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Old May 14th, 2011, 22:05
Alexia Alexia is offline
NAXJA Forum User
Join Date: Aug 2008
Location: Huntsville, AL
Posts: 737
Re: Cherokee Resurrection - Build Thread

Stripping down the front end of the a Cherokee is fairly easy. There are no hidden bolts and there are no Torx bolts until you get to the fenders. The exact details about the number of screws/bolts apply to Cherokees up to 1996, but the process is essentially the same for 1997-2001 Cherokees.

When removing nuts and bolts tape them to the part that was removed or bundle them together in a piece of tape and label the tape.

Steps to remove components in front of the engine.
1.) Start by removing the orange side markers held in with two screws. Tape the screws to the marker. The marker bulb holder twists counter clock wise to remove it. Remove the bulb and set it aside to prevent breaking it.

2.) Remove the head light bezels. Two screws are under where the side marker lights were and one in the upper left/right of the bezel by the grill.

3.) Remove the four screws holding the chrome head light trim on and disconnect the head lights. The head light buckets will come off with the header.

4.) Remove the two screws that hold in the front marker lights. Again, twist the bulb holder counter clock wise to remove it. Remove the bulb and set it aside to prevent breaking it.

5.) Lift the hood. Remove the four bolts at the top of the grill. There are four more bolts, two on each side, that were previously hidden by the side marker lights. Once all eight bolts are removed the header plus grill should come free. Carefully unclip the wire loom from the header and set the header aside.

6.) The radiator support is held in by six bolts and four nuts. There are three large bolts that connect each end to the inner fenders. Four nuts along the top hold the support to the radiator. Once these are all removed it will lift away.

6a.) Models with AC: Remove the two tabs on the top of the radiator that holds the AC condenser to the radiator.

7.) At this point it is time to drain the radiator. If your radiator has a drain valve, use it, otherwise remove the bottom hose and let it drain into a bucket. Afterwards remove the top hose with the bucket underneath to catch any excess.

7a.) Models with automatic transmissions: There are two transmission cooler lines that must be removed from the left side of the radiator. Prepare to a rag, hose clamp, or stopper to prevent the losing transmission fluid. The top fitting is removed with a crescent wrench. The bottom fitting is a quick disconnect fitting. Depending on what year your Jeep this may require a special tool. If you see two plastic tabs, squeeze, pull on the tabs, and yank the line off.

8.) With some wiggling and fiddling, remove the radiator straight upwards.

9.) Models with AC: Removing the AC condenser. WARNING: The AC system is under high pressure! Releasing the pressure/removing the refrigerant without facial, eye, and arm protection can cause frostbite burns on exposed skin and blindness if splashed in the eyes. You must use a reclamation system on the service port to prevent venting the refrigerant into the atmosphere. Not using the proper reclamation tools, if found out, can result in massive fines from the federal government. Once you have drained the AC refrigerant use two wrenches to remove the fittings at the condenser. One to hold the condenser side to prevent damage, if in good condition, and one to remove the compression fitting.

10.) Recover all brackets from the AC condenser and radiator. Not all aftermarket replacements come with the brackets needed.

Congratulations! You now have full access to the front of the engine and can now begin working on the inner and out fenders.

Stripped down front.

Damaged inner fender pieces. From the look of the damage they can probably be hand pulled straight.

Back side of the damaged radiator, shown upside down. Steering pump pulley indentation on the right and fan indentation on the left.

The only salvageable parts from the front end which are mostly bolts and small brackets.
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