1994 JEEP CHEROKEE clutch

AW-4 IN-VEHICLE SERVICE
INDEX
page page
Accumulator Pistons and Springs........... 179
Adapter Housing Seal Replacement.......... 182
Checking Fluid Level and Condition.......... 173
Manual Valve Shaft Seal Replacement....... 178
Park Interlock Cable Adjustment............ 186
Park Rod and Pawl Service................ 181
Park/Neutral Position Switch............... 173
Second Coast Brake Servo................ 181
Shift Cable Adjustment................... 186
Speed Sensor.......................... 182Speed Sensor RotorÐSpeedometer Drive Gear . 183
Throttle Position Sensor (TPS) Service....... 184
Transmission Control Module (TCM) Service . . . 173
Transmission Cooler Line Fittings........... 187
Transmission Cooler Service............... 187
Transmission Throttle Cable Adjustment....... 185
Transmission Throttle Cable Replacement..... 184
Transmission Valve Body Installation......... 177
Transmission Valve Body Removal.......... 176
Transmission Valve Body Solenoids.......... 175
CHECKING FLUID LEVEL AND CONDITION
Recommended fluid for AW-4 transmissions is Mo-
par Dexron IIE/Mercon. Mopar Dexron II may be
used if Mercon fluid is not readily available.
CHECKING FLUID LEVEL
(1) Be sure transmission fluid is at normal operat-
ing temperature. Normal operating temperature is
reached after approximately 15 miles (25 km) of op-
eration.
(2) Position vehicle on level surface. This is impor-
tant for an accurate fluid level check.
(3) Shift transmission through all gear ranges and
back to Park.
(4) Apply parking brakes.
(5) Verify that transmission is in Park.
(6) Wipe off dipstick handle to prevent dirt from
entering fill tube. Then remove dipstick and check
fluid level and condition.
(7) Correct fluid level isto FULL mark on dip-
stick when fluid is at normal operating temper-
ature(Fig. 1).
(8) If fluid level is low, top off level with Mopar
Dexron IIE/Mercon. Mopar Dexron II may also be
used if Mercon is not available.Do not overfill
transmission. Add only enough fluid to bring
level to Full mark.
CHECKING FLUID CONDITION
Inspect the appearance of the fluid during the fluid
level check. The fluid should be clear and free of for-eign material or particles. If the fluid is dark brown
or black in color and smells burnt, the fluid has been
overheated and should be replaced.
Transmission operation should also be checked if
the fluid is severely discolored and contains quanti-
ties of foreign material, metal particles, or clutch disc
friction material.
A small quantity of friction material or metal
particles in the oil pan is normal. The particles
are usually generated during the break-in pe-
riod and indicate normal seating of the various
transmission components.
TRANSMISSION CONTROL MODULE (TCM)
SERVICE
Use the DRB II scan tool to diagnose transmission
control module function whenever a fault is sus-
pected. Replace the module only when actually faulty.
TRANSMISSION CONTROL MODULE
REPLACEMENT
The transmission control module is mounted under
the instrument panel. On left hand drive models, it is
at the driver side of the lower finish panel (Fig. 2).
On right hand drive models, it is at the passenger
side of the lower finish panel (Fig. 3).
To remove the module, disconnect the wire harness,
remove the mounting screws and remove the module
from the finish panel. Tighten the module mounting
screws securely after installation. Also be sure the
wire harness is not twisted, kinked or touching any
body panels.
PARK/NEUTRAL POSITION SWITCH
SWITCH TESTING
Test switch continuity with an ohmmeter. Discon-
nect the switch and check continuity at the connector
terminal positions and in the gear ranges indicated
in Figure 3. Switch continuity should be as follows:Fig. 1 Transmission Fluid Level
JAW-4 IN-VEHICLE SERVICE 21 - 173

(5) Disconnect throttle cable from throttle cam
(Fig. 13).
(6) Remove valve body bolts. Bolt locations are out-
lined in Figure 14.
(7) Lower valve body and remove overdrive clutch
accumulator springs, direct clutch accumulator
springs and second brake accumulator spring (Fig.
15)
(8) Remove valve body and check ball and spring
(Fig. 16).
TRANSMISSION VALVE BODY INSTALLATION
(1) Connect cable to throttle cam (Fig. 13).
(2) Install check ball and spring (Fig. 16).
(3) Position accumulator springs and spacers on
valve body.(4) Align valve body manual valve with shift sector
(Fig. 17) and carefully position valve body on case.
(5) Install valve body bolts (Fig. 14). Tighten bolts
evenly to 10 Nzm (7 ft. lbs.) torque.
(6) Install valve body oil tubes. Be sure tube ends
(L) and (M) are installed as shown in Figure 18.
(7) Remove old sealer material from oil pan and
transmission case.
(8) Clean oil screen and oil pan with solvent (if not
done previously). Dry both components with com-
pressed air only. Do not use shop towels.
(9) Install new gaskets on oil screen and install
screen on case. Tighten screen attaching bolts to 10
Nzm (7 ft. lbs.) torque.
Fig. 13 Removing/Installing Throttle Cable
Fig. 14 Transmission Valve Body Bolt Locations
Fig. 15 Accumulator Springs
Fig. 16 Removing/Installing Check Ball And Spring
JAW-4 IN-VEHICLE SERVICE 21 - 177

TRANSMISSION COOLER SERVICE
Main Cooler
The transmission main cooler is located in the ra-
diator. The main cooler can be flushed when neces-
sary, however, the cooler is not a repairable
component. If the cooler is damaged, plugged, or
leaking, the radiator will have to be replaced.
Auxiliary Cooler
The auxiliary cooler is mounted in front of the ra-
diator at the driver side of the vehicle (Fig. 48). The
cooler can be flushed when necessary, while mounted
in the vehicle. The cooler can also be removed for ac-
cess, repair, or replacement as needed.
The main and auxiliary coolers should both be
flushed whenever a transmission or converter clutch
malfunction generates sludge, debris, or particles of
clutch friction material.
Cooler Service
The main cooler (and radiator) and the auxiliary
cooler can be removed for service or access to other
components. Auxiliary cooler removal requires that
the front bumper and radiator support be removed
for access to the cooler lines and attaching bracket.
REVERSE FLUSHING MAIN AND AUXILIARY
COOLERS AND COOLER LINES
Reverse flushing the cooler and lines will prevent
sludge and particles from flowing back into the
transmission after repair. The flushing procedure ap-
plies to standard (in-radiator) coolers and auxiliary
coolers equally.
Pressure equipment is preferred for reverse flush-
ing. However, reverse flushing can be performed us-
ing hand operated equipment as described in the
following procedure.
(1) Disconnect cooler lines at transmission and at
auxiliary cooler (Figs. 48 and 49).
(2) Position drain pan under cooler line to catch
material flushed through coolers and lines.
(3) Reverse flush each cooler using hand operated
suction gun filled with mineral spirits. Insert gun
nozzle (or hose) into cooler inlet (return) line. Then
force mineral spirits through into line and through
cooler.(4) Continue reverse flushing until fluid exiting in-
let (pressure) line is clear and free of debris/residue.
(5) Replace radiator if fluid cannot be pumped
through main cooler. Replace auxiliary cooler if leaks
are evident, or if fluid cannot be pumped through it.
(6) Clear flushing materials from coolers and lines
with short pulses of compressed air. Insert air gun
nozzle into cooler inlet (return) line and continue
short pulses of air until all fluid is cleared from
cooler and lines.
(7) Pump one quart of fresh automatic transmis-
sion fluid through cooler and lines before reconnect-
ing cooler lines.
FLOW TESTING TRANSMISSION MAIN
COOLER
Cooler flow is checked by measuring the amount of
fluid flow through the cooler in a 20 second time pe-
riod. The test is performed with the engine running
and transmission in neutral. Fluid is then pumped
through the cooler by the transmission oil pump.
(1) Disconnect cooler inlet line at transmission fit-
ting.
(2) Securely attach hose to end of inlet line and po-
sition line in a one quart test container.
(3) Add extra quart of fluid to transmission.
(4) Use stopwatch to check flow test time.
(5) Shift transmission into neutral and set parking
brake.
(6) Start and run engine at curb idle speed and im-
mediately note cooler flow. Approximately one quart
of fluid should flow into test container in 20 second
period.
(7) If cooler flow is intermittent, flows less than
one quart in 20 seconds, or does not flow at all,
cooler is faulty and must be replaced.
TRANSMISSION COOLER LINE FITTINGS
Quick disconnect fittings are used at the transmis-
sion cooler line connections. The fitting seals and
guides are serviceable.
Replace the seals and guides whenever the fittings
exhibit leakage, or will not properly snap into place.
JAW-4 IN-VEHICLE SERVICE 21 - 187

AW-4 TRANSMISSION REMOVAL AND INSTALLATION
INDEX
page page
Oil Pump Seal Replacement............... 189
Torque Converter Stator Clutch Inspection..... 189Transmission and Torque Converter Installation . 190
Transmission and Torque Converter Removal . . 189
TRANSMISSION AND TORQUE CONVERTER
REMOVAL
(1) Raise vehicle.
(2) Drain transmission fluid and reinstall oil pan
drain plug.
(3) Remove upper half of transmission fill tube
(Fig. 50).
(4) Disconnect cooler lines at transmission. Cooler
lines have quick-disconnect fittings. Press fitting re-
lease tabs and pull cooler lines and fittings out of
case or use Special Tool 7555 to disconnect them.
(5) Support engine with safety stand and support
transmission with jack.
(6) Disconnect transmission and transfer case shift
linkage.
(7) Remove necessary exhaust components.
(8) Disconnect vehicle speed sensor wires
(9) Mark position of front and rear propeller shafts
for alignment reference. Then remove shafts from ve-
hicle.
(10) Remove rear crossmember.
(11) Disconnect transmission shift cable at trans-
mission. Then disconnect transmission throttle valve
cable at engine.(12) Disconnect necessary vacuum and fluid hoses.
(13) Remove transfer case from transmission.
(14) Disconnect and remove crankshaft position
sensor.
CAUTION: The crankshaft position sensor can be
damaged if the sensor is still in place when the
transmission is removed. To avoid damage, remove
the sensor before transmission removal.
(15) Remove starter motor.
(16) Remove bolts attaching converter to drive
plate.
(17) Remove bolts attaching converter housing to
engine.
(18) Secure transmission to jack with safety
chains.
(19) Pull transmission rearward for access to con-
verter. Then secure converter in pump with C-clamp
or strap bolted to converter housing.
(20) Remove transmission from under vehicle.
(21) Remove torque converter if converter or oil
pump seal are to be serviced.
TORQUE CONVERTER STATOR CLUTCH
INSPECTION
(1) Insert Rotating Tool 7547 into converter hub
and seat tool in one-way clutch (Fig. 51).
(2) Insert Stopper Tool 7548 in one converter hub
notch and into outer race of rotating tool.
(3) Turn rotating tool clockwise. Converter clutch
should rotate freely and smoothly. Less than 2.5 Nzm
(22 in. lbs.) of torque should be required to rotate
clutch in clockwise direction.
(4) Turn rotating tool in counterclockwise direction.
Converter clutch should lock.
(5)
Replace converter if clutch binds or will not lock.
OIL PUMP SEAL REPLACEMENT
(1) Remove converter.
(2) Remove old seal. Use blunt punch to collapse
seal and pry seal out of pump housing. Do not
scratch or damage seal bore.
(3) Lubricate lip of new seal with Mopar Mercon
transmission fluid and install seal in pump with tool
7549 (Fig. 52).
(4) Lubricate converter drive hub with Mopar Mer-
con transmission fluid.
Fig. 50 Two-Piece Transmission Fill Tube
JAW-4 TRANSMISSION REMOVAL AND INSTALLATION 21 - 189

(5) Align and install converter in oil pump.
TRANSMISSION AND TORQUE CONVERTER
INSTALLATION
(1) Mount transmission on transmission jack. Then
secure transmission to jack with safety chains.
(2) Lubricate converter drive hub and oil pump
seal lip with Mopar Mercon transmission fluid. Then
install converter. Be sure converter is fully seated in
oil pump gears before proceeding. Hold converter in
place with C-clamp or strap attached to converter
housing.
(3) Align and position transmission and converter
on engine.
(4) Remove clamp or strap used to hold torque con-
verter in place.
(5) Move transmission forward seat and it on en-
gine. Be sure torque converter hub is fully seated.
(6)
Install converter housing-to-engine bolts (Fig.
53).
(7) Install converter-to-drive plate bolts.
(8) Install and connect starter motor.
(9) Install and connect crankshaft position sensor.
(10) Install transfer case on transmission. Tighten
transfer case attaching nuts to 41 Nzm (30 ft. lbs.)
torque
(11) Connect transfer case shift linkage and vac-
uum hoses.
(12) Connect exhaust components.
(13) Install rear crossmember and remove jack
used to support transmission assembly.
(14) Connect speed sensor wire harness to sensor.
(15) Connect wire harness to park/neutral position
switch.
(16) Align and connect front and rear propeller
shafts.
Fig. 51 Checking Operation Of Torque Converter
Stator One-Way Clutch
Fig. 52 Installing Oil Pump Seal
21 - 190 AW-4 TRANSMISSION REMOVAL AND INSTALLATIONJ

AW-4 TRANSMISSION OVERHAUL
INDEX
page page
Cleaning and Inspection................... 76
Direct Clutch Overhaul................... 219
First-Reverse Brake Piston and Transmission
Case Overhaul........................ 237
Forward Clutch Overhaul.................. 223
Front Planetary Gear Overhaul............. 228
Manual Valve Shaft Overhaul.............. 205
Oil Pump Overhaul...................... 206
Overdrive Planetary Gear and Clutch Overhaul . 209Overdrive Support Overhaul................ 216
Overhaul Service Tools................... 192
Rear Planetary, No. 2 One-Way Clutch and
Output Shaft Overhaul.................. 100
Second Brake Overhaul................... 100
Sun Gear and No. 1 One-Way Clutch Overhaul . 99
Transmission Assembly and Adjustment....... 255
Transmission Disassembly................. 192
Transmission Valve Body Overhaul.......... 101
OVERHAUL SERVICE TOOLS
The special tools needed to overhaul the AW-4
transmission are provided in Tool Kit 6294. However,
Pressure Test Port Adapter 7554 is not included in
this kit and must be ordered separately. The over-
haul tool kit and test port adapter are available
through the parts division and dealer special tool
program.
TRANSMISSION DISASSEMBLY
(1) Remove torque converter.
(2) Remove lower half of filler tube if not previ-
ously removed.
(3) Remove clamps attaching wire harness and
throttle cable (Fig. 1) to transmission.(4) Remove shift lever from manual valve shaft at
left side of transmission.
(5) Remove park/neutral position switch.
(6) Remove speed sensor (Fig. 2).
Fig. 1 Typical Harness And Cable Clamp Attachment
Fig. 2 Speed Sensor Removal
21 - 192 AW-4 TRANSMISSION OVERHAULJ

(16) Disconnect throttle cable from throttle cam
(Fig. 11).
(17) Remove valve body from case. Then remove
accumulator springs, spacers and check ball and
spring (Fig. 12).
(18) Remove second brake and clutch accumulator
pistons with compressed air (Fig. 13). Apply air pres-
sure through feed port and ease the pistons out of
the bore.
(19) Remove overdrive brake accumulator piston
with compressed air (Fig. 13).
(20) Remove overdrive clutch accumulator piston
with compressed air (Fig. 13).
(21) Remove throttle cable.
Fig. 11 Disconnecting Throttle Cable
Fig. 12 Removing Accumulator Springs, Spacers
And Check Ball
Fig. 13 Removing Accumulator Pistons
JAW-4 TRANSMISSION OVERHAUL 21 - 195

(22) Remove oil pump bolts and remove pump with
bridge-type Puller 7536 (Fig. 14).
(23) Remove race from oil pump (Fig. 15).
(24) Remove fourth gear overdrive planetary gear
and overdrive direct clutch assembly (Fig. 16).
(25) Remove race from fourth gear overdrive plan-
etary (Fig. 17).
(26) Remove thrust bearing, race and overdrive
planetary ring gear (Fig. 18).
(27) Measure stroke length of overdrive brake pis-
ton as follows:
(a) Mount dial indicator on case (Fig. 19).
(b) Mount Gauge Tool 7546 so it contacts piston
(Fig. 19).(c) Apply 57-114 psi air pressure through piston
apply port and note piston stroke on dial indicator.
Stroke length should be: 1.40 - 1.70 mm (0.055 -
0.0699 in.).
Fig. 14 Oil Pump Removal
Fig. 15 Oil Pump Race Removal
Fig. 16 Removing Fourth Gear Planetary And Direct
Clutch Assembly
Fig. 17 Fourth Gear Planetary Race Removal
21 - 196 AW-4 TRANSMISSION OVERHAULJ