the engine air cleaner filter, and replace if necessary. X
Inspect the PCV Valve, replace if necessary.L X
Replace the spark plugs. X

Inspect the drive belt, replace if necessary.* X
Inspect the brake linings. X
Flush and replace the engine coolant/anti-freeze if not done at

102,000 miles (170 000 km).
Drain the transfer case and refill. X

X

X

X

Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all
receipts.

L This maintenance is recommended by the manufacturer to the owner, but is not required to maintain emissions
warranty.

* This maintenance is not required if the belt was previously replaced.

WARNING: You can be badly injured working on or around a motor vehicle. Do only that service work for
which you have the proper equipment. If you have any doubt about your ability to perform a service job,
take your vehicle to a competent mechanic.

XK LUBRICATION & MAINTENANCE 0 - 17

LIFT POINTS

STANDARD PROCEDURE - HOISTING AND JACKING RECOMMENDATIONS

FLOOR JACK

When properly positioned, a floor jack can be used to
lift the vehicle (3 and 4). Support the vehicle in the
raised position with jack stands at the front and rear
ends of the frame rails (1 and 2).

CAUTION: Do not attempt to lift a vehicle with a
floor jack positioned under:

• Aluminum differential.

• A body side sill.

• A steering linkage component.

• A drive shaft.

• The engine or transmission oil pan.

• The fuel tank.

HOIST

A vehicle can be lifted with:

• A single-post, frame-contact hoist.

• A twin-post, chassis hoist.

• A ramp-type, drive-on hoist.

NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (1 and

2).

WARNING: The hoisting and jack lifting points provided are for a complete vehicle. When a chassis or driv­etrain component is removed from a vehicle, the center of gravity is altered making some hoisting condi­tions unstable. Properly support or secure vehicle to hoisting device when these conditions exist.

0 - 18 LUBRICATION & MAINTENANCE XK

JUMP STARTING

STANDARD PROCEDURE - JUMP STARTING

WARNING: Review all safety precautions and warnings in the Battery System section of the service manual.

• Do not jump start a frozen battery, personal injury can result.

• If equipped, do not jump start when maintenance free battery indicator dot is yellow or bright color.

• Do not jump start a vehicle when the battery fluid is below the top of lead plates.

• Do not allow jumper cable clamps to touch each other when connected to a booster source.

• Do not use open flame near battery.

• Remove metallic jewelry worn on hands or wrists to avoid injury by accidental arcing of battery current.

• When using a high output boosting device, do not allow battery voltage to exceed 16 volts. Refer to

instructions provided with device being used.
Failure to follow these instructions may result in personal injury or death.

CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can
be damaged on either vehicle.

TO JUMP START A DISABLED VEHICLE:

1. Raise hood on disabled vehicle and visually inspect
engine compartment for:

• Battery cable clamp condition, clean if necessary.

• Frozen battery.

• Yellow or bright color test indicator, if equipped.

• Low battery fluid level.

• Generator drive belt condition and tension.

• Fuel fumes or leakage, correct if necessary.

CAUTION: If the cause of starting problem on dis­abled vehicle is severe, damage to booster vehicle
charging system can result.

2. When using another vehicle as a booster source,
park the booster vehicle within cable reach. Turn
off all accessories, set the parking brake, place the
automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.

3. On disabled vehicle, place gear selector in park or neutral and set park brake. Turn off all accessories.

4. Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to negative terminal
(-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this
procedure.

5. On disabled vehicle, connect RED jumper cable clamp (2) to positive (+) terminal. Connect BLACK jumper cable
clamp (1) to engine ground as close to the ground cable attaching point as possible.

6. Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the
engine in the vehicle with the discharged battery.

CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat
and could fail.

7. Allow battery (4) in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start
engine. If engine does not start within 15 seconds, stop cranking engine and allow starter to cool (15 min.),
before cranking again.

XK LUBRICATION & MAINTENANCE 0 - 19

DISCONNECT CABLE CLAMPS AS FOLLOWS:

• Disconnect BLACK cable clamp (1) from engine ground on disabled vehicle.

• When using a Booster vehicle, disconnect BLACK cable clamp from battery negative terminal. Disconnect RED

cable clamp from battery positive terminal.

• Disconnect RED cable clamp (2) from battery positive terminal on disabled vehicle.

0 - 20 LUBRICATION & MAINTENANCE XK

EMERGENCY TOW HOOKS

DESCRIPTION

WARNING: Remain at a safe distance from a vehi­cle that is being towed via its tow hooks. The tow
straps/chains could break and cause serious
injury.

Some Jeep vehicles are equipped with front emer­gency tow hooks. The tow hooks should be used for

EMERGENCY purposes only.
CAUTION: DO NOT use emergency tow hooks for

tow truck hook-up or highway towing.

XK LUBRICATION & MAINTENANCE 0 - 21

TOWING

STANDARD PROCEDURE - TOWING RECOMMENDATIONS

A vehicle equipped with SAE approved wheel lift type towing equipment can be used to tow WK/WH vehicles. When
towing a 4WD vehicle using a wheel lift towing device, use tow dollies under the opposite end of the vehicle. A
vehicle with a flatbed device can also be used to transport a disabled vehicle.

SAFETY PRECAUTIONS

CAUTION: The following safety precautions must
be observed when towing a vehicle:

• Secure loose and protruding parts.

• Always use a safety chain system that is inde-

pendent of the lifting and towing equipment.

• Do not allow towing equipment to contact the
disabled vehicle’s fuel tank.

• Do not allow anyone under the disabled vehicle
while it is lifted by the towing device.

• Do not allow passengers to ride in a vehicle
being towed.

• Always observe state and local laws regarding
towing regulations.

• Do not tow a vehicle in a manner that could
jeopardize the safety of the operator, pedestrians
or other motorists.

• Do not attach tow chains, T-hooks, or J-hooks to a bumper, steering linkage, drive shafts or a non-reinforced
frame hole.

• Do not tow a heavily loaded vehicle. Use a flatbed device to transport a loaded vehicle.

TWO WHEEL DRIVE VEHICLE TOWING

DaimlerChrysler Corporation recommends that a vehicle be towed with the rear end lifted, whenever possible.

WARNING: When towing a disabled vehicle and the drive wheels are secured in a wheel lift or tow dollies,
ensure the transmission is in the park position (automatic transmission) or a forward drive gear (manual
transmission).

WARNING: Ensure vehicle is on a level surface or the wheels are blocked to prevent vehicle from rolling.

TWO WHEEL DRIVE TOWING - REAR END LIFTED

CAUTION: Do not use steering column lock to secure steering wheel during towing operation.

2WD vehicles can be towed with the front wheels on the surface for extended distances at speeds not exceeding 48
km/h (30 mph).

1. Attach wheel lift device to rear wheels.

2. Place the transmission in neutral.

3. Raise vehicle to towing position.

4. Attach safety chains. Route chains so not to interfere with tail pipe when vehicle is lifted.

5. Turn the ignition switch to the OFF position to unlock the steering wheel.

CAUTION: Do not use steering column lock to secure steering wheel during towing operation.

6. Secure steering wheel in straight ahead position with a clamp device designed for towing.

7. Place transmission in park.

0 - 22 LUBRICATION & MAINTENANCE XK

TWO WHEEL DRIVE TOWING - FRONT END LIFTED

CAUTION: Towing is allowed ONLY if the driveshaft is removed. Towing with the rear wheels on the ground
while the driveshaft is connected can result in severe transmission damage which is not covered under the
Limited Warranty.

CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid com­ponent damage, a wheel lift towing vehicle or a flat bed hauling vehicle is recommended.

1. Attach wheel lift device to rear wheels.

2. Place the transmission in neutral.

3. Raise the rear of the vehicle off the ground and install tow dollies under rear wheels.

4. Attach wheel lift device to front wheels and raise vehicle to towing position.

5. Attach the safety chains.

CAUTION: Do not use steering column lock to secure steering wheel during towing operation.

6. Turn the ignition switch to the OFF position to unlock the steering wheel.

7. Secure steering wheel in straight ahead position with a clamp device designed for towing.

8. Place transmission in park.

FOUR WHEEL DRIVE VEHICLE TOWING

DaimlerChrysler Corporation recommends that a 4WD vehicle be transported on a flat bed device. A wheel lift
device can be used provided the trailing wheels are off the ground and positioned in tow dollies.

WARNING: When towing a disabled vehicle and the drive wheels are secured in a wheel lift or tow dollies,
ensure the transmission is in the park position.

CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid com­ponent damage, a wheel lift towing vehicle or a flat bed hauling vehicle is recommended.

FOUR WHEEL DRIVE TOWING - REAR END LIFTED

WARNING: Ensure vehicle is on a level surface or the wheels are blocked to prevent vehicle from rolling.

1. Attach wheel lift device to front wheels.

2. Place the transmission in neutral.

3. Raise the front of the vehicle off the ground and install tow dollies under front wheels.

4. Attach wheel lift device to rear wheels and raise vehicle to towing position.

5. Attach safety chains. Route chains so not to interfere with tail pipe when vehicle is lifted.

6. Turn the ignition switch to the OFF position to unlock the steering wheel.

CAUTION: Do not use steering column lock to secure steering wheel during towing operation.

7. Secure steering wheel in straight ahead position with a clamp device designed for towing.

8. Place transmission in park.

FOUR WHEEL DRIVE TOWING - FRONT END LIFTED

WARNING: Ensure vehicle is on a level surface or the wheels are blocked to prevent vehicle from rolling.

1. Attach wheel lift device to rear wheels.

2. Place the transmission in neutral.

3. Raise the rear of the vehicle off the ground and install tow dollies under rear wheels.

XK LUBRICATION & MAINTENANCE 0 - 23

4. Attach wheel lift device to front wheels and raise vehicle to towing position.

5. Attach the safety chains.

CAUTION: Do not use steering column lock to secure steering wheel during towing operation.

6. Turn the ignition switch to the OFF position to unlock the steering wheel.

7. Secure steering wheel in straight ahead position with a clamp device designed for towing.

8. Place transmission in park.

RECREATIONAL TOWING (BEHIND MOTORHOME, ETC.)

Towing - 2WD Models

CAUTION: Recreational towing is allowed ONLY if the driveshaft is removed. Towing with the rear wheels on
the ground while the driveshaft is connected can result in severe transmission damage which is not cov­ered under the Limited Warranty.

Towing - Quadra-Trac I (Single-Speed Transfer Case) 4WD Models

CAUTION: Recreational towing is not allowed. This model does not have a N (Neutral) position in the trans­fer case.

Towing - Quadra–Trac II /Quadra–Drive II 4WD Models

CAUTION: Internal damage to the transfer case will occur if a front or rear wheel lift is used when recre­ational towing. The transfer case must be in the N (Neutral) position, and the transmission must be in the
P (Park) position for recreational towing.

Shifting Into Neutral (N)

CAUTION: Use the following procedure to prepare the vehicle for recreational towing. It is necessary to fol­low these steps to be certain that the transfer case is fully in N (Neutral) before recreational towing to pre­vent damage to internal parts.

1. Depress brake pedal.

2. Shift transmission into N (Neutral).

3. Shift transfer case lever into N (Neutral). Refer to “Four Wheel Drive Operation” in this section. Start engine.

4. Shift transmission into D (Drive).

5. Release brake pedal and ensure that there is no vehicle movement.

6. Shut the engine OFF and place the ignition key into the unlocked OFF position.

7. Shift transmission into P (Park).

8. Apply parking brake.

9. Attach vehicle to the tow vehicle with tow bar.

10. Release parking brake.

CAUTION: Transmission damage may occur if the transmission is shifted into P (Park) with the transfer
case in N (Neutral) and the engine running. With the transfer case in N (Neutral) ensure that the engine is
OFF prior to shifting the transmission into P (Park) (refer to steps7–8above).

Shifting Out Of Neutral (N) Use the following procedure to prepare the vehicle for normal usage.

1. Turn the ignition key to the unlocked OFF position.

2. Shift transmission into N (Neutral).

3. Shift transfer case lever to desired position. Refer to “Four Wheel Drive Operation” in this section.

4. Shift transmission into P (Park).

0 - 24 LUBRICATION & MAINTENANCE XK

5. Start the engine.

6. Shift transmission into D (Drive).

NOTE: When shifting out of transfer case N (Neutral), turning the engine OFF may be required to avoid gear
clash.

WARNING: You or others could be injured if you leave the vehicle unattended with the transfer case in the
N (Neutral) position without first fully engaging the parking brake. The transfer case N (Neutral) position
disengages both the front and rear driveshafts from the powertrain and will allow the vehicle to move
regardless of the transmission position. The parking brake should always be applied when the driver is not
in the vehicle.

CAUTION: Do not use a bumper mounted clamp on tow bar on the vehicle. The bumper face bar will be
damaged.

XK SUSPENSION 2 - 1

SUSPENSION

TABLE OF CONTENTS

page page

WHEEL ALIGNMENT ......................1

FRONT .................................7

WHEEL ALIGNMENT

TABLE OF CONTENTS

page page

WHEEL ALIGNMENT

DESCRIPTION .................................2

OPERATION ...................................2

DIAGNOSIS AND TESTING

PRE-ALIGNMENT INSPECTION ...............3

REAR .................................53

STANDARD PROCEDURE

CAMBER, CASTER AND TOE ADJUSTMENT . . . 4

TOE ADJUSTMENT ..........................5

SPECIFICATIONS

ALIGNMENT .................................5

2 - 2 WHEEL ALIGNMENT XK

WHEEL ALIGNMENT

DESCRIPTION

CAUTION: STEERING COLUMN MODULE IS CENTERED TO THE VEHICLES STEERING SYSTEM. FAILURE
TO KEEP THE SYSTEM AND STEERING COLUMN MODULE CENTERED AND LOCKED/INHIBITED FROM
ROTATING CAN RESULT IN STEERING COLUMN MODULE DAMAGE. (Refer to 8 - ELECTRICAL/RE­STRAINTS/CLOCKSPRING - STANDARD PROCEDURE).

NOTE: Suspension components with rubber/ure­thane bushings should be tightened with the vehi­cle at normal ride height. It is important to have
the springs supporting the weight of the vehicle
when the fasteners are torqued. If springs are not
at their normal ride position, vehicle ride comfort
could be affected and premature bushing wear
may occur.

Wheel alignment involves the correct positioning of the
wheels in relation to the vehicle. The positioning is
accomplished through suspension and steering link­age adjustments. An alignment is considered essential
for efficient steering, good directional stability and to
minimize tire wear. The most important measurements
of an alignment are caster, camber and toe.

CAUTION: Never attempt to modify suspension or steering components by heating or bending.

OPERATION

• CASTER (1) is the forward or rearward tilt of the
steering knuckle from vertical. Tilting the top of
the knuckle forward provides less positive caster.
Tilting the top of the knuckle rearward provides
more positive caster. Positive caster promotes
directional stability. This angle enables the front
wheels to return to a straight ahead position after
turns.

• CAMBER (2) is the inward or outward tilt of the
wheel relative to the center of the vehicle. Tilting
the top of the wheel inward provides negative
camber. Tilting the top of the wheel outward pro­vides positive camber. Incorrect camber will
cause wear on the inside or outside edge of the
tire.

• TOE (4) is the difference between the leading
inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause’s unstable
steering, uneven tire wear and steering wheel off- center. The wheel toe position is the final front wheel align­ment adjustment.

• THRUST ANGLE (3) is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle
can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s)
must be replaced to correct the thrust angle.

XK WHEEL ALIGNMENT 2 - 3

DIAGNOSIS AND TESTING
PRE-ALIGNMENT INSPECTION

Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to
Suspension and Steering System Diagnosis Chart below for additional information.

1. Inspect tires for size, air pressure and tread wear.

2. Inspect front wheel bearings for wear.

3. Inspect front wheels for excessive radial or lateral runout and balance.

4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding.

5. Inspect suspension components for wear and noise.

6. Check suspension ride height.

7. Road test the vehicle.

SUSPENSION AND STEERING SYSTEM DIAGNOSIS

CONDITION POSSIBLE CAUSES CORRECTION

FRONT END NOISE 1. Loose or worn wheel bearing. 1. Replace wheel bearing.

2. Loose or worn steering or
suspension components.

3. Loose or worn steering or
suspension components.

EXCESSIVE PLAY IN
STEERING

FRONT WHEELS SHIMMY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.

VEHICLE INSTABILITY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.

1. Loose or worn wheel bearing. 1. Replace wheel bearing.

2. Loose or worn steering or
suspension components.

3. Loose or worn steering gear. 3. Replace steering gear.

2. Loose or worn steering or
suspension components.

3. Tires worn or out of balance. 3. Replace or balance tires.

4. Alignment. 4. Align vehicle to specifications.

2. Loose or worn steering or
suspension components.

3. Tire pressure. 3. Adjust tire pressure.

4. Alignment. 4. Align vehicle to specifications.

2. Tighten or replace components as
necessary.

3. Tighten or replace components as
necessary.

2. Tighten or replace components as
necessary.

2. Tighten or replace components as
necessary.

2. Tighten or replace components as
necessary.

EXCESSIVE STEERING
EFFORT

1. Loose or worn steering gear. 1. Replace steering gear.

2. Column coupler binding. 2. Replace coupler.

3. Tire pressure. 3. Adjust tire pressure.

4. Alignment. 4. Align vehicle to specifications.

2 - 4 WHEEL ALIGNMENT XK

CONDITION POSSIBLE CAUSES CORRECTION

VEHICLE PULLS TO ONE
SIDE

1. Tire pressure. 1. Adjust tire pressure.

2. Tire. 2. Criss-Cross Front Tires.

3. Alignment. 3. Align vehicle to specifications.

4. Loose or worn steering or
suspension components.

5. Radial tire lead. 5. Rotate or replace tire as necessary.

6. Brake pull. 6. Repair brake as necessary.

7. Ride height. 7. Measure and adjust ride height.

4. Tighten or replace components as
necessary.

STANDARD PROCEDURE
CAMBER, CASTER AND TOE ADJUSTMENT

NOTE: SUSPENSION HEIGHT MEASUREMENT MUST BE PERFORMED BEFORE AN ALIGNMENT.

Camber and caster angle adjustments involve changing the position of the lower control arm with the slots in the
frame brackets to move the lower control arm inwards or outwards for proper adjustment. This can be achieved by

using a long pry bar with a curved tip and inserting the pry bar into the lower control arm frame brackets
and prying inwards or outwards.

NOTE: Camber and caster adjustments must be made at the lower control arm. Do not use the upper con­trol arm for Camber and Caster adjustments.

NOTE: When the lower control arm pivot bolts are loosened the lower control arm will normally go outwards
automatically with the weight of the vehicle.

CASTER

Moving the rear position of the lower control arm at the frame in or out, will change the caster angle significantly
and camber angle only slightly. To maintain the camber angle while adjusting caster, move the rear of the lower
control arm in or out. Then move the front of the lower control arm slightly in the opposite direction.

CAMBER

Move both the front and rear of the lower control arm together in or out. This will change the camber angle signif­icantly and caster angle slightly.

After adjustment is made tighten the lower control arm bolt & nuts to FRONT169 N·m (125 ft. lbs.) and the REAR
88 N·m (65 ft. lbs.).

XK WHEEL ALIGNMENT 2 - 5

TOE ADJUSTMENT

The wheel toe position adjustment is the final adjust­ment.

1. Start the engine and turn wheels both ways before
straightening the wheels. Secure the steering
wheel with the front wheels in the straight-ahead
position.

2. Loosen the tie rod jam nuts (3).

NOTE: Each front wheel should be adjusted for
one-half of the total toe position specification.
This will ensure the steering wheel will be cen­tered when the wheels are positioned straight­ahead.

3. Adjust the wheel toe position by turning the inner
tie rod (4) as necessary.

4. Tighten the tie rod jam nut (3) to 75N·m (55 ft. lbs.).

5. Verify the specifications.

6. Turn off engine.

TOE ADJUSTMENT

SUSPENSION HEIGHT MESUREMENT MUST BE
PERFORMED BEFORE AN ALIGNMENT.

The wheel toe position adjustment is the final adjust­ment.

1. Start the engine and turn wheels both ways before
straightening the wheels. Secure the steering
wheel with the front wheels in the straight-ahead
position.

2. Loosen the tie rod jam nuts (3).

NOTE: Each front wheel should be adjusted for
one-half of the total toe position specification.
This will ensure the steering wheel will be cen­tered when the wheels are positioned straight­ahead.

3. Adjust the wheel toe position by turning the inner tie rod (4) as necessary.

4. Tighten the tie rod jam nut (3) to 75N·m (55 ft. lbs.).

5. Verify the specifications.

6. Turn off engine.

SPECIFICATIONS
ALIGNMENT

NOTE: Specifications are in degrees.

FRONT

SPECIFICATIONS

2 - 6 WHEEL ALIGNMENT XK

DESCRIPTION SPECIFICATION

PREFERRED CASTER

4.0°

RANGE 3.55° to 4.45° + 0.15° to - 0.70° 0° to + 0.5°

MAX RT/LT DIFFERENCE 0.5° 0.5° 0.5°

CAMBER

2 0.25°

TOTAL TOE-IN

+ 0.25°

REAR AXLE

SPECIFICATIONS

DESCRIPTION SPECIFICATION

PREFERRED CAMBER

-.25°

RANGE 0° ± 0.5° 0° ± 0.25° 0° + 0.5°

THRUST ANGLE

0°

TOTAL TOE-IN

+.25°

XK FRONT 2 - 7

FRONT

TABLE OF CONTENTS

page page

FRONT

DESCRIPTION .................................8

SPECIFICATIONS

TORQUE ....................................8

SPECIAL TOOLS

FRONT SUSPENSION ........................9

BUSHINGS

DESCRIPTION ................................10

REMOVAL

STABILIZER BAR TO FRAME BUSHING ......10

CLEVIS BRACKET BUSHING ................10

INSTALLATION

STABILIZER BAR TO FRAME BUSHING .......11

CLEVIS BRACKET BUSHING ................12

HUB / BEARING

DESCRIPTION ................................13

OPERATION ..................................13

REMOVAL ....................................13

INSTALLATION ...............................15

KNUCKLE

DESCRIPTION ................................17

OPERATION ..................................17

REMOVAL ....................................17

INSTALLATION ...............................20

LOWER BALL JOINT

DIAGNOSIS AND TESTING

LOWER BALL JOINT ........................23

REMOVAL ....................................23

INSTALLATION ...............................25

LOWER CONTROL ARM

DESCRIPTION ................................26

OPERATION ..................................26

REMOVAL ....................................26

INSTALLATION ...............................27

SHOCK

DESCRIPTION ................................29

OPERATION ..................................29

REMOVAL

RIGHT FRONT ..............................29

LEFT FRONT ...............................31

INSTALLATION

RIGHT FRONT ..............................33

LEFT FRONT ...............................34

SPRING

REMOVAL ....................................37

INSTALLATION ...............................37

STABILIZER BAR

DESCRIPTION ................................39

OPERATION ..................................39

REMOVAL ....................................39

INSTALLATION ...............................40

STABILIZER LINK

REMOVAL ....................................41

INSTALLATION ...............................41

UPPER BALL JOINT

DIAGNOSIS AND TESTING

UPPER BALL JOINT ........................42

REMOVAL ....................................42

INSTALLATION ...............................44

UPPER CONTROL ARM

DESCRIPTION ................................46

OPERATION ..................................46

REMOVAL ....................................46

INSTALLATION ...............................47

CLEVIS BRACKET

REMOVAL ....................................49

INSTALLATION ...............................51

2 - 8 FRONT XK

FRONT

DESCRIPTION

NOTE: Suspension components with rubber/ure­thane bushings should be tightened with the vehi­cle at normal ride height. It is important to have
the springs supporting the weight of the vehicle
when the fasteners are torqued. If springs are not
at their normal ride position, vehicle ride comfort
could be affected and premature bushing wear
may occur.

The front suspension is designed to allow each wheel
to adapt to different road surfaces independently. The
wheels are mounted to hub bearings on the steering
knuckle spindles (5). The double-row hub bearings are
sealed and lubricated for life. The steering knuckles
turn (pivot) on ball joints integral to the outboard por­tion of the upper control arms (3) and pressed into the
lower steering knuckle. The ball joints are lubricated
for life.

SPECIFICATIONS
TORQUE

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Shock Absorber Upper

Nuts

Shock Absorber Clevis

Bracket

Shock upper Mounting Nut 39 25 —

Clevis Bracket to Lower

Control Arm

Upper Control Arm

Bolt/Nut to Body

Lower Control Arm Bolt

Rear Pivot

Lower Control Arm

Bolt/Nut

Front Pivot
Upper Ball Joint Nut 95 70 —
Lower Ball Joint Nut 95 70 —

Stabilizer Bar Retainer

Bolts

Stabilizer Bar Link Upper

Nut

Stabilizer Bar Link Lower

Bolt

Hub Bearing Knuckle Bolts 115 85 —

95 70 —

122 90 —

169 125 —

108 80 —

88 65 —

169 125 —

129 95 —

108 80 —

115 85 —

XK FRONT 2 - 9

SPECIAL TOOLS
FRONT SUSPENSION

CLEVIS BUSHING - 9653

Remover C-4150A

BALL JOINT PRESS - C-4212F

PULLER - 8677

BALL JOINT - 9654

BALL JOINT - C-4212-3

Puller C-3894–A

2 - 10 FRONT XK

BUSHINGS

DESCRIPTION

Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height.
It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are
not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur.

REMOVAL
STABILIZER BAR TO FRAME BUSHING

1. Raise and support the vehicle.

2. Remove the front splash shield.

3. Remove the two stabilizer bar retainer bracket bolts
(2).

4. Remove the bushing clamp (2).

5. Remove the stabilizer bar bushing (3).

CLEVIS BRACKET BUSHING

1. Remove the clevis bracket (3) from the shock (1)
(Refer to 2 - SUSPENSION/FRONT/CLEVIS
BRACKET - REMOVAL).

XK FRONT 2 - 11

NOTE: On 4X4 vehicles install the C-4212-F
between the axle shaft and the lower control in
order to allow the tool clearance to press the
bushing in and out.

NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure
proper operation during the removal and installa­tion process.

2. Press the bushing out using special tools C-4212-F
(Press) (1), 9653–1 (driver) (4) and 9653–2
(Receiver) (2) from the lower control arm (3).

INSTALLATION
STABILIZER BAR TO FRAME BUSHING

1. Install the stabilizer bar bushing (3) to the bar (1).

2. Install the stabilizer bar bushing reatainer bracket
(2) bolts and tighten the two mounting bolts.

3. Install the front splash shield.

4. Lower the vehicle.

2 - 12 FRONT XK

CLEVIS BRACKET BUSHING

NOTE: On 4X4 vehicles install the C-4212-F
between the axle shaft and the lower control in
order to allow the tool clearance to press the
bushing in and out.

NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure
proper operation during the removal and installa­tion process.

1. Install the new clevis bracket bushing (3) into the
lower control arm (5) using tools C-4212-F (Press)
(1), 9653–3 (driver) (2), 9653–4 (Depth gauge) (4)
the depth gauge will automatically set the depth of
the bushing (3) in the control arm (5).

2. Install the clevis bracket (3) to the shock (1) (Refer
to 2 - SUSPENSION/FRONT/CLEVIS BRACKET ­INSTALLATION).

XK FRONT 2 - 13

HUB / BEARING

DESCRIPTION

The bearing used on the front hub of this vehicle is the combined hub and bearing unit type assembly. This unit
assembly combines the front wheel mounting hub (flange) and the front wheel bearing into a one piece unit. The
wheel mounting studs are the only replaceable component of the hub/bearing assembly.

OPERATION

The hub/bearing assembly is mounted to the steering knuckle and is retained by three mounting bolts accessible
from the back of the steering knuckle. The hub/bearing unit is not serviceable and must be replaced as an assembly
if the bearing or the hub is determined to be defective.

REMOVAL

1. Raise and support the vehicle.

2. Remove the wheel and tire assembly.

Support the caliper, Do not let the caliper hang by
the hose.

3. Remove the disc brake caliper (1) (Refer to 5 ­BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).

4. Remove the brake caliper adaptor (1) (Refer to 5 ­BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).

2 - 14 FRONT XK

5. Remove and discard the o-ring (2) and then
remove the disc brake rotor (1) (Refer to 5 ­BRAKES/HYDRAULIC/MECHANICAL/ROTORS ­REMOVAL).

6. Remove the wheel speed sensor nut (2).

7. Remove the wheel speed sensor (Refer to 5 ­BRAKES/ELECTRICAL/FRONT WHEEL SPEED
SENSOR - REMOVAL).

8. Remove the 3 hub bearing mounting bolts from the
back of the steering knuckle. Remove hub bearing
(3) from the steering knuckle.

XK FRONT 2 - 15

INSTALLATION

1. Install the hub bearing (3) to the knuckle.

2. Install the hub bearing to knuckle and the 3 bolts
then tighten to 115 N·m (85 ft. lbs.).

3. Install the wheel speed sensor (Refer to 5 ­BRAKES/ELECTRICAL/FRONT WHEEL SPEED
SENSOR - INSTALLATION).

4. Install the wheel speed sensor nut (2).

5. Install the brake rotor (1) (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/ROTORS ­INSTALLATION).

2 - 16 FRONT XK

6. Install the brake caliper adaptor (1) (Refer to 5 ­BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).

7. Install the caliper (1) (Refer to 5 - BRAKES/HY­DRAULIC/MECHANICAL/DISC BRAKE CALIPERS

- INSTALLATION).

8. Install the wheel and tire assembly (Refer to 22 - TIRES/WHEELS - STANDARD PROCEDURE).

9. Remove the support and lower the vehicle.

XK FRONT 2 - 17

KNUCKLE

DESCRIPTION

The knuckle is a single casting with legs machined for the upper and lower ball joints. The knuckle also has
machined mounting locations for the front brake calipers and hub bearing.

OPERATION

The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows
the vehicle to be steered.

REMOVAL

1. Raise and support the vehicle.

2. Remove the tire and wheel assembly.

CAUTION: Never allow the disc brake caliper to
hang from the brake hose. Damage to the brake
hose will result. Provide a suitable support to
hang the caliper securely.

3. Remove the brake caliper (1).

4. Remove the caliper adapter (1). (Refer to 5 ­BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).

2 - 18 FRONT XK

5. Remove the o-ring (2) and discard then remove
disc brake rotor (1). (Refer to 5 - BRAKES/HY­DRAULIC/MECHANICAL/ROTORS - REMOVAL).

6. Remove the wheel speed sensor bolt (2) and dis­connect the wire from the retaining clips from the
knuckle (Refer to 5 - BRAKES/ELECTRICAL/
FRONT WHEEL SPEED SENSOR - REMOVAL).

7. Remove the axle shaft nut. (if equipped with four
wheel drive)

8. Remove the hub/bearing (3). (Refer to 2 - SUS­PENSION/FRONT/HUB / BEARING - REMOVAL).

9. Remove the outer tie rod end retaining nut.

10. Seperate the outer tie rod end (3) from the steer-

ing knuckle using special tool 8677(5). (Refer to
19 - STEERING/LINKAGE/TIE ROD END ­REMOVAL).

XK FRONT 2 - 19

11. Remove the lower ball joint nut.

12. Seperate the lower ball joint from the knuckle (1)

using tool C–4150A (2).

13. Remove the upper ball joint nut.

14. Seperate the upper ball joint (2) from the knuckle

(3) using tool 8677 (1).

15. Remove the knuckle (3) from the vehicle.

2 - 20 FRONT XK

INSTALLATION

1. Install the knuckle (1) to the vehicle.

2. Install the lower ball joint into the knuckle.

3. Install the lower ball joint nut. Tighten the nut to 95
N·m (70 ft.lbs.).

4. Install the upper ball joint (2) into the knuckle (3)

5. Install the upper ball joint nut (4). Tighten the nut to
95 N·m (70 ft.lbs.).

XK FRONT 2 - 21

6. Install the outer tie rod end to the steering knuckle.
(Refer to 19 - STEERING/LINKAGE/TIE ROD END

- INSTALLATION).

7. Install the hub/bearing (3), Tighten to 115 N·m (85
ft.lbs.). (Refer to 2 - SUSPENSION/FRONT/HUB /
BEARING - INSTALLATION).

8. Install the axle shaft nut. Tighten the nut to 135
N·m (96 ft.lbs.).(if equipped with four wheel drive).

9. Install the wheel speed sensor (2) and reclip the
wire to the knuckle. (Refer to 5 - BRAKES/ELEC­TRICAL/FRONT WHEEL SPEED SENSOR ­INSTALLATION).

10. Install the disc brake rotor (1). (Refer to 5 -

BRAKES/HYDRAULIC/MECHANICAL/ROTORS ­INSTALLATION).

2 - 22 FRONT XK

11. Install the caliper adapter (1). (Refer to 5 -

BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).

12. Install the tire and wheel assembly. (Refer to 22 -

TIRES/WHEELS/WHEELS - STANDARD PROCE­DURE).

13. Perform wheel alignment (Refer to 2 - SUSPEN-

SION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).

XK FRONT 2 - 23

LOWER BALL JOINT

DIAGNOSIS AND TESTING
LOWER BALL JOINT

1. Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as pos­sible. Lower the vehicle to allow the stands to support some or all of the vehicle weight.

2. Mount a dial indicator solidly to the topside of the lower control arm and then zero the dial indicator.

3. Position the indicator plunger against the bottom surface of the steering knuckle.

NOTE: The dial indicator plunger must be perpendicular to the machined surface of the steering knuckle.

4. Position a pry bar under the tire assembly. Pry upwards on the tire assembly.

5. If the travel exceeds 0.5 mm (0.020 in.), replace the lower ball joint (Refer to 2 - SUSPENSION/FRONT/LOWER
BALL JOINT - REMOVAL).

REMOVAL

1. Remove the tire and wheel assembly.

2. Remove the brake caliper and rotor (Refer to 5 ­BRAKES/HYDRAULIC/MECHANICAL/ROTORS ­REMOVAL).

3. Disconnect the tie rod (2) from the steering knuckle
(4) using special tool C-3894-A (1) (Refer to 19 ­STEERING/LINKAGE/TIE ROD END - REMOVAL).

4. Separate the upper ball joint (2) from the knuckle
(3) using special tool 8677 (1).

2 - 24 FRONT XK

5. Separate the lower ball joint (3) from the steering
knuckle (1) using special tool 8677 (2).

6. Remove the steering knuckle (Refer to 2 - SUSPENSION/FRONT/KNUCKLE - REMOVAL).

7. Remove the clevis bracket and move the halfshaft to the side and support the halfshaft out of the way 4X4 only
(Refer to 2 - SUSPENSION/FRONT/CLEVIS BRACKET - REMOVAL).

NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure
proper operation during the removal and installa­tion process.

8. Press the ball joint from the lower control arm (3)
using special tools C-4212-F (PRESS) (1),
C–4212–3 (Driver) (2) and 9654–3 (Receiver) (4).

XK FRONT 2 - 25

INSTALLATION

NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure
proper operation during the removal and installa­tion process.

1. Install the ball joint (4) into the control arm (3) and
press in using special tools C-4212-F (press) (1),
9654–1 (Driver) (5) and 9654–2 (Receiver) (2).

2. Stake the ball joint flange in four evenly spaced places around the ball joint flange, using a chisel and hammer.

3. Remove the support for the halfshaft and install into position, then install the clevis bracket. 4X4 only (Refer to
2 - SUSPENSION/FRONT/CLEVIS BRACKET - INSTALLATION).

4. Install the steering knuckle (Refer to 2 - SUSPENSION/FRONT/KNUCKLE - INSTALLATION).

5. Install the tie rod end into the steering knuckle (Refer to 19 - STEERING/LINKAGE/TIE ROD END - INSTALLA­TION).

6. Install and tighten the halfshaft nut to 251 N·m (185 ft. lbs.). (If Equipped).

7. Install the brake caliper and rotor (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - INSTALLA­TION).

8. Install the tire and wheel assembly (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PROCEDURE).

9. Check the vehicle ride height (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).

10. Perform a wheel alignment (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).

2 - 26 FRONT XK

LOWER CONTROL ARM

DESCRIPTION

The front lower suspension arms are cast iron.

OPERATION

The bushings provide isolation from the road. The arms mount to the cradle bracket and the knuckle. The arm and
bushings provide location and react to loads from the road.

REMOVAL

1. Raise and support the vehicle.

2. Remove the tire and wheel assembly.

3. Remove the steering knuckle (3). (Refer to 2 ­SUSPENSION/FRONT/KNUCKLE - REMOVAL).

4. Remove the shock clevis bracket (3) from the lower
control arm.

5. Remove the stabilizer link (2) at the lower control
arm.

XK FRONT 2 - 27

6. Remove the nut and bolt from the front of the lower
control arm.

7. Remove the rear bolts (2) and flag nuts (3) from
the lower control arm (1).

8. Remove the lower control arm from the vehicle.

INSTALLATION

1. Position the lower suspension arm into the cradle.

2. Install the rear bolts (2) and flag nuts (3) to secure
the lower control arm (1) to the frame, Tighten the
bolts (3) to 88 N·m (65 ft lbs).

3. Install the nut and bolt for the front of the lower
control arm Tighten to 169 N·m (125 ft lbs).

2 - 28 FRONT XK

NOTE: Orientation of the flag bolt is critical Flag
and head of the bolt (7) must be installed on the
forward side of the lower control arm.

4. Install the lower clevis bolt at the lower control arm
and tighten to 169 N·m (125 ft lbs).

5. Install the stabilizer link (6) at the lower control arm
and tighten to 115 N·m (85 ft lbs).

6. Install the steering knuckle (3) to the upper ball
joint (2) and tighten the nut (4) to 95 N·m (70 ft.
lbs.) (Refer to 2 - SUSPENSION/FRONT/
KNUCKLE - INSTALLATION).

7. Install the tire and wheel assembly.

8. Lower the vehicle.

9. Perform wheel alignment (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).

XK FRONT 2 - 29

SHOCK

DESCRIPTION

The top of the shock absorbers are bolted to the body. The bottom of the shocks are bolted to the clevis bracket
then the bracket is bolted to the lower control arm. The standard shocks have conventional twin tube construction
and are low pressure gas charged. Gas charging prevents cavitation during rough road operation.

OPERATION

The shock absorbers dampen jounce and rebound motion of the vehicle over various road conditions and limit sus­pension rebound travel.

REMOVAL
RIGHT FRONT

1. Remove the air box cover and air intake hose.

2. Disconnect the cruise control servo electrical connector.

3. Remove the coolant reservoir mounting bolt and move the coolant reservoir off to the side.

4. Remove the four upper shock mounting nuts (1).

5. Raise and support the vehicle.

6. Remove the tire.

7. Remove the two brake caliper adapter bolts.

8. Support the brake caliper adaptor and caliper. Do not allow the caliper to hang by the brake hose.

9. Remove the disc brake rotor.

2 - 30 FRONT XK

10. Remove the upper ball joint nut.

11. Separate the upper ball joint (2) from the knuckle

(3) using special tool 8677(1).

12. Remove the lower clevis bolt (3) at the lower con-

trol arm.

13. Remove the lower stabilizer bolt (2) at the lower

control arm.

14. Remove the shock from the vehicle.

15. Remove the spring if necessary (Refer to 2 -

SUSPENSION/FRONT/SPRING - REMOVAL).

XK FRONT 2 - 31

LEFT FRONT

1. Remove the air box cover and air intake hose.

2. Remove the 3 PDC bracket nuts (1).

3. Move the PDC (1) off to the side to access the four
upper shock mount nuts (2).

4. Remove the four upper shock mount nuts (2).

5. Raise and support the vehicle.

6. Remove the tire.

7. Remove the two brake caliper adapter bolts.

8. Support the brake caliper adaptor and caliper. Do not allow the caliper to hang by the brake hose.

9. Remove the disc brake rotor.

2 - 32 FRONT XK

10. Remove the upper ball joint nut.

11. Separate the upper ball joint (2) from the knuckle

(3) using special tool 8677 (1).

12. Remove the lower clevis bolt (3) at the lower con-

trol arm.

13. Remove the lower stabilizer bolt (2) at the lower

control arm.

14. Remove the shock (3) from the vehicle.

15. Remove the spring if necessary (Refer to 2 -

SUSPENSION/FRONT/SPRING - REMOVAL).

XK FRONT 2 - 33

INSTALLATION
RIGHT FRONT

1. Install the clevis bracket (4) to the shock (3) and
tighten to 122 N·m (90 ft. lbs.).

2. Install the shock assembly (3) to the vehicle.

3. Install the four upper shock nuts (1), Tighten to 95
N·m ( 70 ft. lbs.).

4. Install the coolant reservoir bolt.

5. Reconnect the cruise control servo wiring connector.

6. Install the air box cover and air intake hose.

7. Raise the vehicle up.

2 - 34 FRONT XK

8. Install the lower stabilizer bolt (3) at the lower con­trol arm.

9. Install the lower clevis bolt (2) at the lower control
arm and tighten to 169 N·m (125 ft. lbs.).

10. Install the upper ball joint into the knuckle (1) and

tighten the nut to 75 N·m (55 ft. lbs.).

11. Install the disc brake rotor.

12. Install the caliper adaptor mounting bolts to 176 N·m (130 ft. lbs.).

13. Install the tire and wheel assembly.

14. Lower the vehicle.

LEFT FRONT

1. Install the clevis bracket (4) to the shock (3) and
tighten to 122 N·m (90 ft. lbs.).

2. Install the shock assembly (3) to the vehicle.

XK FRONT 2 - 35

3. Install the four upper shock nuts (2), Tighten to 95
N·m ( 70 ft. lbs.).

4. Install the 3 PDC (1) bracket nuts.

5. Raise the vehicle up.

6. Install the lower stabilizer bolt (3) at the lower con­trol arm and tighten to 115 N·m (85 ft. lbs.).

7. Install the lower clevis bolt (2) at the lower control
arm and tighten to 169 N·m (125 ft. lbs.).

8. Install the upper ball joint into the knuckle (1) and
tighten the nut to 75 N·m (55 ft. lbs.).

9. Install the disc brake rotor.

2 - 36 FRONT XK

10. Install the caliper adaptor mounting bolts to 176 N·m (130 ft. lbs.).

11. Install the tire and wheel assembly.

12. Lower the vehicle.

XK FRONT 2 - 37

SPRING

REMOVAL

1. Remove the shock (Refer to 2 - SUSPENSION/
FRONT/SHOCK - REMOVAL).

2. Install the shock assembly in the Branick 7200T
spring removal/installation tool or equivalent (1).

3. Compress the spring (2).

4. Remove the upper shock nut (2).

NOTE: The nub (1) in the upper shock mount (3)
must be 180° from the centerline of the lower
bracket (9) on the shock (8) for proper installation.

5. Remove the shock (8).

6. Remove the shock upper mount (3).

7. Remove and inspect the upper (5) and lower (7)
spring isolators.

INSTALLATION

1. Compress the spring (2).

2 - 38 FRONT XK

2. Install the lower isolator (7).

3. Position the shock (8) into the coil spring (6) make
sure the jounce bumper (4) is on the shock rod.

4. Install the upper isolator (5).

NOTE: For proper orientation the nub hole (1) in
the upper shock plate (3) must be 180° in a cen­terline from the bracket (9) at the bottom of the
shock (8).

5. Install the upper shock mount (3).

6. Install the shock upper mounting nut (2) Tighten to
39 N·m ( 25 ft. lbs.).

7. Decompress the spring.

8. Remove the shock assembly from the spring com­pressor tool (1).

9. Install the shock assembly (Refer to 2 - SUSPEN­SION/FRONT/SHOCK - INSTALLATION).

XK FRONT 2 - 39

STABILIZER BAR

DESCRIPTION

The bar extends across the front underside of the chassis and is mounted to the cradle. Links are connected from
the bar to the lower control arms. The stabilizer bar and links are isolated by rubber bushings.

OPERATION

The stabilizer bar is used to control vehicle body sway during turns. The spring steel bar helps to control the vehicle
body in relationship to the suspension.

REMOVAL

1. Raise and support the vehicle.

2. Remove the front splash shield.

3. Remove the stabilizer bar link upper nut (1) & bolt
(2).

4. Remove the two stabilizer bushing clamp (2) bolts.

5. Remove the stabilizer bar (1).

2 - 40 FRONT XK

INSTALLATION

1. Install the stabilizer bar (1) to the vehicle.

2. Install the stabilizer bushing clamp (2) and tighten
the bolts to 129N·m ( 95 ft. lbs.).

3. Install the upper stabilizer link (3) and tighten nut
(1) & bolt (2) to 108 N·m (80 ft. lbs.).

4. Install the front splash shield.

5. Lower the vehicle.

XK FRONT 2 - 41

STABILIZER LINK

REMOVAL

1. Raise and support the vehicle.

2. Remove the tire and wheel assembly.

3. Remove the upper link bolt/nut (1&2).

4. Remove the lower link bolt (6).

5. Remove the stabilizer link (3).

INSTALLATION

1. Install the stabilizer link (3) to the vehicle.

2. Install the lower link bolt (6) and tighten to 115 N·m
(85 ft. lbs.)

3. Install the upper link bolt/nut (1&2) and tighten to
108 N·m (80 ft. lbs.).

4. Install the tire and wheel assembly.

5. lower the vehicle.

2 - 42 FRONT XK

UPPER BALL JOINT

DIAGNOSIS AND TESTING
UPPER BALL JOINT

1. Raise the front of the vehicle. Place safety floor
stands under both lower control arms as far out­board as possible. Lower the vehicle to allow the
stands to support some or all of the vehicle weight.

2. Remove the front tires.

3. Mount a dial indicator (1) solidly to the frame and
then zero the dial indicator.

4. Position dial indicator plunger on the topside of the
upper ball joint (5).

NOTE: The dial indicator plunger must be perpen­dicular to the machined surface of the ball joint.

NOTE: Use care not to pry or tear the ball joint
boot, when checking the free play.

5. Position a pry bar (3) between the steering knuckle (4) and the upper control arm (2). Pry upwards on the upper
control arm.

6. If the travel exceeds 0.5 mm (0.020 in.), replace the upper ball joint (Refer to 2 - SUSPENSION/FRONT/UPPER
BALL JOINT - REMOVAL).

7. If the upper ball joint is within specs reinstall the front tires (Refer to 22 - TIRES/WHEELS/WHEELS - STAN­DARD PROCEDURE).

REMOVAL

1. Raise vehicle and support the axle.

2. Remove the tire and wheel.

3. Remove the upper ball joint retaining nut.

4. Separate the upper ball joint (2) from the knuckle
(3) using special tool #8677 (1).

XK FRONT 2 - 43

5. Move the knuckle (3) out of the way to allow ball
joint removal tool access.

NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure
proper operation during the removal and installa­tion process.

6. Press the ball joint from the upper control arm (1)
using special tools C-4212-F (PRESS) (2) and
9652 (Driver) (3).

2 - 44 FRONT XK

INSTALLATION

NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure
proper operation during the removal and installa­tion process.

1. Install the ball joint (4) into the upper control arm
(5) and press in using special tools C-4212-F
(press) (2), 9652 (Driver) (1) and 8975–2
(Receiver) (4).

2. Install the upper ball joint (2) into the knuckle (3).

3. Install the upper ball joint retaining nut (4) and
tighten to 95N·m (70 ft. lbs.).

XK FRONT 2 - 45

4. Install the tire and wheel.

5. Remove the supports and lower the vehicle.

6. Perform a wheel alignment (Refer to 2 - SUSPEN­SION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).

2 - 46 FRONT XK

UPPER CONTROL ARM

DESCRIPTION

The upper suspension arms are forged steel and use rubber bushings at each end of the arm.

OPERATION

The arms mount to the unibody frame rail bracket and the knuckle. The arm and bushings provide location and
react to loads from the road. The bushings provide isolation from the road.

REMOVAL

1. Raise vehicle and support the axle.

2. Remove the tire and wheel.

3. Remove the inner fender well (2).

4. Remove the upper ball joint retaining nut.

5. Seperate the upper ball joint (2) from the knuckle
(3) using special tool #8677 (1).

XK FRONT 2 - 47

6. Remove the nut and bolt (1) securing the upper
control arm (5) to the body.

7. Remove the upper control arm (5) from the vehicle.

INSTALLATION

1. Install the upper control arm (5) to the vehicle.

2. Install the nut and bolt (1) securing the upper con­trol arm (5) to the body and tighten to 108 N·m (80
ft lbs)..

2 - 48 FRONT XK

3. Install the upper ball joint (2) into the knuckle (3).

4. Install the upper ball joint retaining nut (4) and
tighten the nut to 95N·m (70 ft.lbs.).

5. Install the inner fender well (2).

6. Install the tire and wheel.

7. Remove the supports and lower the vehicle.

8. Perform a wheel alignment (Refer to 2 - SUSPEN­SION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).

XK FRONT 2 - 49

CLEVIS BRACKET

REMOVAL

1. Raise and support the vehicle.

2. Remove the tire.

3. Remove the two brake caliper adapter bolts (3).

4. Support the brake caliper adaptor and caliper. Do

not allow the caliper to hang by the brake hose.

5. Remove the disc brake rotor.

6. Remove the upper ball joint nut (4).

7. Separate the upper ball joint (2) from the knuckle
(3) using special tool 8677.

2 - 50 FRONT XK

8. Remove the clevis bolt (2) at the shock (1).

9. Remove the lower clevis bolt/nut (4) at the lower
control arm.

10. Remove the lower stabilizer link bolt (6).

11. Remove the clevis bracket (3).

XK FRONT 2 - 51

INSTALLATION

1. Install the clevis bracket (3) to the shock (1) and
tighten bolt (2) to 122 N·m (90 ft. lbs.).

NOTE: Orientation of the flag bolt is critical Flag
and head of the bolt (7) must be installed on the
forward side of the lower control arm.

2. Install the lower stabilizer link bolt (6) and tighten to
115 N·m (85 ft. lbs.).

2 - 52 FRONT XK

3. Install the lower clevis bolt/nut (4) at the lower con­trol arm and tighten to 169 N·m (125 ft. lbs.).

4. Install the upper ball joint (2) into the knuckle (3)
and tighten the nut to 95N·m ( 70ft. lbs.).

5. Install the disc brake rotor.

6. Install the caliper adaptor mounting bolts (3) to 25
N·m ( 18 ft. lbs.).

7. Install the tire and wheel assembly.

8. Lower the vehicle.

XK REAR 2 - 53

REAR

TABLE OF CONTENTS

page page

REAR

DESCRIPTION ................................54

WARNING ....................................54

DIAGNOSIS AND TESTING - REAR

SUSPENSION ..............................54

SPECIFICATIONS

TORQUE ...................................55

BUSHINGS

REMOVAL ....................................56

INSTALLATION ...............................56

LOWER CONTROL ARM

DESCRIPTION ................................57

OPERATION ..................................57

REMOVAL

LEFT SIDE .................................57

RIGHT SIDE ................................58

INSTALLATION

LEFT SIDE .................................59

RIGHT SIDE ................................60

UPPER CONTROL ARM

DESCRIPTION ................................62

OPERATION ..................................62

REMOVAL

LEFT SIDE .................................62

RIGHT SIDE ................................63

INSTALLATION

LEFT SIDE .................................63

RIGHT SIDE ................................64

SHOCK

DESCRIPTION ................................66

OPERATION ..................................66

REMOVAL ....................................66

INSTALLATION ...............................67

SPRING

DESCRIPTION ................................68

OPERATION ..................................68

REMOVAL ....................................68

INSTALLATION ...............................68

JOUNCE BUMPER/CUP

REMOVAL ....................................70

INSTALLATION ...............................70

STABILIZER BAR

DESCRIPTION ................................72

OPERATION ..................................72

REMOVAL ....................................72

INSTALLATION ...............................73

STABILIZER LINK

REMOVAL ....................................74

INSTALLATION ...............................74

TRACK BAR

REMOVAL ....................................75

INSTALLATION ...............................76

2 - 54 REAR XK

REAR

DESCRIPTION

The rear suspension is comprised of :

• Drive axle

• Shock absorbers

• Coil springs

• Lower suspension arms (3)

• Upper suspension arm

• Stabilizer bar

CAUTION: Suspension components with rubber/
urethane bushings should be tightened with the
vehicle at normal ride height. It is important to
have the springs supporting the weight of the
vehicle when the fasteners are torqued. This will
maintain vehicle ride comfort and prevent prema­ture bushing wear.

WARNING

WARNING: Suspension components with rubber bushings must be tightened with the vehicle at normal ride
height. It is important to have the springs supporting the weight of the vehicle when the fasteners are
torqued. If springs are not at their normal ride position, vehicle ride comfort will be affected and cause
premature bushing wear.

DIAGNOSIS AND TESTING - REAR SUSPENSION

CONDITION POSSIBLE CAUSES CORRECTION

VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Replace wheel bearings.

VEHICLE PULLS TO ONE
SIDE

2. Loose, worn or bent suspension
components.

3. Tire pressure. 3. Adjust tire pressure.

1. Weak or broken spring. 1. Replace spring.

2. Alignment. 2. Align vehicle to specifications.

3.Tires. 3. Replace tires.

4.Tire Pressure 4.Adjust tire Pressure

5. Brakes. 5. Repair as necassary.

2. Inspect, tighten or replace components
as necessary.

KNOCKING, RATTLING
OR SQUEAKING

1. Worn shock bushings. 1. Replace shock.

2. Loose shock mounting. 2. Tighten to specifications.

3. Shock valve. 3. Replace shock.

4. Weak or broken spring. 4. Replace spring.

5. Loose, worn or bent suspension
components.

5. Inspect, tighten or replace components
as necessary.

XK REAR 2 - 55

CONDITION POSSIBLE CAUSES CORRECTION

IMPROPER TRACKING 1. Loose, worn or bent suspension

components.

2. Bent axle. 2.Replace axle.

1. Inspect, tighten or replace components
as necessary.

SPECIFICATIONS
TORQUE

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Shock Absorber Upper

Bolt/Nut

Shock Absorber Lower

Bolt/Nut

Suspension Arms Lower

Axle Bracket Nut

Suspension Arms Lower

Frame Bracket Nut

Suspension Arms Upper

Axle Bracket Nut

Suspension Arms Upper

Frame Bracket Nut

Track Bar to Axle 190 140 —

Track Bar to Rear

Structure

Stabilizer Bar Retainer

Bolts

Stabilizer Link Nut to

Stabilizer Bar

Stabilizer Link to Body

Bolt

Jounce Bumper Bolt to

Body

95 70 —

115 85 —

210 155 —

176 130 —

136 100 —

129 95 —

190 140 —

42 31 —

122 90 —

102 75 —

54 40 —

2 - 56 REAR XK

BUSHINGS

REMOVAL

1. Raise and support vehicle.

2. Remove the stabilizer bushing clamp.

3. Remove the bushing from the stabilizer bar.

INSTALLATION

1. Install the bushing to the stabilizer bar.

2. Install the stabilizer bar bushing retainer clamp and bolts. Tighten the bolts to 46 N·m (31 ft.lbs.).

3. Lower the vehicle.

XK REAR 2 - 57

LOWER CONTROL ARM

DESCRIPTION

The lower suspension arms (3) are tubular steel and
use a voided round bushing at the arm on the axle
side. The body side uses a solid round bushing.

OPERATION

The bushings provide isolation from the axle. The arms mount to the unibody frame rail bracket and the axle brack­ets. The arm and bushings provide location and react to loads.

REMOVAL
LEFT SIDE

1. Raise the vehicle and support the rear axle.

2. Remove the fuel tank (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TANK - REMOVAL).

3. Remove the lower suspension arm nut (2) and bolt
(1) from the axle bracket.

2 - 58 REAR XK

4. Remove the nut (1) and bolt (8) from the frame rail
and remove the lower suspension arm (9).

RIGHT SIDE

1. Raise the vehicle and support the rear axle.

2. Remove the lower suspension arm nut (2) and bolt
(1) from the axle bracket.

XK REAR 2 - 59

3. Remove the nut (1) and bolt (8) from the frame rail
and remove the lower suspension arm (9).

INSTALLATION
LEFT SIDE

NOTE: All torques should be done with vehicle on the ground with full vehicle weight.

1. Position the lower suspension arm (9) in the frame
rail.

2. Install the frame rail bracket bolt (8) and nut (1)
tighten to176 N·m (130 ft. lbs.).

2 - 60 REAR XK

3. Position the lower suspension arm(3) in the axle
bracket.

4. Install the axle bracket bolt (1) and nut (2) Tighten
to 210 N·m (155 ft. lbs.).

5. Install the fuel tank (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL TANK - INSTALLATION).

6. Remove the supports and lower the vehicle.

RIGHT SIDE

NOTE: All torques should be done with vehicle on the ground with full vehicle weight.

1. Position the lower suspension arm (9) in the frame
rail.

2. Install the frame rail bracket bolt (8) and nut (1)
tighten to176 N·m (130 ft. lbs.).

XK REAR 2 - 61

3. Position the lower suspension arm(3) in the axle
bracket.

4. Install the axle bracket bolt (1) and nut (2) Tighten
to 210 N·m (155 ft. lbs.).

5. Remove the supports and lower the vehicle.

2 - 62 REAR XK

UPPER CONTROL ARM

DESCRIPTION

The suspension arm uses bushings to isolate road noise. The suspension arm is bolted through bushings to a
bracket at the body and axle.

OPERATION

The upper suspension arm provides fore/aft and lateral location of the rear axle. The suspension arm travel is lim­ited through the use of jounce bumpers in compression and shock absorbers in rebound.

REMOVAL
LEFT SIDE

1. Raise and support the vehicle.

2. Support the rear axle.

3. Lower the fuel tank in order to gain access to the bolt (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL
TANK - REMOVAL).

4. Remove the upper suspension arm nut (2) and bolt
(3) from the axle bracket.

5. Remove the nut (1) and bolt (7) from the frame rail
and remove the upper suspension arm (2).

XK REAR 2 - 63

RIGHT SIDE

1. Raise and support the vehicle.

2. Support the rear axle.

3. Remove the upper suspension arm nut (2) and bolt
(3) from the axle bracket.

4. Remove the nut (1) and bolt (7) from the frame rail
and remove the upper suspension arm (2).

INSTALLATION
LEFT SIDE

NOTE: All torques should be done with vehicle on the ground with full vehicle weight.