1994 JEEP CHEROKEE ABS

(12) Install assembled driving shell and sun gear
on output shaft (Fig. 88).
(13) Install rear thrust washer on front planetary
gear (Fig. 89). Use enough petroleum jelly to hold
washer in place and be sure all four washer tabs are
seated.
(14) Install front planetary gear on output shaft
and in driving shell (Fig. 90).
(15) Install front thrust washer on front planetary
gear. Use enough petroleum jelly to hold washer in
place and be sure all four washer tabs are seated.
(16) Assemble front annulus gear and support, if
necessary. Be sure support snap ring is seated.
(17) Install front annulus on front planetary (Fig.
90).
(18) Position thrust plate on front annulus gear
support (Fig. 91).Note that plate has two tabs on
it. These tabs fit in notches of annulus hub.(19) Install thrust washer in front annulus (Fig.
92).Align flat on washer with flat on planetary
hub. Also be sure washer tab is facing up.
(20) Install front annulus snap ring (Fig. 93). Use
snap ring pliers to avoid distorting ring during in-
stallation. Also be sure ring is fully seated.
Fig. 88 Installing Assembled Sun Gear And Driving
Shell On Output Shaft
Fig. 89 Installing Rear Thrust Washer On Front
Planetary Gear
Fig. 90 Installing Front Planetary And Annulus
Gears
Fig. 91 Positioning Thrust Plate On Annulus
Support
Fig. 92 Installing Front Annulus Thrust Washer
J30RH/32RH TRANSMISSION OVERHAUL 21 - 135

²Continuity should exist between terminals B and
C with the transmission in Park and Neutral only
(Fig. 4).
²Continuity should exist between terminals A and E
with the transmission in Reverse (Fig. 4).
²Continuity should exist between terminals A and
G with the transmission in third gear (Fig. 4).
²Continuity should exist between terminals A and
H with the transmission in first and/or second gear
(Fig. 4).
²Continuity should not exist in D position.
PARK/NEUTRAL POSITION SWITCH REMOVAL
(1) Raise vehicle.
(2) Disconnect switch wire harness connector.
(3) Pry washer lock tabs upward and remove
switch attaching nut and tabbed washer (Fig. 5).
(4) Remove switch adjusting bolt (Fig. 5).
(5) Slide switch off manual valve shaft.
PARK/NEUTRAL POSITION SWITCH
INSTALLATION AND ADJUSTMENT
(1) Disconnect shift linkage rod from shift lever on
left side of transmission.
(2) Rotate manual shift lever all the way rearward.
Then rotate lever forward two detent positions to
Neutral.
(3) Install switch on manual valve shaft and in-
stall switch adjusting bolt finger tight. Do not tighten
bolt at this time.(4) Install tabbed washer on manual valve shaft
and install switch attaching nut. Tighten nut to 6.9
Nzm (61 in. lbs.) torque but do not bend washer lock
tabs over nut at this time.
(5) Verify that transmission is in Neutral.
(6) Rotate switch to align neutral standard line
with vertical groove on manual valve shaft (Fig. 6).
(7) Align switch standard line with groove or flat
on manual valve shaft.
Fig. 2 Transmission Control Module Location And
Mounting (Left Hand Drive)
Fig. 3 Transmission Control Module Location And
Mounting (Right Hand Drive)
Fig. 4 Park/Neutral Position Switch Terminals And
Testing
Fig. 5 Park/Neutral Position Switch Removal/
Installation
21 - 174 AW-4 IN-VEHICLE SERVICEJ

(8) Tighten switch adjusting bolt to 13 Nzm(9ft.
lbs.) torque.
(9) Bend at least two washer lock tabs over switch
attaching nut to secure it.
(10) Connect shift linkage rod to shift lever on left
side of case.
(11) Connect switch wires to harness and lower ve-
hicle.
(12) Check switch operation. Engine should start
in Park and Neutral only.
TRANSMISSION VALVE BODY SOLENOIDS
SOLENOID REMOVAL
(1) Remove transmission oil pan drain plug and
drain fluid.
(2) Remove pan bolts and remove oil pan.
(3) Remove oil screen bolts and remove screen (Fig.
7) and gasket. Discard the gasket.(4) Disconnect solenoid wire connector (Fig. 8).
(5) If all solenoids are being removed, mark or tag
wires for assembly reference before disconnecting
them.
(6) Remove bolt attaching solenoids to valve body
and remove solenoids (Fig. 9). Do not allow any valve
body components to fall out when solenoids are re-
moved.
(7) Clean oil filter and pan with solvent and dry
with compressed air.
(8) Remove old sealer material from oil pan and
transmission case.
Solenoid Testing
Test solenoid resistance with an ohmmeter. Con-
nect the ohmmeter leads to the solenoid mounting
bracket and to the solenoid wire terminal (Fig. 10).
Fig. 8 Solenoid Wire Connectors
Fig. 9 Transmission Valve Body Solenoids
Fig. 6 Park/Neutral Position Switch Adjustment
Fig. 7 Oil Screen Removal/Installation
JAW-4 IN-VEHICLE SERVICE 21 - 175

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) Support sun gear on wood block (Fig. 6). Then
remove first sun gear snap ring and separate drum
from gear.
(6) Remove remaining snap ring from sun gear
(Fig. 7).
(7) Measure inside diameter of sun gear bushings
with bore gauge or inside micrometer (Fig. 8). Maxi-
mum allowable diameter is 27.08 mm (1.0661 in.).
Replace sun gear if bushing inside diameter is
greater than specified.
SUN GEAR AND CLUTCH ASSEMBLY
(1) Install first snap ring on sun gear.
(2) Install sun gear in drum and install remaining
snap ring.(3) Coat replacement seal rings with petroleum
jelly and install them on sun gear.Be sure seal
ring ends are interlocked.
(4) Install thrust washer. Be sure washer tabs are
seated in drum slots.
(5) Install one-way clutch/second brake hub assem-
bly on sun gear. Deep side of hub flange faces up-
ward (Fig. 9).
(6) Check one-way clutch operation again (Fig. 2).
Hold sun gear and turn second brake hub clockwise
and counterclockwise. Hub should turn clockwise
freely, but lock when turned counterclockwise.
Fig. 2 Checking One-Way Clutch Operation
Fig. 3 Removing/Installing Brake Hub And Clutch
Assembly
Fig. 4 Removing/Installing Thrust Washer
Fig. 5 Removing/Installing Sun Gear Seal Rings
21 - 230 AW-4 TRANSMISSION OVERHAULJ

(3) Compress return springs with shop press and
Compressor Tool 7538. Install piston snap ring and
remove brake assembly from press.
(4) Check brake piston operation with low pressure
compressed air (Fig. 7). Apply air pressure through
feed hole in drum. Piston should move smoothly
when applying-releasing air pressure.
(5) Coat thrust washer with petroleum jelly and
install it in drum. Be sure washer notches are
aligned with tabs on spring retainer (Fig. 8).
(6) Set brake components aside for final assembly.
Fig. 6 Measuring Second Brake Piston Return Springs
Fig. 7 Checking Second Brake Piston Operation
Fig. 8 Installing Second Brake Thrust Washer
Fig. 4 Removing/Installing Second Brake Piston Snap Ring
Fig. 5 Removing/Installing Piston And Sleeve
JAW-4 TRANSMISSION OVERHAUL 21 - 233

(22) Install planetary sun gear and input drum
(Fig. 17). Be sure drum thrust washer tabs are
seated in drum. Use petroleum jelly to hold thrust
washer in position if necessary.
(23) Install front planetary gear on sun gear (Fig.
18).
(24) Support output shaft with wood blocks (Fig.
19).
(25) Install planetary snap ring on sun gear with
snap ring plier tool 7541 (Fig. 20).(26) Install tabbed thrust race on front planetary
gear (Fig. 21). Washer tabs face down and toward
gear. Race outer diameter is 47.8 mm (1.882 in.). In-
side diameter is 34.3 mm (1.350 in.).
(27) Install second coast brake band (Fig. 22).
(28) Install pin in second coast brake band. Then
install retaining ring on pin (Fig. 23).
(29) Install thrust bearing and race in forward-di-
rect clutch (Fig. 24). Coat bearing/race with petro-
leum jelly to hold them in place.
(30) Verify forward-direct clutch thrust bearing
size.
Fig. 17 Installing Sun Gear And Input Drum
Fig. 18 Installing Front Planetary Gear
Fig. 19 Supporting Output Shaft
Fig. 20 Installing Front Planetary Snap Ring
JAW-4 TRANSMISSION OVERHAUL 21 - 259

(87) Install spacer and speedometer drive gear on
output shaft. Then install retaining snap ring (Fig.
64).
(88) Apply bead of Mopar or Loctite 599 sealer to
sealing surface at rear of case (Fig. 65).
(89) Install adapter housing on transmission.
Tighten adapter bolts to 34 Nzm (25 ft. lbs.) torque.
(90) Install transmission speed sensor (Fig. 66).
Tighten sensor bolt to 7.4 Nzm (65 in. lbs.) torque
and connect sensor wire harness connector.
(91) Install converter housing (Fig. 67). Tighten 12
mm diameter housing bolts to 57 Nzm (42 ft. lbs.)
torque. Tighten 10 mm diameter housing bolts to 34
Nzm (25 ft. lbs.) torque.(92) Install transmission shift lever on manual
valve shaft. Do not install lever attaching nut at this
time.
(93) Move transmission shift lever fully rearward.
Then move lever two detent positions forward.
(94) Mount park/neutral position switch on manual
valve shaft and tighten switch adjusting bolt just
enough to keep switch from moving (Fig. 68).
(95) Install park/neutral position switch tabbed
washer and retaining nut (Fig. 68). Tighten nut to
6.9 Nzm (61 in. lbs.) torque, but do not bend any of
the washer tabs against the nut at this time.
(96) Align park/neutral position switch standard
line with groove or flat on manual shaft (Fig. 68).
(97) Tighten park/neutral position switch adjusting
bolt to 13 Nzm (9 ft. lbs.) torque.
(98) Install transmission shift lever on manual
Fig. 66 Installing Transmission Speed Sensor
Fig. 67 Installing Converter Housing
Fig. 64 Installing Spacer And Speedometer Drive
Gear
Fig. 65 Applying Sealer To Case Rear Flange
21 - 270 AW-4 TRANSMISSION OVERHAULJ