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FRAME AND BUMPERS
13 - 1
FRAME AND BUMPERS
CONTENTS
page
page
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FRAME
INDEX
page
Frame Dimensions . . . . . . . . . . . . . . . . . .
Front Skid Plate . . . . . . . . . . . . . . . . . . . .
Fuel Filler Hose Splash Shield—XJ Vehicles
Fuel Tank Skid Plate . . . . . . . . . . . . . . . . .
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4
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Fuel Tank Support Strap . . . . . . . . . . . . . . . . . . . . . 4
General Information . . . . . . . . . . . . . . . . . . . . . . . . 1
Transfer Case Skid Plate . . . . . . . . . . . . . . . . . . . . 3
•
The other (lessor) body damage—secondary dam-
age.
•
Damage to the exterior trim and other surface-at-
tached components.
•
Damage to the mechanical components.
•
The interior trim and accessory damage.
When there is damage to a vehicle, the alignment
points must be returned too specifications.
GENERAL INFORMATION
Jeep XJ Vehicles (Fig. 1) and the cab section of
Jeep are constructed as a unitized body and frame.
FRAME DIMENSIONS
Frame dimensions are listed in millimeter scale.
All dimensions are from center to center of Principal
Locating Point (PLP), or from center to center of PLP
and fastener location (Fig. 2).
FRONT SKID PLATE
REMOVAL
(1) Remove the screws that attach skid plate to
side sills (Fig. 3).
(2) Remove the nuts that attach the skid plate to
the crossmember (Fig. 3).
(3) Remove the skid plate from the vehicle (Fig. 3).
INSTALLATION
(1) Position the skid plate at front crossmember
and side sills (Fig. 3).
(2) Install the nuts to attach the skid plate to
crossmember.
(3) Install the screws to attach skid plate to side
sills.
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.
A vehicle constructed as a unibody reacts differ-
ently to the impact of a collision. While the damage
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 ar-
eas to examine to expose damage:
•
Damage at the immediate point of impact—pri-
mary damage.
13 - 2
XJ—FRAME
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Fig. 2 Frame Alignment Reference Dimensions—XJ Vehicles
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XJ—FRAME
13 - 3
(2) Attach the skid plate to the frame sill and
crossmember with bolts. Tighten bolts to 22 N m (16
ft. lbs.) torque.
FUEL TANK SKID PLATE
REMOVAL
(1) Position a support under skid plate.
(2) Remove the bolts that attach skid plate to un-
derbody side rails (Fig. 5 and 6).
Fig. 3 Front Skid Plate Removal/Installation
TRANSFER CASE SKID PLATE
REMOVAL
(1) Support the skid plate.
(2) Remove the bolts that attach the skid plate to
the transmission support crossmember and frame sill
(Fig. 4).
Fig. 5 Fuel Tank Skid Plate W/O Trailer Hitch Or Tow
Hook
Fig. 6 Fuel Tank Skid Plate With Trailer Hitch Or
Tow Hook
Fig. 4 Transfer Case Skid Plate
(3) Remove the support and skid plate from the ve-
hicle.
(3) Remove the support and the skid plate from
the vehicle.
INSTALLATION
(1) Position and support the skid plate at the
frame sill and transmission support crossmember
(Fig. 4).
INSTALLATION
(1) Position and support skid plate under fuel
tank.
(2) Install bolts to attach the skid plate to under-
body rails. Tighten the bolts to 50 N m (37 ft. lbs.)
torque.
(3) Remove the support from under skid plate.
13 - 4
XJ—FRAME
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FUEL FILLER HOSE SPLASH SHIELD—XJ
VEHICLES
REMOVAL
(1) Remove the screws that attach fuel filler hose
splash shield to wheelhouse panel and frame rail
(Fig. 7).
Fig. 8 Fuel Tank Support Strap—XJ Vehicles
Fig. 7 Fuel Filler Hose Splash Shield—XJ Vehicles
(2) Remove the hose splash shield from wheel-
house panel and frame rail (Fig. 7).
INSTALLATION
(1) Position fuel filler hose splash shield at wheel-
house panel and frame rail.
(2) Install screws to attach splash shield to wheel-
house panel and frame rail.
FUEL TANK SUPPORT STRAP
SERVICE INFORMATION
XJ fuel tank support straps are attached to the un-
derside of the vehicle via T-slots and hole-slots in the
frame members.
REMOVAL
(1) If equipped, position a support under skid
plate.
(2) If equipped, remove the bolts that attach skid
plate to underbody side rails.
(3) If applicable, remove the support and skid plate
from fuel tank.
(4) Support fuel tank.
(5) Loosen nut from fuel tank support strap bolt to
allow bolt head to be removed from hole-slot in frame
member (Fig. 8).
(6) Remove the strap T-end from frame member T-
slot (Fig. 9).
(7) Separate support strap from fuel tank and re-
move it from vehicle.
Fig. 9 Fuel Tank Support Straps—XJ Vehicles
INSTALLATION
(1) Position support strap around fuel tank.
(2) Insert strap T-end in frame member T-slot.
(3) Insert bolt in hole-slot in frame member.
Tighten nut on the bolt until bolt-head and T-end are
seat and strap is tight against the bottom of fuel
tank.
(4) Remove the support from the fuel tank.
(5) If removed, position and support and the fuel
tank skid plate under the fuel tank.
(6) If applicable, install the bolts that attach the
skid plate to the underbody side rails. Tighten the
bolts to 50 N m (37 ft. lbs.) torque.
(7) Remove the support from under the skid plate.
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BUMPERS
INDEX
page
Front Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front Tow Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
XJ—BUMPERS
13 - 5
page
Rear Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rear Tow Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
(2) Disconnect the fog lamp wire harness connec-
tors, if equipped (Fig. 1).
(3) Disconnect the vacuum reservoir tube harness
connectors (Fig. 2 and 3).
(4) Remove the locknuts and Torx-head bolts that
attach the tow hook straps (Fig. 4) to the underbody
sillmember.
FRONT BUMPER
REMOVAL/DISASSEMBLY
(1) The bumper guards, end caps and tow hooks can
be removed from XJ front bumpers with the bumper at-
tached to the vehicle. Do not remove the bumper from
the vehicle if only these components require service.
If equipped with a brush guard, refer to the Brush
Guard Removal within Group 23, Body Components.
Fig. 3 Vacuum Reservoir—Right Side With Speed
Control Only
Fig. 1 Fog Lamp Wire Harness Connector
Fig. 2 Vacuum Reservoir—Left Side
Fig. 4 Tow Hook & Strap—XJ Vehicles

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