Frame and Bumpers

8/14/2019 Frame and Bumpers

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FRAME AND BUMPERS

CONTENTS

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BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

BUMPERS

INDEX

page page

REMOVAL AND INSTALLATIONFRONT BUMPER EXTENSION . . . . . . . . . . . . . . . 1FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . 2

FRONT TOW HOOK . . . . . . . . . . . . . . . . . . . . . . . 1REAR BUMPER EXTENSION . . . . . . . . . . . . . . . . 2REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . 2

REMOVAL AND IN STALLATI ON

FRONT TOW HOOK

Some J eep vehicles are equipped with front emer-

gency tow hooks. The tow hooks should be used for

EM ERGENCY purposes only.

REMOVAL

(1) Remove the torx bolts that attach the tow hookto the bumper (Fig. 1).

(2) Separate the tow hook from the bumper.

INSTALLATION

(1) Position the tow hook on the bumper.

( 2 ) I n s t a l l t h e t o r x b o l t s t h a t a t t a c h t h e t o w h o o k

t o t h e b u m p e r . T i g h t e n t h e b o l t s t o 1 0 8 N m ( 8 0 f t .

lbs.) torque.

FRONT BUMPER EXTENSION

REMOVAL

(1) R em ove t h e s cr ew s a t t a ch in g t h e b um pe r

extension to the bumper (Fig. 2).

(2) Separate the extension from the bumper.

INSTALLATION

(1) Position the extension on the bumper.

(2) Install the screws attaching the bumper exten-

sion to the bumper.

Fig. 1 Front Tow Hook

Fig. 2 Bumper Extension

T J FRAME AND BUMPERS 13 - 1


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FRONT BUMPER

REMOVAL

(1 ) I f e qu i p pe d , d is con n e ct t h e fog l a m p h a r n e s s

connector.

( 2 ) R e m o v e t h e s c r e w s t h a t a t t a c h t h e b u m p e r t o

the frame rail (Fig. 3).(3) If equipped, remove t he tow hook.

(4) Separate the bumper from the vehicle.

INSTALLATION

(1) Position the bumper on the vehicle.

(2) If equipped, install the tow hook.

(3 ) I n st a ll t h e s cr e ws t h a t a t t a ch t h e b u m pe r t o

the frame rail . Tighten the screws to 104 Nm (77 ft .

lbs.) torque.

(4) If equipped, Connect t he fog lamp har ness con-

nector.

REAR BUMPER EXTENSION

REMOVAL

(1 ) R em ove t h e s cr ew s a t t a ch in g t h e b um pe rextension to the bumper (Fig. 4).

(2) Separate the extension from the bumper.

INSTALLATION

(1) Position the extension on the bumper.

(2) Install the screws attaching the bumper exten-

sion to the bumper.

REAR BUMPER

REMOVAL

(1) Remove the bolt atta ching the bumper t o frame

rail (Fig. 4).

(2) If equipped, separate the rear tow eye from the

bumper.

( 3 ) R e m o v e t h e n u t s a t t a c h i n g t h e b u m p e r t o t h e

rear frame crossmember.

(4) Separate the bumper from the vehicle.

INSTALLATION

(1) Position the bumper on the vehicle.

(2 ) I n st a ll t h e n u t s a t t a ch in g t h e b u m pe r t o t h e

rear frame crossmember. Tighten the nuts to 67 Nm

(50 ft.lbs.) t orque.

(3 ) I f e qu i pp e d, p os it i on t h e r e a r t ow e ye on t h e

bumper.

( 4 ) I n s t a l l t h e b o l t a t t a c h i n g t h e b u m p e r t o f r a m e

rail . Tighten the bolts to 67 Nm (50 ft .lbs.) torque.

Fig. 3 Front Bumper Components

Fig. 4 Bumper Components

13 - 2 FRAME AND BUMPERS T J

REMOVAL AND INSTALLATION (Continued)


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FRAME

INDEX

page page

GENERAL INFORMATION

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3SERVICE PROCEDURES

FRAME SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . 4REMOVAL AND INSTALLATION

FUEL TANK SKID PLATE . . . . . . . . . . . . . . . . . . . 6

TRANSFER CASE SKID PLATE . . . . . . . . . . . . . . 5

SPECIFICATIONSTORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 13VEHICLE DIMENSIONS . . . . . . . . . . . . . . . . . . . . 7

GENERAL INFORMATION

GENERAL INFORMATION

T h e J e ep T J fr a m e i s t h e s t r u ct u r a l c en t e r of t h e

vehicle. In addition to supporting the body and pay-load, t he frame provides a station for the engine. The

vehicle body is attached to the frame with holddowns

(Fig. 1).

The frame is constru cted of mild-strength rectan-

gular tubing a nd crossmembers. The crossmembers

joi n t h e s id e r a il s a n d r e t a in t h e m i n a l ig n m en t i n

r e la t i on t o e a ch ot h e r. T h is p r ov id e s r e s is t a n ce t o

f r a m e t w i s t s a n d s t r a i n s .

Fig. 1 Body Holddowns



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SERVICE PROCEDURES

FRAME SERVICE

SAFETY PRECAUTI O NS AND W ARNI NG S

WARNING: USE EYE PROTECTION WHEN GRIND-ING OR WELDING METAL, SERIOUS EYE INJURY

CAN RESULT. BEFORE PROCEEDING WITH FRAMEREPAIR INVOLVING GRINDING OR WELDING, VER-IFY THAT VEHICLE FUEL SYSTEM IS NOT LEAKINGOR IN CONTACT WITH REPAIR AREA, PERSONAL

INJURY CAN RESULT. DO NOT ALLOW OPENFLAME TO CONTACT PLASTIC BODY PANELS.FIRE OR EXPLOSION CAN RESULT. WHENWELDED FRAME COMPONENTS ARE REPLACED,

100% PENETRATION WELD MUST BE ACHIEVEDDURING INSTALLATION. IF NOT, DANGEROUSOPERATING CONDITIONS CAN RESULT. STAND

CLEAR OF CABLES OR CHAINS ON PULLINGEQUIPMENT DURING FRAME STRAIGHTENINGOPERATIONS, PERSONAL INJURY CAN RESULT.DO NOT VENTURE UNDER A HOISTED VEHICLETHAT IS NOT SUPPORTED ON SAFETY STANDS,PERSONAL INJURY CAN RESULT.

CAUTION: Do not reuse damaged fasteners, qual-ity of repair would be suspect. Do not drill holes intop or bottom frame rail flanges, frame rail failure

can result. Do Not use softer than Grade 3 bolts toreplace production fasteners, loosening or failure

can result. When using heat to straighten framecomponents do not exceed 566C (1050F), metalfatigue can result. Welding the joints around riveted

cross members and frame side rails can weakenframe.

FRAM E STRAI G HTENI NG

When necessary, a conventional frame that is bent

or twisted can be str aightened by application of heat.

T h e t e m p er a t u r e m u s t n ot e xce ed 5 66 C (1 05 0F ).

T h e m e t a l w il l h a v e a d u ll r e d g low a t t h e d e si r ed

t em pe ra t u r e. E xce ss ive h ea t w ill d ecr ea s e t h e

s t re ngt h of t h e m et a l a n d r es u lt in a w ea k en ed

frame.

Welding th e joints around riveted cross members

and frame side rails is not recommended.

A straightening repair process should be l imited t o

f r a m e m e m b e r s t h a t a r e n o t s e v e r e l y d a m a g e d . T h e

r e p la ce m en t b ol t s, n u t s a n d r i ve t s t h a t a r e u s e d t o

join the frame members should conform to the same

specifications as the original bolts, nuts and rivets.

FRAME REPAIRS

DRILLING HOLES

D o n o t d r i l l h o l e s i n t h e t o p a n d b o t t o m o f f r a m e

rail , metal fatigue can result causing frame failure.

Holes dril led in the side of the frame rail must be at

lea s t 3 8 m m (1 .5 in .) fr om t h e t op a n d b ot t omflanges.

Additional drill holes should be located away from

existing holes.

WELDING

Use MIG, TIG or arc welding equipment to repair

welded frame components.

Frame components that have been damaged should

be inspected for cracks before return ing the vehicle

to use. If cracks are found in accessible frame com-

ponents perform the following procedures.

( 1 ) D r i l l a h o l e a t e a c h e n d o f t h e c r a c k w i t h a 3

mm (O.125 in.) diameter drill bit.(2) Using a suitable die grinder with 3 inch cut off

wheel, V-groove t he crack t o allow 100% weld pen e-

tration.

(3) Weld th e crack.

(4) If necessary when a side rail is repaired, grind

the weld smooth and install a reinforcement channel

(Fig. 2) over the repaired area.

CAUTION: A reinforcement should never be usedon the front section of the frame. The frame section

forward of the suspension mounts contains energymanagement holes (Fig. 3). Reinforcing this area

may effect energy management.

NOTE: If a reinforcement is required, it should

completely cover the repaired area. The reinforce-ment should also overlap the top and bottom of theframe by more than 50% of its width. Weld as indi-cated (Fig. 2).

Fig. 2 Frame Reinforcement



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FRAME FASTENERS

Bolts and nuts and can be used to repair frames or

to install a reinforcement section on the frame.

Conical-type wash ers are preferred over the split-

ring type lock washers. Normally, grade-5 bolts are

adequate for frame repair. G ra d e -3 b o l t s o r s o f te r

s h o u l d n o t b e u s e d . Tightening bolts/nuts with the

correct torque, refer to the Introduction Group at the

front of this manual for t ightening information.

REMOVAL AND IN STALLATI ON

TRANSFER CASE SKID PLATE

The tr ansmission and tran sfer case crossmember is

integrated with the transfer case skid plate.

REMOVAL

WARNING: THE TRANSFER CASE AND TRANSMIS-SION ARE SUPPORTED BY THE TRANSFER CASE

SKID PLATE. BEFORE REMOVING THE TRANSFERCASE SKID PLATE, ENSURE THAT THE TRANSMIS-SION IS PROPERLY SUPPORTED.

(1) Raise and support the vehicle.(2) Place a support under the transmission.

(3 ) Re m ov e t h e n u t s a t t a c h in g t h e t r a n s m i s si on

mount to the skid plate (Fig. 4) and (Fig. 5).

(4 ) R em ov e t h e b ol t s a t t a c h in g t h e s k id p la t e t o

the frame (Fig. 6).

(5) Separate the skid plate from the vehicle.

INSTALLATION

(1) Position the skid plate on the vehicle. (2) Install the bolts attaching the skid plate to the

fr a m e . T ig h te n t h e b olt s t o 7 4 N m ( 5 5 ft . lb s. )

torque.

Fig. 3 Energy Management Holes

Fig. 4 Transmission MountAutomaticTransmission

Fig. 5 Transmission MountManual Transmission

Fig. 6 Transfer Case Skid Plate


SERVI CE PROCEDURES (Continued)


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(3 ) I n st a ll t h e n u t s a t t a ch in g t h e t r a n s m is sion

m o u n t t o t h e s k i d p l a t e . T i g h t e n t h e n u t s t o 2 8 N m

( 21 ft. lbs.) torque.

(4) Remove the support under the transmission.

(5) Remove the support from under the vehicle and

lower the vehicle.

FUEL TANK SKID PLATE

REMOVAL

(1 ) P os it ion a s u p por t u n d er t h e fu e l t a n k s k id

plate.

(2) Remove the protective caps from the end of the

s t r a p s t u d s .

( 3 ) R e m o v e t h e n u t s t h a t a t t a c h t h e s k i d p l a t e t o

the straps and to the crossmembers (Fig. 7).

(4 ) S ep a ra t e t h e fu el t a n k s t ra p fr om t h e s kid

plate.

(5 ) Su p por t t h e fu el t a n k a n d r em ove t h e s kid

plate from the vehicle.

INSTALLATION

( 1 ) A t t a c h t h e s k i d p l a t e t o t h e f u e l t a n k s t r a p .

(2 ) P o s it i on a n d s u p p or t t h e s k id p la t e u n d e r t h e

fuel tank.

( 3 ) I n s t a l l t h e n u t s t o a t t a c h t h e s k i d p l a t e t o t h e

s t r a p s a n d t o t h e fr a m e cr os s m em b er s . T i gh t e n t h e

fu e l t a n k s t r a p n u t s t o 5 N m (4 0 i n . l b s. ) t or q u e.

Tighten the skid plate-to-crossmember nuts with 16

Nm (138 in. lbs.) torque.

(4 ) I n s t a ll t h e p r ot e ct i ve ca p s on t h e e n d of t h e

s t r a p s t u d s .

(5) Remove the support from under the skid plate.

Fig. 7 Fuel Tank Skid Plate


REMOVAL AND INSTALLATION (Continued)


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SPECIFICATIONS

VEHICLE DIMENSIONS

W I NDSHI ELD O PENI NG

A & B . C e n t e r o f r a d i u s a t b o t t o m t o c e n t e r o f

radius top.

DOOR OPENING

A. Center of radius at bottom front to center of

r a d i u s a t t o p r e a r .

B. Center of door lower r ear corner to center of

top of windshield frame.

C . C e n t e r of d o or l ow er r e a r cor n e r t o t op of

cowl.

D. Center of door hinge mount to center of door

striker mount.



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Q UARTER W I NDO W O PENI N G


SPECIFICATIONS (Continued)


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ENG I NE CO M PARTM ENT

TAILGATE AND LIFTGATE OPENING

A. Center of liftgat e opening to floor.

B . C en t e r of r a d iu s u p pe r cor n e r t o ce n t er of

body and floor corner.

C. Liftgate opening distance.

D. Tailgate opening distance.




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FRAM E SI DE VI EW




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FRAM E TO P VI EW




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TORQUE SPECIFICATIONS

D E S CRIP TION TOR QU E

Front Bumper Screw. . . . . . . . . .104 Nm (77 ft. lbs.)

Front Tow Hook Screw . . . . . . . .108 Nm (80 ft. lbs.)

Fuel Tank Skid Plate Nuts . . . . .16 Nm (138 in. lbs.)

Fuel Tank St rap Nuts . . . . . . . . . .5 Nm (40 in. lbs.)Rear Bumper Bolt. . . . . . . . . . . . .67 Nm (50 ft. lbs.)

Rear Bum per Nu t . . . . . . . . . . . . .67 Nm (50 ft . lbs.)

Transfer Case Skid Plate Bolts . . .74 Nm (55 ft. lbs.)

Transm ission Moun t N ut s . . . . . .28 Nm (21 ft. lbs.)




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Frame and Bumpers