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1987-2001 Jeep Cherokees Neutral Safety Switch - Rebuild The Master Switch

AW-4 NSS Restoration
By Pete Trasborg
1987 2001 Cherokee Neutral Safety Switch Jeep Gears
1987 2001 Cherokee Neutral Safety Switch Electrical Contact Cleaner
Electrical-contact cleaner... 
   
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1987 2001 Cherokee Neutral Safety Switch Electrical Contact Cleaner
Electrical-contact cleaner (brake cleaner might eat the switch), dielectric grease (to lubricate the moving parts and keep oxidation at bay), and fine sandpaper (to clean oxidation and crud off the contacts) are all that's needed for this project, in addition to some basic handtools.
1987 2001 Cherokee Neutral Safety Switch Switch Contact Arm
The other side of the switch... 
   
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1987 2001 Cherokee Neutral Safety Switch Switch Contact Arm
The other side of the switch contains the contact arm, which has two small, springloaded copper contacts. The switch is sealed by an O-ring. We were warned that the contacts like to jump out. The arm was so cruddy, we had to pry the contacts out to be cleaned, sanded, and greased before we could put them back.
1987 2001 Cherokee Neutral Safety Switch Before
Before
1987 2001 Cherokee Neutral Safety Switch After
After - The service manual... 
   
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1987 2001 Cherokee Neutral Safety Switch After
After - The service manual says to cut a few zip ties, unplug the switch, and slide it out, but that's not as easy as you might think. There were two zip ties on our XJ that we couldn't get to with our knife, the only cutting tool in the garage where we did this. We found that after cutting the zip ties in the engine compartment and unplugging the switch, we were able to unbolt it from the transmission and pull it down far enough for cleaning.
1987 2001 Cherokee Neutral Safety Switch Nss Adjustment
The adjustment of the NSS... 
   
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1987 2001 Cherokee Neutral Safety Switch Nss Adjustment
The adjustment of the NSS is the hardest part of this procedure. Some say to put the transmission in Neutral and align the line on the switch with the line of the shaft sticking through it, while others just put it in Reverse with the key on and figure out where the middle of the turn-on/turn-off point is for the backup lights.

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