1994 JEEP CHEROKEE oil

(10) Apply bead of Mopar or Loctite 599 sealer to
sealing surface of oil pan. Sealer bead should be at
least 3 mm (1/8 in.) wide. Then install oil pan and
tighten pan bolts to 7.4 Nzm (65 in. lbs.) torque.
(11) Install new gasket on oil pan drain plug and
install plug in pan. Tighten plug to 20 Nzm (15 ft.
lbs.) torque.
(12) Fill transmission with Mopar MerconŸ fluid.
MANUAL VALVE SHAFT SEAL REPLACEMENT
(1) Remove park/neutral position switch and dis-
connect transmission shift lever.
(2) Remove oil pan and valve body.(3) Remove bolts attaching park rod bracket to
case (Fig. 20).
(4) Remove park rod from shift sector (Fig. 21).
(5) Cut spacer sleeve with chisel and remove it
from manual valve shaft (Fig. 22).
(6) Remove pin from shaft and sector with pin
punch.
(7) Remove shaft and sector from case.
(8) Pry shaft seals out of case (Fig. 23).
(9) Inspect the manual valve shaft and sector. Re-
place either component if worn or damaged.
Fig. 19 Manual Valve Shaft And Seals
Fig. 20 Removing/Installing Park Rod Bracket
Fig. 17 Shift Sector And Manual Valve Alignment
Fig. 18 Installing Transmission Valve Body Oil
Tubes
21 - 178 AW-4 IN-VEHICLE SERVICEJ

(10) Coat replacement shaft seals with petroleum
jelly and seat them in the case (Fig. 24).
(11) Install new spacer sleeve on sector (Fig. 25).
(12) Lubricate manual valve shaft with petroleum
jelly and install it in case.
(13) Lubricate sector and sleeve with petroleum
jelly and install them on shaft.
(14) Align hole in spacer sleeve with notch in sec-
tor. Then install shift sector roll pin. Tap pin into
sector and shaft and stake sleeve to sector and shaft
securely.
(15) Connect park rod to sector (Fig. 21).
(16) Install park rod bracket (Fig. 26). Tighten
bracket bolts to 10 Nzm (7 ft. lbs.) torque.(17) Install valve body, oil screen and oil pan. Use
Mopar or Loctite 599 sealer on oil pan seal surface.
(18) Install park/neutral position switch.
ACCUMULATOR PISTONS AND SPRINGS
ACCUMULATOR PISTON AND SPRING
REMOVAL
(1) Remove valve body. Refer to procedure in this
section.
Fig. 23 Removing Manual Valve Shaft Seals
Fig. 24 Installing Manual Valve Shaft Seals
Fig. 21 Removing/Installing Park Rod
Fig. 22 Cutting Spacer Sleeve
JAW-4 IN-VEHICLE SERVICE 21 - 179

(2) Remove accumulator pistons with compressed
air (Fig. 27). Apply air through small feed hole next
to each piston bore. Catch each piston in a shop
towel as it exits bore.
CAUTION: Use only enough air pressure to ease
each piston out of the bore. In addition, remove the
pistons one at a time and tag the pistons and
springs for assembly reference. Do not intermix
them.
(3) Remove and discard piston O-ring seals. Then
clean pistons and springs with solvent.(4) Inspect pistons, springs and piston bores. Re-
place worn damaged pistons. Replace broken, col-
lapsed or distorted springs. Replace case if piston
bores are damaged.
(5) If small cushion spring in any piston must be
replaced, remove spring retainer clip and remove
spring from piston (Fig. 28). A small hooked tool or
small thin blade screwdriver can be used to remove
clip. A thin wall, deep socket, or pin punch can be
used to reseat clip after spring replacement.
(6) Install new O-ring seals on pistons. Lubricate
seals and pistons and piston bores with transmission
fluid.
(7) Install pistons and springs (Fig. 29).
(8) Install valve body, oil screen and oil pan. Use
Mopar or Loctite 599 on oil pan sealing surface.
Fig. 25 Installing Spacer Sleeve On Sector
Fig. 26 Installing Park Rod Bracket
Fig. 27 Accumulator Piston Removal
Fig. 28 Small Cushion Spring Retention
21 - 180 AW-4 IN-VEHICLE SERVICEJ

SECOND COAST BRAKE SERVO
SERVO OVERHAUL
(1) Remove valve body as outlined in this section.
(2) Remove servo piston cover snap ring with snap
ring pliers (Fig. 30).
(3) Remove servo piston and cover with com-
pressed air. Apply compressed air through oil hole in
servo boss to ease piston out of bore (Fig. 31).
(4) Remove and discard seal and O-rings from
cover and piston (Fig. 32). Inspect E-ring, piston,
spring and retainer, piston rod and piston spring. Re-
place worn or damaged parts.
(5) Install new seals on cover and piston.
(6) Lubricate servo components with transmission
fluid.
(7) Assemble and install servo components in case.
Be sure servo piston rod is properly engaged in the
second coast brake band.
(8) Compress cover and piston and install cover
snap ring.
(9) Install valve body, oil screen and oil pan. Use
Mopar or Loctite 599 on oil pan sealing surface.
PARK ROD AND PAWL SERVICE
(1) Remove valve body as outlined in this section.
(2) Remove bolts attaching park rod bracket to
case (Fig. 33).(3) Remove park rod from manual valve shaft sec-
tor (Fig. 34).
(4) Remove park rod.
(5) Remove park pawl, pin and spring (Fig. 35).
(6) Examine park rod, pawl, pin and spring. Re-
place any component that is worn or damaged.
(7) Install pawl in case. Insert pin and install
spring. Be sure spring is positioned as shown in Fig-
ure 35.
Fig. 29 Accumulator Pistons, Springs And Spacers
Fig. 30 Removing/Installing Servo Piston Cover
Snap Ring
Fig. 31 Removing Servo Cover And Piston
JAW-4 IN-VEHICLE SERVICE 21 - 181

(8) Install park rod and bracket (Fig. 33). Tighten
bracket bolts to 10 Nzm (7 ft. lbs.) torque.
(9) Install valve body, oil screen and oil pan as out-
lined in this section.
ADAPTER HOUSING SEAL REPLACEMENT
(1) Raise vehicle.
(2) Disconnect or remove components necessary to
gain access to seal (e.g. propeller shaft, crossmember,
shift linkage, transfer case, exhaust components,
hoses, wires).
(3) Remove dust shield and remove seal from
adapter housing (Fig. 36).
(4) Install new seal with appropriate size seal in-
staller and install dust shield.(5) Reinstall components removed to gain access to
seal.
(6) Top off transmission fluid if necessary.SPEED SENSOR
SPEED SENSOR TESTING
Test the speed sensor with an ohmmeter. Place the
ohmmeter leads on the terminals in the sensor con-
nector (Fig. 37).
Rotate the transmission output shaft and observe
the ohmmeter needle. The needle should deflect indi-
cating the switch is opening/closing as the rotor
Fig. 34 Removing/Installing Park Rod
Fig. 35 Removing/Installing Park Pawl, Pin And
Spring
Fig. 32 Second Coast Brake Servo Components
Fig. 33 Removing/Installing Park Rod Bracket
21 - 182 AW-4 IN-VEHICLE SERVICEJ

(3) Tighten adaptor housing bolts to 34 Nzm (25 ft.
lbs.) torque.
(4) Install components removed to gain access to
rotor and drive gear.
THROTTLE POSITION SENSOR (TPS) SERVICE
A separate throttle position sensor is used for au-
tomatic transmission applications. The sensor is at-
tached to the base of the throttle body. Refer to
Group 14 for TPS service and adjustment.
TRANSMISSION THROTTLE CABLE REPLACEMENT
THROTTLE CABLE REMOVAL
(1) In engine compartment, disconnect cable from
throttle linkage. Then compress cable mounting ears
and remove cable from engine bracket (Fig. 41).
(2) Raise vehicle.
(3) Remove transmission oil pan.
(4) Disengage cable from throttle valve cam (Fig.
42).
Fig. 41 Transmission Throttle Cable Attachment
Fig. 40 Removing Speed Sensor Rotor
Fig. 39 Removing/Installation Speedometer Drive
Gear
21 - 184 AW-4 IN-VEHICLE SERVICEJ

(5) Remove cable bracket bolt and remove cable
and bracket from case (Fig. 43).
(6) Remove and discard cable seal.
THROTTLE CABLE INSTALLATION
(1) Lubricate and install new seal on cable.
(2) Insert cable in transmission case.
(3) Attach cable to throttle cam (Fig. 42).
(4) Install cable bracket on case and tighten at-
taching bolt to 10 Nzm (7 ft-lbs) torque (Fig. 43).
(5) Remove old sealer material from oil pan and
transmission case. Clean oil pan with solvent and dry
it with compressed air.(6) Apply bead of Mopar or Loctite 599 sealer to oil
pan sealing surface. Sealer bead should be at least 3
mm (1/8 in.) wide. Then install pan and tighten pan
bolts to 7 Nzm (65 in. lbs.) torque.
(7) Install new gasket on oil pan drain plug. Install
and tighten plug to 20 Nzm (15 ft. lbs.) torque.
(8) Connect cable to engine bracket and throttle
linkage.
(9) Fill transmission with Mopar Mercon.
(10) Adjust the cable as described in cable adjust-
ment procedure.
TRANSMISSION THROTTLE CABLE ADJUSTMENT
(1) Shift transmission into Park, shut engine off
and raise hood.
(2) Press cable release button (Fig. 44).
(3) Push cable conduit back into cable sheath as
far as possible (Fig. 45).
(4) Rotate lever on throttle body to wide open
throttle position. Cable will ratchet to correct adjust-
ment point as lever is rotated (Fig. 45).
Fig. 42 Removing/Installing Transmission Throttle
Cable
Fig. 43 Removing/Installing Transmission Throttle
Cable And Bracket
Fig. 44 Throttle Cable Components
Fig. 45 Throttle Cable Adjustment
JAW-4 IN-VEHICLE SERVICE 21 - 185

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