Frame and Bumpers
Transcript of Frame and Bumpers
-
8/14/2019 Frame and Bumpers
1/14
FRAME AND BUMPERS
CONTENTS
page page
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
-
8/14/2019 Frame and Bumpers
2/14
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)
-
8/14/2019 Frame and Bumpers
3/14
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
T J FRAME AND BUMPERS 13 - 3
-
8/14/2019 Frame and Bumpers
4/14
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
13 - 4 FRAME AND BUMPERS T J
-
8/14/2019 Frame and Bumpers
5/14
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
T J FRAME AND BUMPERS 13 - 5
SERVI CE PROCEDURES (Continued)
-
8/14/2019 Frame and Bumpers
6/14
(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
13 - 6 FRAME AND BUMPERS T J
REMOVAL AND INSTALLATION (Continued)
-
8/14/2019 Frame and Bumpers
7/14
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.
T J FRAME AND BUMPERS 13 - 7
-
8/14/2019 Frame and Bumpers
8/14
Q UARTER W I NDO W O PENI N G
13 - 8 FRAME AND BUMPERS T J
SPECIFICATIONS (Continued)
-
8/14/2019 Frame and Bumpers
9/14
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.
T J FRAME AND BUMPERS 13 - 9
SPECIFICATIONS (Continued)
-
8/14/2019 Frame and Bumpers
10/14
13 - 10 FRAME AND BUMPERS T J
SPECIFICATIONS (Continued)
-
8/14/2019 Frame and Bumpers
11/14
FRAM E SI DE VI EW
T J FRAME AND BUMPERS 13 - 11
SPECIFICATIONS (Continued)
-
8/14/2019 Frame and Bumpers
12/14
FRAM E TO P VI EW
13 - 12 FRAME AND BUMPERS T J
SPECIFICATIONS (Continued)
-
8/14/2019 Frame and Bumpers
13/14
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.)
T J FRAME AND BUMPERS 13 - 13
SPECIFICATIONS (Continued)
-
8/14/2019 Frame and Bumpers
14/14