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FRAME AND BUMPERS
13 - 1
FRAME AND BUMPERS
CONTENTS
page
page
XJ BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
XJ UNIBODY CONSTRUCTION . . . . . . . . . . . . . 1
YJ BUMPERS AND FRAME ATTACHED
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 14
YJ FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
XJ UNIBODY CONSTRUCTION
INDEX
page
Collision Damage Torque
................... 1
General Information
page
........................ 1
GENERAL INFORMATION
Jeep XJ Vehicles (Fig. 1) and the cab section of
Jeep are constructed as a unitized body and frame.
at the immediate point of impact is easily recogniz-
able, the damage must be diagnosed to expose it.
With unibody construction, there are five logical
areas to examine to expose damage.
(1) Damage at the immediate point of impact—pri-
mary damage.
(2) The other (lessor) body damage—secondary
damage.
(3) Damage to the exterior trim and other surface-
attached components.
(4) Damage to the mechanical components.
(5) The interior trim and accessory damage.
Fig. 1 Jeep XJ
Jeep XJ unibodies are constructed from special
high-strength steel and coated metals. These types of
metals reduce weight and provide strength.
COLLISION DAMAGE TORQUE
DAMAGE DIAGNOSIS
A vehicle constructed as a unibody reacts differ-
ently to the impact of a collision. While the damage
DAMAGE REPAIR
A logical approach to the sequence of damage re-
pair must also be used. Usually, during vehicle re-
pair, the tasks are accomplished in the reverse order
of consequence.
When there is damage to a vehicle, the alignment
points must be returned too specifications. This en-
tails:
•
accurate measurement;
•
repetitive measurement; and
•
re-check of measurements.
Collision damage repair can be completed ‘‘right’’
the first time:
•
if the fundamental steps for collision damage re-
pair are correctly followed, and
•
if the basic structural details of unibody construc-
tion are correctly considered.
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FRAME AND BUMPERS
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Fig. 2 Frame Alignment Reference Dimensions—XJ Vehicles
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XJ BUMPERS
INDEX
page
Front Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front Tow Hooks
......................... 5
Rear Bumper
FRAME AND BUMPERS
13 - 3
page
............................ 6
FRONT BUMPER
REMOVAL/DISASSEMBLY
(1) The bumper guards, end caps and tow hooks
can be removed from XJ front bumpers with the
bumper attached to the vehicle. Do not remove the
bumper from the vehicle if only these components re-
quire service.
If equipped with a brush guard, refer to the
Brush Guard Removal within Group 23—Body
Components.
(2) If equipped, disconnect the fog lamp wire har-
ness connectors (Fig. 1).
Fig. 2 Vacuum Reservoir—Left Side
Fig. 1 Fog Lamp Wire Harness Connector
(3) Disconnect the vacuum reservoir tube harness
connectors (Figs. 2 and 3).
(4) If equipped, remove the locknuts and Torx-head
bolts that attach the tow hook straps (Fig. 4) to the
underbody sillmember.
The retaining screws and the steering gear
skid plate must be removed before the left strap
can be removed from the sillmember.
(5) Detach the tow hook straps from the sillmem-
ber.
(6) Support the bumper.
(7) Remove the bolts that attach the bumper sup-
port brackets to the right and left sillmembers (Fig.
5).
(8) Remove the support and the bumper from the
vehicle. 5).
Fig. 3 Vacuum Reservoir—Right Side With Speed
Control Only
(9) If equipped, remove the nuts and bolts that at-
tach the tow hooks to the bumper support brackets.
(10) Remove the support brackets (Fig. 6), bumper
guards (Fig. 7) and caps (Fig. 8) from the bumper
rail.
(11) Remove the license plate bracket (Fig. 9), if
equipped, from the bumper rail.
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FRAME AND BUMPERS
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Fig. 6 Bumper Support Bracket Removal/Installation
Fig. 4 Tow Hook & Strap—XJ Vehicles
Fig. 7 Bumper Guard Removal/Installation
Fig. 5 Front Bumper Removal/Installation
(12) If equipped, remove the fog lamps (Fig. 10)
from the bumper rail.
(13) If necessary, remove the vacuum reservoir(s)
from the bumper rail.
(14) If necessary, remove the sill crossmember re-
inforcement brackets from the sillmembers.
Fig. 8 Bumper End Cap Removal/Installation
ASSEMBLY/INSTALLATION
(1) If removed, install the sill crossmember rein-
forcement brackets on the sillmembers (Fig. 11).
Tighten bolts to 56 N m (41 ft-lbs) torque.
(2) If equipped, install the bumper support brack-
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FRAME AND BUMPERS
13 - 5
Fig. 9 Bumper License Plate Bracket Removal/
Installation
(3) If not equipped with bumper guards, install the
bumper support brackets on the bumper rail. Tighten
bolts to 56 N m (41 ft-lbs) torque.
(4) If equipped with tow hooks, install the bolts
and nuts that attach them to the bumper support
brackets. Tighten nuts with 100 N m (74 ft-lbs)
torque.
(5) Install the bumper end caps on the bumper rail
(Fig. 8). Tighten nuts with 8 N m (72 in-lbs) torque.
(6) Install the license plate bracket on the bumper
rail. Tighten the nuts securely.
(7) If equipped, install the fog lamps on the
bumper rail. Tighten the nuts securely.
(8) If removed, install the vacuum reservoir(s) on
the bumper rail. Tighten the retaining screws and
bolts to 8 N m (72 in-lbs) torque.
(9) Position and support the bumper at the front of
the vehicle.
(10) Attach the bumper support brackets to the
right and left sillmembers and reinforcement brack-
ets. Tighten screws and bolts to 56 N m (41 ft-lbs)
torque.
(11) If equipped, install the Torx-head bolts and
locknuts that attach the tow hook straps to the un-
derbody sillmember. Tighten locknuts with 30 N m
(22 ft-lbs) torque.
Install the steering gear skid plate and screws
after the left tow hook strap has been installed.
(12) If equipped, connect the fog lamp wire harness
connectors.
(13) Connect the vacuum reservoir tube harness
connectors.
(14) Remove the bumper support.
Fig. 10 Fog Lamp
FRONT TOW HOOKS
If a tow hook must be replaced or removed only for
service access, remove the nuts and bolts that attach
it to the bumper support bracket. When installing a
tow hook, tighten nuts with 100 N m (74 ft-lbs)
torque.
If a tow hook/bumper support bracket must be re-
placed, refer to the following removal and installa-
tion procedures.
Fig. 11 Reinforcement Brackets
ets and bumper guards on the bumper rail. Tighten
hardware in the sequence indicated in Figure 7.
Tighten the locknuts with 20 N m (15 ft-lbs) torque.
Tighten bolts to 56 N m (41 ft-lbs) torque.
REMOVAL
If equipped with a brush guard, refer to the
Brush Guard Removal within Group 23—Body
Components.
(1) If equipped, disconnect the fog lamp wire har-
ness connectors.
(2) Disconnect the vacuum reservoir tube harness
connectors.
(3) Support the bumper.
(4) Remove the bolts that attach the bumper sup-
port brackets to the right and left sillmembers.
(5) Remove the locknuts and Torx-head bolts that
attach the tow hook straps to the underbody sillmem-
ber.

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