1987-1995 Jeep Wrangler Field Service Manual PDF

The 1987-1995 Jeep Wrangler Field Service Manual is a comprehensive technical guide covering maintenance, repair, and service procedures for Jeep Wrangler models from 1987 through 1995. This manual includes detailed information on engine systems (2.5L 4-cylinder and 4.0L 6-cylinder), transmission, drivetrain, suspension, brakes, electrical systems, body, and chassis components. Below are key sections for specifications, maintenance schedules, troubleshooting, repair procedures, and technical data.

1. Vehicle Specifications 2. Maintenance Schedules 3. Engine Systems 4. Transmission & Drivetrain 5. Suspension & Steering 6. Brake Systems 7. Electrical Systems 8. Body & Interior 9. Troubleshooting Guide 10. Technical Data 11. Wiring Diagrams

Vehicle Specifications

Key specifications for 1987-1995 Jeep Wrangler models including engine options, dimensions, capacities, and performance data.

Specification	Description
Engine Options	2.5L AMC 150 I4, 4.0L AMC 242 I6
Transmission	AX-5 5-speed manual, AX-15 5-speed manual, TF904 3-speed automatic
Transfer Case	Command-Trac part-time 4WD, Selec-Trac full-time 4WD
Wheelbase	93.4 inches
Overall Length	152.0 inches
Fuel Capacity	15.0 gallons
Gross Vehicle Weight	4,500 lbs
Towing Capacity	2,000 lbs
Ground Clearance	8.3 inches
Turning Circle	34.8 feet

Maintenance Schedules

Recommended maintenance intervals and service procedures for optimal vehicle performance and longevity.

Oil and Filter Change: Every 3,000 miles or 3 months
Air Filter Replacement: Every 15,000 miles
Spark Plugs: Every 30,000 miles
Coolant Flush: Every 30,000 miles or 24 months
Transmission Fluid: Every 30,000 miles
Transfer Case Fluid: Every 30,000 miles
Differential Fluid: Every 30,000 miles
Brake Fluid: Every 30,000 miles or 24 months
Timing Belt: Every 60,000 miles (2.5L only)

WARNING! Always use manufacturer-recommended fluids and follow proper safety procedures when performing maintenance.

Engine Systems

Detailed service procedures for 2.5L and 4.0L engine systems including diagnostics, repair, and adjustment specifications.

2.5L I4 Engine: 150 CID, 117-130 hp, 135-149 lb-ft torque
4.0L I6 Engine: 242 CID, 180-190 hp, 220-225 lb-ft torque
Fuel System: TBI (Throttle Body Injection) or MPI (Multi-Port Injection)
Ignition System: Electronic distributor with electronic spark control
Cooling System: Cross-flow radiator with electric fan
Emission Controls: PCV, EGR, catalytic converter, evaporative control
Compression Ratio: 2.5L: 9.2:1, 4.0L: 8.8:1
Oil Capacity: 2.5L: 5 quarts, 4.0L: 6 quarts

Transmission & Drivetrain

Service procedures for manual and automatic transmissions, transfer cases, and drivetrain components.

Manual Transmissions: AX-5 (2.5L), AX-15 (4.0L) - 5-speed synchronized

Automatic Transmission: TF904 3-speed with lock-up torque converter

Transfer Case: NP231 Command-Trac (part-time), NP242 Selec-Trac (full-time) with 2.72:1 low range

Drive Axles: Dana 30 front, Dana 35 rear with optional Trac-Lok limited slip

Gear Ratios: 3.07:1, 3.55:1, 4.10:1 depending on model and options

Suspension & Steering

Leaf spring suspension system and steering component service procedures.

Front Suspension: Multi-leaf springs with track bar and stabilizer bar
Rear Suspension: Multi-leaf springs with track bar
Shock Absorbers: Hydraulic, front and rear
Steering Gear: Saginaw recirculating ball, 17:1 ratio
Steering Linkage: Drag link and tie rods
Wheel Alignment: Toe-in 1/16" to 1/8", caster 5° to 7°, camber 0° to 1°

Tip: Always check for worn bushings and loose components during suspension service.

Brake Systems

Hydraulic brake system service including disc brakes front, drum brakes rear.

Front Brakes: 10.88" disc with single piston calipers
Rear Brakes: 10x1.75" drum with self-adjusting mechanism
Master Cylinder: Tandem type with 1" bore
Brake Booster: Vacuum assisted, 8" diameter
Parking Brake: Mechanical, rear wheel actuation
Brake Fluid: DOT 3 recommended
Rotor Thickness: Standard 1.25", minimum 1.18"
Drum Diameter: Standard 10.0", maximum 10.06"

WARNING! Always bleed brake system after service and test brakes before driving.

Electrical Systems

12-volt electrical system with negative ground, including charging, starting, and accessory systems.

Component	Specification
Battery	12V, 58-70 Ah, Group 58 or 34
Alternator	78-90 amp, internally regulated
Starter	12V, 1.4 kW reduction gear type
Ignition System	Electronic, magnetic pickup distributor
Fusible Links	16 ga. pink (5A), 14 ga. brown (7.5A), 12 ga. green (10A)
Light Bulbs	Headlight 6052, Brake/Tail 1157, Turn 1156

Body & Interior

Body structure, soft top, doors, and interior component service procedures.

Body: Steel body tub with removable doors and fold-down windshield

Top: Vinyl soft top with plastic windows, optional hard top

Doors: Removable steel half-doors with optional full doors

Seats: Vinyl or cloth bucket seats with manual adjustments

Instrument Panel: Standard gauges including speedometer, fuel, temperature, oil pressure

Troubleshooting Guide

Common problems and diagnostic procedures for 1987-1995 Jeep Wrangler.

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, or compression issue	Check fuel pressure, spark plugs, compression test
Rough idle	Vacuum leak, dirty injectors	Check vacuum lines, clean throttle body, test fuel injectors
4WD not engaging	Transfer case linkage, vacuum disconnect	Adjust linkage, check vacuum lines to front axle
Brake pull	Stuck caliper, contaminated linings	Replace caliper, clean or replace brake pads/shoes
Electrical problems	Ground connections, alternator	Clean battery terminals, test alternator output

Technical Data

Torque specifications, fluid capacities, and critical measurements.

Spark Plug Torque: 20-25 ft-lbs
Wheel Lug Nut Torque: 85-110 ft-lbs
Cylinder Head Bolts: 2.5L: 80 ft-lbs, 4.0L: 110 ft-lbs
Oil Pressure: 30-60 psi at 2000 RPM
Fuel Pressure: 14.5-15.0 psi (TBI), 39 psi (MPI)
Cooling System Pressure: 15-18 psi cap
Compression Pressure: 120-150 psi, variation max 25 psi between cylinders

Wiring Diagrams

Complete electrical schematics for all vehicle systems including color codes and connector locations.

Engine Control: ECM wiring, sensors, actuators

Lighting: Headlight, tail light, turn signal circuits

Instrument Cluster: Gauge and warning light wiring

Accessory: Radio, heater, wiper circuits

Charging System: Alternator, regulator, battery connections

Note: Always disconnect battery before working on electrical systems.