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Jeep Comanche 1984-1996 WSM Service Manual Repair

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🏷️ Basic Information Identification Make: Jeep Model: Comanche Model Code: MJ Production Years Covered: 1984-1996 Codes Chassis Code: MJ 👋 Introduction Market Position Vehicle Segment: Compact Pickup Truck Jeep Heritage: Leveraged Jeep's reputation for ruggedness and off-road capability in a utility segment Competitive Analysis Key Competitors: Toyota Pickup, Nissan Hardbody, Ford Ranger, Chevrolet S-10 Key Features Unique Selling Proposition: Unibody construction (shared with Cherokee XJ) for lighter weight and improved ride compared to body-on-frame competitors, available 4x4 system. Design Philosophy: Practical, durable, and capable, mirroring the core Jeep brand values. 📋 Manual Details Coverage Areas Manual Type: Factory Service Manual / Workshop Manual Language: English Format: Digital (likely PDF) Intended Audience: Professional Technicians and Enthusiast Owners Page Count: Extensive (typical WSM for this era exceeds 1000 pages, specific count not provided in product info) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, exhaust system, lubrication system, engine control systems (ECU diagnostics) Transmission: Manual and Automatic Transmission repair, overhaul, diagnostics, clutch, driveshafts, transfer case Chassis: Suspension (front and rear), steering system, brakes (hydraulic, power assist, parking brake), wheels and tires Electrical: Wiring diagrams, lighting systems, starting and charging systems, instrumentation, power accessories, body electrical components, diagnostic procedures for electrical faults Body: Body structure, exterior panels, interior trim, glass, doors, hoods, tailgates, collision repair information Procedures Included Maintenance: Scheduled maintenance intervals, fluid changes, filter replacements, lubrication points, inspections Repair: Detailed step-by-step repair procedures for all major components and systems, including disassembly, assembly, and adjustment Troubleshooting: Diagnostic charts, symptom-based troubleshooting guides, fault code interpretation (where applicable) Specifications: Torque values, clearances, fluid capacities, electrical resistance values, pressure specifications Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures, including methods for identifying and resolving complex mechanical and electrical issues Rebuild Procedures: Comprehensive overhaul instructions for engines, transmissions, differentials, and other major mechanical assemblies Wiring Diagrams: Detailed and accurate wiring diagrams for all electrical systems, essential for diagnosis and repair 📊 Manual Specifications File Format Compatibility: Viewable on most devices with PDF reader (Adobe Acrobat Reader recommended) Searchability: Likely text-searchable for quick information retrieval Printability: Printable pages for hands-on workshop use Print Quality Clarity: High-resolution, clear text and diagrams Binding Type Type: N/A (Digital Format) Paper Type Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: 4.0L Inline-6 (High Output) Displacement: 3960 cc (242 cubic inches) Horsepower Output: Approx. 170-182 hp (depending on year and specific tune) Torque Output: Approx. 220-235 lb-ft (depending on year and specific tune) Optional Engine Engine Code: 2.5L Inline-4 (AMC 150) Displacement: 2469 cc (150 cubic inches) Horsepower Output: Approx. 105-120 hp Torque Output: Approx. 135-140 lb-ft Performance Fuel Type: Unleaded Gasoline Fuel System Induction Type: Multi-Port Fuel Injection (MPI) for 4.0L, Throttle Body Injection (TBI) for early 2.5L, later 2.5L also MPI. 🔧 Transmission Standard Transmission Type: 5-Speed Manual (e.g., AX-5) Optional Transmission Type: 3-Speed Automatic (e.g., Aisin AW4) Type Later Years: 4-Speed Automatic (e.g., AW4 or 42RH/44RE for later models) Features Transfer Case Options: Command-Trac (2WD/4WD Part-Time), Selec-Trac (2WD/4WD Full-Time and Part-Time) - NP231, NP242 📐 Dimensions Exterior Wheelbase Short: 113.0 inches (2870 mm) Wheelbase Long: 121.0 inches (3073 mm) Bed Lengths: 6-foot and 7-foot bed options Weights Curb Weight: Approx. 3,500 - 4,000 lbs (depending on configuration) 🛡️ Safety Features Ratings NHTSA Ratings: N/A (Vehicle Safety Administration ratings were less standardized during this period for trucks) Active Features ABS: Available on some later models, primarily rear-wheel ABS Passive Features Airbags: Driver airbag became standard in later years, passenger airbags were not common. Seatbelts: Lap and shoulder belts 💡 Technology Features Infotainment Radio Options: AM/FM radio with cassette player, optional premium sound systems Driver Assistance Cruise Control: Available as an option on most trims Connectivity Early Tech: Focus on functional utility rather than advanced technology; basic driver controls and comfort features. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000 miles or 3 months for conventional oil, potentially longer with synthetic. Consult manual for specifics. Transmission Fluid Interval: Every 30,000-50,000 miles, depending on usage and transmission type. Consult manual. Spark Plug Replacement: Varies by plug type, typically 30,000-100,000 miles. Consult manual for specific recommendations. Fluid Specifications Engine Oil: SAE 10W-30 or 10W-40 (consult manual for specific 4.0L/2.5L recommendations and API service classification) Transmission Fluid Auto: ATF+3 or ATF+4 (for later models), consult manual for specific AW4/42RH/44RE requirements Transmission Fluid Manual: GL-3 or GL-4 gear oil (e.g., SAE 75W-90 or 80W-90), check manual for AX-5 specification Coolant: 50/50 mix of Mopar Antifreeze/Coolant (MS-9769) or equivalent ethylene glycol-based coolant with demineralized water Brake Fluid: DOT 3 brake fluid Known Issues Common Concerns Engine: Oil filter adapter O-rings leakage (4.0L), rear main seal leaks, intake manifold gasket leaks (especially 4.0L '99+ style, but can occur earlier). Common Concerns Transmission: AX-5 manual transmission synchro wear, AW4 automatic transmission solenoid issues, transfer case chain stretch (NP231). Common...
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Jeep Comanche 1984-1996 WSM Service Manual Repair
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Comanche
Model Code:
MJ
Production Years Covered:
1984-1996
Codes
Chassis Code:
MJ
👋 Introduction
Market Position
Vehicle Segment:
Compact Pickup Truck
Jeep Heritage:
Leveraged Jeep's reputation for ruggedness and off-road capability in a utility segment
Competitive Analysis
Key Competitors:
Toyota Pickup, Nissan Hardbody, Ford Ranger, Chevrolet S-10
Key Features
Unique Selling Proposition:
Unibody construction (shared with Cherokee XJ) for lighter weight and improved ride compared to body-on-frame competitors, available 4x4 system.
Design Philosophy:
Practical, durable, and capable, mirroring the core Jeep brand values.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Manual / Workshop Manual
Language:
English
Format:
Digital (likely PDF)
Intended Audience:
Professional Technicians and Enthusiast Owners
Page Count:
Extensive (typical WSM for this era exceeds 1000 pages, specific count not provided in product info)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, cooling system, exhaust system, lubrication system, engine control systems (ECU diagnostics)
Transmission:
Manual and Automatic Transmission repair, overhaul, diagnostics, clutch, driveshafts, transfer case
Chassis:
Suspension (front and rear), steering system, brakes (hydraulic, power assist, parking brake), wheels and tires
Electrical:
Wiring diagrams, lighting systems, starting and charging systems, instrumentation, power accessories, body electrical components, diagnostic procedures for electrical faults
Body:
Body structure, exterior panels, interior trim, glass, doors, hoods, tailgates, collision repair information
Procedures Included
Maintenance:
Scheduled maintenance intervals, fluid changes, filter replacements, lubrication points, inspections
Repair:
Detailed step-by-step repair procedures for all major components and systems, including disassembly, assembly, and adjustment
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting guides, fault code interpretation (where applicable)
Specifications:
Torque values, clearances, fluid capacities, electrical resistance values, pressure specifications
Technical Depth
Diagnostic Capabilities:
Advanced diagnostic procedures, including methods for identifying and resolving complex mechanical and electrical issues
Rebuild Procedures:
Comprehensive overhaul instructions for engines, transmissions, differentials, and other major mechanical assemblies
Wiring Diagrams:
Detailed and accurate wiring diagrams for all electrical systems, essential for diagnosis and repair
📊 Manual Specifications
File Format
Compatibility:
Viewable on most devices with PDF reader (Adobe Acrobat Reader recommended)
Searchability:
Likely text-searchable for quick information retrieval
Printability:
Printable pages for hands-on workshop use
Print Quality
Clarity:
High-resolution, clear text and diagrams
Binding Type
Type:
N/A (Digital Format)
Paper Type
Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4.0L Inline-6 (High Output)
Displacement:
3960 cc (242 cubic inches)
Horsepower Output:
Approx. 170-182 hp (depending on year and specific tune)
Torque Output:
Approx. 220-235 lb-ft (depending on year and specific tune)
Optional Engine
Engine Code:
2.5L Inline-4 (AMC 150)
Displacement:
2469 cc (150 cubic inches)
Horsepower Output:
Approx. 105-120 hp
Torque Output:
Approx. 135-140 lb-ft
Performance
Fuel Type:
Unleaded Gasoline
Fuel System
Induction Type:
Multi-Port Fuel Injection (MPI) for 4.0L, Throttle Body Injection (TBI) for early 2.5L, later 2.5L also MPI.
🔧 Transmission
Standard Transmission
Type:
5-Speed Manual (e.g., AX-5)
Optional Transmission
Type:
3-Speed Automatic (e.g., Aisin AW4)
Type Later Years:
4-Speed Automatic (e.g., AW4 or 42RH/44RE for later models)
Features
Transfer Case Options:
Command-Trac (2WD/4WD Part-Time), Selec-Trac (2WD/4WD Full-Time and Part-Time) - NP231, NP242
📐 Dimensions
Exterior
Wheelbase Short:
113.0 inches (2870 mm)
Wheelbase Long:
121.0 inches (3073 mm)
Bed Lengths:
6-foot and 7-foot bed options
Weights
Curb Weight:
Approx. 3,500 - 4,000 lbs (depending on configuration)
🛡️ Safety Features
Ratings
NHTSA Ratings:
N/A (Vehicle Safety Administration ratings were less standardized during this period for trucks)
Active Features
ABS:
Available on some later models, primarily rear-wheel ABS
Passive Features
Airbags:
Driver airbag became standard in later years, passenger airbags were not common.
Seatbelts:
Lap and shoulder belts
💡 Technology Features
Infotainment
Radio Options:
AM/FM radio with cassette player, optional premium sound systems
Driver Assistance
Cruise Control:
Available as an option on most trims
Connectivity
Early Tech:
Focus on functional utility rather than advanced technology; basic driver controls and comfort features.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000 miles or 3 months for conventional oil, potentially longer with synthetic. Consult manual for specifics.
Transmission Fluid Interval:
Every 30,000-50,000 miles, depending on usage and transmission type. Consult manual.
Spark Plug Replacement:
Varies by plug type, typically 30,000-100,000 miles. Consult manual for specific recommendations.
Fluid Specifications
Engine Oil:
SAE 10W-30 or 10W-40 (consult manual for specific 4.0L/2.5L recommendations and API service classification)
Transmission Fluid Auto:
ATF+3 or ATF+4 (for later models), consult manual for specific AW4/42RH/44RE requirements
Transmission Fluid Manual:
GL-3 or GL-4 gear oil (e.g., SAE 75W-90 or 80W-90), check manual for AX-5 specification
Coolant:
50/50 mix of Mopar Antifreeze/Coolant (MS-9769) or equivalent ethylene glycol-based coolant with demineralized water
Brake Fluid:
DOT 3 brake fluid
Known Issues
Common Concerns Engine:
Oil filter adapter O-rings leakage (4.0L), rear main seal leaks, intake manifold gasket leaks (especially 4.0L '99+ style, but can occur earlier).
Common Concerns Transmission:
AX-5 manual transmission synchro wear, AW4 automatic transmission solenoid issues, transfer case chain stretch (NP231).
Common Concerns Chassis:
Leaf spring eyelet wear, front sway bar links, U-joint wear, front axle universal joint wear.
Common Concerns Electrical:
Headlight switch failure, instrument cluster gauge issues, grounds corrosion.
Common Concerns Body:
Rust in common Jeep areas: floor pans, rocker panels, rear quarter panels, tailgate.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Built upon Jeep's legacy of robust off-road vehicles and utility.
Model Evolution
Introduction:
Introduced for the 1986 model year as a compact pickup truck, sharing its platform with the popular Cherokee XJ SUV.
Facelifts Updates:
Received minor styling updates and powertrain enhancements throughout its production run, including the introduction of the 4.0L I6 engine in 1987 and electronic fuel injection advancements.
Production
Manufacturing Location:
Toledo, Ohio, USA
Discontinuation:
Production ended in 1992, but the manual covers up to the 1996 model year (indicating potential overlap or specific market variations).
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
Praised for its robust powertrain (especially the 4.0L) and Jeep's signature off-road capability within the compact truck segment. Often considered more rugged than its competitors.
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