| Fastener | Spec |
|---|---|
| Lug nuts | 80–110 ft-lb |
| Oil drain plug | 25 ft-lb |
| Spark plugs (4.0L) | 22–28 ft-lb |
| Track bar bolts | 55–75 ft-lb |
| Ball joint nut | 75 ft-lb min + cotter pin |
| Tie rod end | 35 ft-lb min + cotter pin |
| Pitman arm nut | 185 ft-lb |
| Drag link | 55 ft-lb min + cotter pin |
| Pinion nut (D30) | 160–200 ft-lb |
| Pinion nut (D35) | 170–260 ft-lb |
| Ring gear bolts (D30) | 55 ft-lb |
| Ring gear bolts (D35) | 45–50 ft-lb |
| Leaf spring U-bolt nuts | 45–52 ft-lb |
| Bellhousing bolts | 25–30 ft-lb |
| Transfer case-to-trans | 23–30 ft-lb |
| Fastener | Spec |
|---|---|
| Valve cover (w/ RTV) | 28 in-lb |
| Valve cover (w/ gasket) | 55 in-lb |
| Intake manifold | 23 ft-lb |
| Exhaust manifold | 23–30 ft-lb |
| Head bolts (4.0L) | 110 ft-lb (steps: 22/45/45/110) |
| Flywheel bolts | 105 ft-lb |
| Connecting rod bolts | 33 ft-lb + 90° |
| Main bearing cap bolts | 80 ft-lb |
| Rocker arm bolts | 19 ft-lb |
| Oil pan bolts (1/4-20) | 84 in-lb |
| Oil pan bolts (5/16-18) | 132 in-lb |
| Camshaft sprocket bolt | 50 ft-lb |
* Head bolts use a multi-step sequence (22 > 45 > 45 > 110 ft-lb). NOT torque-to-yield — bolts are reusable.
* Dana 30 spindle nut: torque inner nut to 50 ft-lb while rotating hub, back off, retorque to 50 ft-lb, back off 135-150°, install lock washer and outer nut.
Verify all specs against your FSM.
| System | Fluid | Capacity |
|---|---|---|
| Engine oil | 10W-30 (10W-40 high mile) | 6 qt |
| Coolant | 50/50 green IAT | 10 qt |
| Trans (AX-15 manual) | 75W-90 GL-4 | 3.3 qt |
| Trans (32RH auto) | ATF+4 | ~8 qt w/ converter |
| Transfer case (NP231) | ATF+4 | 2.5 qt |
| Trans (BA10/5 manual) | 80W-90 GL-5 | 3.3 pt |
| Trans (AX-5 manual) | 75W-85 GL-4 | ~3 qt |
| Transfer case (NP207) | ATF | 2 qt |
| Front diff (Dana 30) | 80W-90 GL-5 | 2.5 pt |
| Rear diff (Dana 35) | 80W-90 GL-5 | 3.5 pt |
| Rear diff (Dana 44) | 80W-90 GL-5 | 4.0 pt |
| Brake fluid | DOT 3 | 1 qt |
| Power steering | ATF+4 | 1 qt |
| Clutch hydraulic | DOT 3 | shared w/ brake |
| Fuse | Amp | Circuit |
|---|---|---|
| 1 | 20A | Rear Window Wiper |
| 2 | -- | Not Used |
| 3 | 15A | Stop Lamps, Hazard Flasher, Underhood Lamp, Cruise Control |
| 4 | 15A | Turn Signal Flasher, Backup Lamps |
| 5 | 10A | ASD Relay, Fuel Pump Relay, PCM |
| 6 | 25A | Rear Window Defogger Relay |
| 7 | 20A | Cigar Lighter, Radio, Cruise Control, Illumination Lamps |
| 8 | 20A | Headlamps, Marker Lamps |
| 9 | 15A | Buzzer Module, Defogger Switch, Gauges, Tachometer |
| 10 | 5A | Instrument Panel Illumination |
| 11 | CB | Wiper Switch and Motor (circuit breaker) |
| 12 | 25A | Blower Motor, A/C Compressor Clutch |
| Pos | Amp | Circuit |
|---|---|---|
| F1 | 30A | Fuel Pump / ASD |
| F2 | 50A | Charging (Alt 1) |
| F3 | 50A | Battery / Acc |
| F4 | 40A | Ignition / Starter |
| F5 | 20A | Hazard Flasher |
| F6 | 50A | Charging (Alt 2) |
| F7 | 30A | Headlamp System |
| F8 | 20A | I.O.D. / Horn |
| F9 | 40A | ABS Pump (if equipped) |
| F10 | 30A | ABS Power (if equipped) |
| F15 | 10A | Horn |
| F16 | 10A | I.O.D. (Ignition-Off Draw) |
| Pos | Relay |
|---|---|
| A | Horn |
| B | Fuel Pump |
| C | ABS Pump (if equipped) |
| D | A/C Compressor Clutch |
| E | Auto Shutdown (ASD) |
| F | Starter |
Source: fuse-box.info YJ 1992–1995 verified data
| Fuse | Amp | Circuit |
|---|---|---|
| 1 | 15A | Turn Signals, Back-Up Lights |
| 2 | 20A | Courtesy Light, Cargo Light, Radio |
| 3 | 15A | Hazard Warning, Stoplights, Underhood Light |
| 4 | 25A | Rear Window Defogger |
| 5 | 25A | Blower Motors |
| 6 | 15A | Gauge Package, Seat Belt Indicators, Tachometer |
| 7 | CB | Windshield Wipers/Washer (circuit breaker) |
| 8 | 20A | Parking Lights, Turn Signals |
| 9 | 5A | Instrument Panel Illumination |
| 10 | 30A | Cigarette Lighter, Cruise Control, Radio |
| 11 | 20A | Rear Window Wiper/Washer |
| 12 | 20A | Horn |
| Pos | Amp | Circuit |
|---|---|---|
| F1 | 30A | Fuel System ECU (Renix) |
| F2 | 50A | Alternator Power 1 |
| F3 | 50A | Fuse Block Feed |
| F4 | 40A | Ignition System |
| F5 | 20A | Fog Lamps |
| F6 | 50A | Alternator Power 2 |
| F7 | 30A | Headlamp System |
| F8 | 20A | Ignition Off Draw |
Key difference: Fuse 5 is 25A Blower Motors (87–91) vs 10A ASD/Fuel Pump/PCM (92–95). Fuse 1 is Turn Signals (87–91) vs Rear Wiper (92–95).
Tensioner: 15mm wrench, rotate clockwise to release. Verify routing against the fan shroud diagram on your YJ.
Dana 44 rear available on some models. NP207 (part-time only) used 1987–1990; NP231 (87–95) with command-trac or selec-trac.
Renix 87–90: CPS on bellhousing flange. HO 91–95: CPS in distributor.
Method: Key ON-OFF-ON-OFF-ON (within 5 sec). Watch Check Engine light flashes. Code 55 = end of codes.
1987-1990 Renix Diagnostics: No flash codes. Uses ECU diagnostic connector under dash near steering column.
Connect test light between pins 1 and 6, turn key ON, watch LED blink patterns.
Common Renix faults: 1000 (CTS), 1010 (MAP), 1013 (CPS), 1020 (TPS). Alternatively use Renix-specific scan tool or resistor test method.
| Location | Thread | Length | Grade | Head | Torque* |
|---|
*Torque values are calculated engineering estimates. See Torque Specs panel for FSM-verified values.
SAE Grade 5 = 3 radial lines on head. Grade 8 = 6 lines. Metric 8.8/10.9 = stamped numbers. All YJ frame/body/suspension bolts are SAE unless noted.
Wire colors are FACTORY STANDARD. Prior repairs, aftermarket harnesses, or option packages may differ. ALWAYS verify with a multimeter before cutting or connecting.
1991-1995 CHRYSLER (HO/MPI):| Color | Circuit |
|---|---|
| Dark Blue | 12V Ignition Hot |
| Red | Battery Positive / Always Hot |
| Black | Ground |
| Dark Green | Fuel Injectors |
| Orange | ASD Relay Output (fused B+) |
| Tan/Yellow | CPS Signal |
| Violet/White | VSS Signal |
| Gray | TPS Signal |
| Black/Light Blue | O2 Sensor Signal |
| Dark Blue/Yellow | MAP Signal |
| Tan | IAT Signal |
| Brown | CTS Signal |
| White/Green | IAC Motor |
| Pink | Ignition Switch Feed |
| Light Green | A/C Clutch |
| Yellow | Airbag / Horn |
| Light Blue | Gauges / Instrument Cluster |
| Color | Circuit |
|---|---|
| Red | Battery / Ignition |
| Black | Ground |
| Green | CPS Signal |
| Blue/White | MAP Sensor |
| Brown | CTS Signal |
| Gray | TPS Signal |
| Orange | Fuel Injectors |
| Violet | ECU Main Power |
| White | Diagnostic Output |
| Yellow | Tachometer Signal |
Renix uses Bosch-style connectors. 91+ Chrysler uses Weatherpack. Wire colors may vary on harness repairs.
| Part | Donor Vehicles | Notes |
|---|---|---|
| 4.0L Engine | 1987-2006 XJ/MJ/ZJ/TJ | Same block. 91+ HO has different head/intake |
| 2.5L Engine | 1987-2002 XJ/MJ/TJ | Direct swap |
| AX-15 Trans (manual) | 1989-1999 XJ/MJ (4.0L) | Same bell pattern. Check input shaft spline count (21 vs 23) |
| AX-5 Trans (manual) | 1987-2002 XJ/YJ/TJ (2.5L) | Direct swap |
| 32RH/AW4 Auto Trans | 1987-2001 XJ/ZJ | 32RH for YJ. AW4 is XJ-only (different bellhousing) |
| NP231 Transfer Case | 1987-2001 XJ/YJ/TJ | Check input spline (21 vs 23) and short vs long |
| Dana 30 Front Axle | 1984-2001 XJ/YJ/TJ | Check width, U-bolt vs spring-over, disconnect type |
| Dana 35 Rear Axle | 1984-2001 XJ/YJ/TJ | Same axle. Check width and spring perch spacing |
| Dana 44 Rear (upgrade) | 1970-1986 CJ-5/CJ-7, 1997+ TJ | TJ D44 popular swap. CJ needs brackets. CJ wide-track (82+) closer to YJ width |
| Ford 8.8 Rear (upgrade) | 1986-2004 Explorer/Ranger | Popular swap. Needs brackets, width must be matched |
| Radiator | 1987-1990 XJ (Renix) | Same core, check hose routing |
| Steering Box | 1984-2001 XJ | Same mount pattern |
| Power Steering Pump | 1987-2001 XJ/YJ/TJ | Same pump, check bracket year match |
| Alternator | 1987-2001 XJ/YJ/TJ (4.0L) | Same mount, same connector |
| Starter | 1987-2001 XJ/YJ/TJ | Same bolt pattern |
| Fuel Pump (91-95 MPI) | 1991-1995 XJ | Same in-tank unit. NOT interchangeable with Renix |
| Fuel Pump (87-90 Renix) | 1987-1990 XJ | Different from 91+ MPI unit |
| Brake Calipers (front) | 1990-2001 XJ/TJ | Same single-piston caliper |
| Seats | 1997-2006 TJ | Direct bolt-in (most brackets match) |
| Soft Top Hardware | TJ | NOT compatible -- different frame mounts |
| Distributor (91-95) | 1991-1999 XJ/ZJ 4.0L | Same HO distributor |
| ECU/PCM (91-95) | 1991-1995 XJ 4.0L | Must match trans type (auto/manual) |
| ZJ Grand Cherokee Parts | 1993-1998 ZJ | Engine, trans, Dana 30/44, steering box. Check year-specific diffs |
| Windshield | 1976-1986 CJ-7 | Same size glass. Frame mounting holes differ slightly |
| U-Joints (driveshaft) | 1987-2006 XJ/TJ | Spicer 5-760X (front), 5-1310X (rear). Same across models |
Always verify year-specific compatibility. Spring perch width, input shaft spline count, and wiring connectors are the most common gotchas.
Calculated values are general engineering estimates (K-factor method: T = K x D x P, at 75% proof load).
Always use FSM specs when available -- they account for joint-specific factors like gasket crush and thread engagement.
Based on regular intervals from 0 miles using factory-recommended schedules. For actual overdue tracking, note your last service mileage. Severe = off-road, towing, frequent short trips, or dusty conditions.
| Part | Mopar/OE | Aftermarket | Notes |
|---|
Part numbers verified against common aftermarket catalogs. Always confirm with your parts supplier -- numbers may be superseded.
Approximate 2026 retail pricing. Ranges reflect budget (Harbor Freight) to quality (Snap-on/GearWrench) brands. Actual prices vary by region and retailer.