1994 JEEP CHEROKEE service

CONVERTERÐPUMP SEALÐDRIVE PLATE SERVICE
Drive Plate
The drive plate can be replaced or removed for service
access after the transmission is out of the vehicle (Fig. 2).
CAUTION: On YJ models with a 2.5L engine and
30RH transmission, special bolts are used to attach
the driveplate to the crankshaft. These bolts have a
smaller hex head for torque converter clearance.
DO NOT interchange these bolts with similar size
bolts for any reason.
Torque Converter
The torque converter can be replaced or removed
for service access after the transmission has been re-
moved (Fig. 2).
The torque converter is not a serviceable part. If
the converter is contaminated or damaged in any
way, it must be replaced as an assembly.Do not at-
tempt to flush a converter contaminated by
metal or clutch facing particles. Flushing will
not remove these contaminants.
A new torque converter and oil pump are used in
30RH/32RH transmissions built after the 1993
model year. The new converter has a different
style drive hub. The hub was changed to accept
the new design drive flats on the oil pump inner
gear. The drive flats replace the square lugs used
previously. If converter replacement should be-
come necessary, be sure to use the new style con-
verter. The new converter and oil pump are not
interchangeable with previous style parts.The oil pump seal is accessible and can be replaced af-
ter the transmission and torque converter are removed.
Use Remover Tool C-3981B to remove the seal
(Fig. 3). To use the tool, first start the tool into the
seal by hand. Next, thread the tool into the seal as
far as it will go. Use a wrench on the tool hex to turn
the tool. Continue tightening until all the tool
threads firmly grip the metal part of the seal. Then
tighten the tool puller screw to withdraw the seal
from the pump body.
Use Installer Tool C-4193 to install and seat the
seal (Fig. 4).
Be sure to lubricate the pump seal and converter
hub with transmission fluid before installation.
TRANSMISSION AND CONVERTER INSTALLATION
CAUTION: The transmission oil cooler and lines
must be reverse flushed if repair corrected a prob-
lem that generated sludge and/or debris. Sludge
and metal or friction particles from a gear or clutch
pack failure must be removed before reinstalling
the transmission. This is necessary to avoid re-con-
taminating the repaired transmission. Failure to re-
move sludge or debris from the cooler and lines
will result in a repeat failure and shop comeback.
Fig. 2 Typical Converter And Drive Plate
Fig. 3 Pump Seal Removal
Fig. 4 Pump Seal Installation
J30RH/32RH TRANSMISSION REMOVAL AND INSTALLATION 21 - 109

30RH/32RH TRANSMISSION OVERHAUL
INDEX
page page
Adapter Housing and Park Lock Component
Overhaul............................ 120
Front Clutch Overhaul.................... 125
Front Servo and Band Overhaul............ 136
Governor and Park Gear Overhaul.......... 121
Oil Pump Overhaul...................... 122
Overhaul Service Information............... 118
Overrunning ClutchÐLow-Reverse DrumÐRear
Support Overhaul...................... 118
Planetary Gear Train Overhaul............. 131Rear Clutch Overhaul.................... 128
Rear Servo and Band Overhaul............. 136
Transmission Assembly and Adjustment
Procedures........................... 146
Transmission Assembly Tips............... 146
Transmission Case Cleaning and Inspection . . . 118
Transmission Disassembly................. 112
Valve Body Assembly and Adjustment........ 144
Valve Body Disassembly and Inspection...... 138
TRANSMISSION DISASSEMBLY
(1) Clean transmission exterior with steam gun or
with solvent. Wear eye protection during cleaning
process.
(2) Remove throttle and shift levers from valve
body manual shaft and throttle lever shaft.
(3) Mount transmission in repair stand C-3750-B
(Fig. 1).
(4) Remove nuts attaching adapter, or extension
housing to transmission case.
(5) Remove adapter/extension housing and gasket
(Fig. 2).
(6) Remove rear bearing and snap ring, if
equipped.
(7) Remove park/neutral position switch and seal
(Fig. 3).
Fig. 1 Transmission Mounted On Typical Repair
Stand
Fig. 2 Adapter Housing Removal/Installation (4 x 4
Models)
Fig. 3 Park/Neutral Position Switch Removal/
Installation
21 - 112 30RH/32RH TRANSMISSION OVERHAULJ

OVERHAUL SERVICE INFORMATION
Inspect the transmission bushings during overhaul.
Bushing condition is important as severely worn, or
scored bushings contribute to low pressures, clutch
slip and accelerated wear of other components.How-
ever, do not replace bushings as a matter of
course. Replace bushings only when they are
actually worn, or scored.
Use recommended tools to replace bushings. The
tools are sized and designed to remove, install and
seat bushings correctly. The bushing replacement
tools are included in Bushing Tool Set C-3887-B. The
tool set is manufactured by Miller Tool Co. and is
available through the dealer tool program.
Pre-sized service bushings are available for replace-
ment purposes. Only the sun gear bushings are not
serviced. Low cost of the sun gear assembly makes it
easier to simply replace the gear and bushings as an
assembly.
Heli-Coil inserts are recommended for repairing
damaged, stripped or worn threads in aluminum
parts. These inserts are available from most automo-
tive jobbers. Stainless steel inserts are preferred.
The use of crocus cloth is permissible where neces-
sary. When used on valves, use care to avoid round-
ing off sharp edges. Sharp edges are vital as they
prevent foreign matter from getting between the
valve and valve bore.
Do not reuse oil seals, gaskets, seal rings, or O-
rings during overhaul. Replace these parts as a mat-
ter of course. Also do not reuse snap rings or E-clips
that are bent or distorted. Replace these parts as
well.
Lubricate transmission parts with Mopar ATF
Plus, Type 7176 transmission fluid during overhaul
and assembly.Use petroleum jelly to hold parts like thrust wash-
ers in place during assembly. Use Ru-Glyde, Door
Eze, or similar products to lubricate piston seals and
O-rings to ease installation. Petroleum jelly can also
be used to prelubricate parts during reassembly if de-
sired.
TRANSMISSION CASE CLEANING AND
INSPECTION
Clean the case in a solvent tank. Flush the case
bores and fluid passages thoroughly with solvent.
Dry the case and all fluid passages with compressed
air. Be sure all solvent is removed from the case and
that all fluid passages are clear.
Do not use shop towels or rags to dry the case
(or any other transmission component) unless
they are made from lint-free materials. Lint will
readily adhere to case surfaces and transmission
components and will circulate throughout the
transmission after assembly. A sufficient quan-
tity of lint can block fluid passages and interfere
with valve body operation.
Inspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repaired with Helicoil thread inserts. However, the
case will have to be replaced if it exhibits any type of
damage or wear.
Lubricate the front band adjusting screw threads
with petroleum jelly and thread the screw part-way
into the case. Be sure the screw turns freely.
Remount the case in a repair stand after cleaning
and inspection.
OVERRUNNING CLUTCHÐLOW-REVERSE
DRUMÐREAR SUPPORT OVERHAUL
DISASSEMBLING OVERRUNNING CLUTCH/
LOW-REVERSE DRUM
If the clutch assembly came out with the low-re-
verse drum, thread two clutch cam bolts into the
cam. Then lift the cam out of the drum with the bolts
(Fig. 30). Rotate the cam back and forth to ease re-
moval if necessary. Remove the clutch roller and
spring assembly from the race afterward.
CLEANING AND INSPECTION
Clean the overrunning clutch assembly, clutch
cam, low-reverse drum and rear support in solvent.
Dry them with compressed air after cleaning.
Inspect condition of each clutch part after cleaning.
Replace the overrunning clutch roller and spring as-
sembly if any rollers or springs are worn or dam-
aged, or if the roller cage is distorted, or damaged.
Replace the cam if worn, cracked or damaged.
Replace the low-reverse drum if the clutch race,
roller surface or inside diameter is scored, worn or
damaged.Do not remove the clutch race from the
Fig. 29 Compressing Rear Servo Spring
21 - 118 30RH/32RH TRANSMISSION OVERHAULJ

(3) Remove retainer snap ring and remove com-
pressor tool.
(4) Remove spring retainer and clutch spring. Note
position of retainer on spring for assembly reference.
(5) Remove clutch piston from clutch retainer. Re-
move piston by rotating it up and out of retainer.
(6) Remove seals from clutch piston and clutch re-
tainer hub. Discard both seals as they are not reusable.
FRONT CLUTCH INSPECTION
Clean the front clutch components in solvent and dry
them with compressed air only. Do not use rags or shop
towels to dry any of the clutch parts. Lint from such
materials will adhere to the component surfaces and
could restrict or block fluid passages after assembly.
Replace the clutch discs if warped, worn, scored,
burned or charred, or if the facing is flaking off. Re-
place the steel plates if heavily scored, warped, orbroken. Be sure the driving lugs on the plates are in
good condition. The lugs must not be bent, cracked or
damaged in any way.
Replace the clutch spring and spring retainer if ei-
ther is distorted, warped or broken.
Check the lug grooves in the clutch retainer. The
steel plates should slide freely in the slots. Replace
the retainer if the grooves are worn or damaged.
Check action of the check ball in the retainer (Fig.
59). The ball must move freely and not stick.
Inspect the clutch retainer bushings carefully
(Fig. 60). The retainer bushings are not service-
Fig. 56 Pump Oil Seal Installation
Fig. 57 Front Clutch Components (30RH/32RH)
Fig. 58 Compressing Front Clutch Piston Spring
21 - 126 30RH/32RH TRANSMISSION OVERHAULJ

(7) Remove front planetary rear thrust washer
from driving shell.
(8) Separate and remove driving shell, rear plane-
tary and rear annulus from output shaft (Fig. 78).
(9) Remove tabbed thrust washers from rear plan-
etary gear.(10) Remove snap ring that retains sun gear in
driving shell. Then remove sun gear, spacer and
thrust plates.
PLANETARY GEARTRAIN INSPECTION
Clean the planetary components in solvent and dry
them with compressed air.
Check sun gear and driving shell condition (Fig.
79). Replace the gear if damaged or if the bushings
are scored or worn. The bushings are not serviceable.
Replace the driving shell if worn, cracked or dam-
aged.
Replace planetary gear sets if gears, pinion pins, or
carrier are damaged in any way. Replace the annu-
lus gears and supports if either component is worn or
damaged.
Inspect the geartrain spacers, thrust plates, snap
rings, and thrust washers (Fig. 79). Replace any of
these parts that are worn, distorted or damaged. Do
not attempt to reuse these parts.
The planetary gear thrust washers are different
sizes. The large diameter washers go on the front
planetary and the smaller washers go on the rear
planetary. All the washers have four locating tabs on
them. These tabs fit in the holes or slots provided in
each planetary gear.
Inspect the output shaft carefully. Pay particular
attention to the machined bushing/bearing surfaces
on the shaft and the governor valve shaft bore at the
shaft rear.
Replace the output shaft if the machined surfaces
are scored, pitted, or damaged in any way. Also re-
place the shaft if the splines are damaged, or exhib-
its cracks at any location (especially at the governor
valve shaft bore).
The annulus gears can be removed from their sup-
ports if necessary. Just remove the snap rings and
separate the two parts when replacement is neces-
sary. In addition, the annulus gear bushings can be
replaced if severely worn, or scored. However it is
not necessary to replace the bushings if they only ex-
hibit normal wear. Check bushing fit on the output
shaft to be sure.
ASSEMBLING PLANETARY GEARTRAIN
(1) Lubricate output shaft and planetary compo-
nents with transmission fluid. Use petroleum jelly to
lubricate and hold thrust washers and plates in posi-
tion.
(2) Assemble rear annulus gear and support if dis-
assembled. Be sure support snap ring is seated and
that shoulder-side of support faces rearward (Fig.
80).
(3) Install rear thrust washer on rear planetary
gear (Fig. 79). Use enough petroleum jelly to hold
washer in place. Also be sure all four washer tabs
are properly engaged in gear slots.
Fig. 76 Front Planetary Snap Ring Removal
Fig. 77 Front Planetary And Annulus Gear
Disassembly
Fig. 78 Removing Driving Shell, Rear Planetary And
Rear Annulus
21 - 132 30RH/32RH TRANSMISSION OVERHAULJ

(24) Remove 1-2 shift control valve and spring
from valve body (Fig. 113).
(25) Remove 2-3 shift valve and spring from valve
body (Fig. 113).
(26) Remove 1-2 shift valve and spring from valve
body (Fig. 113).
(27) Remove regulator valve end plate (Fig. 113).
(28) Remove regulator valve line pressure plug,
pressure plug sleeve, throttle pressure plug and
spring (Fig. 113).
VALVE BODY CLEANING AND INSPECTION
The only serviceable valve body components are:
²park lock rod and E-clip
²switch valve and spring
²pressure adjusting screw bracket
²throttle valve lever
²manual lever
²manual lever shaft seal, washer, E-clip and detent
ball
²fluid filter
²converter clutch solenoid
The remaining valve body components are serviced
only as part of a complete valve body assembly.
Clean the valve body components in a parts clean-
ing solution only. Do not use gasoline, kerosene, or
any type of caustic solution. Dry the parts with com-
pressed air. Make sure all passages are clean and
free from obstructions.
Do not use rags or shop towels to wipe off
valve body components. Lint from these materi-als will adhere to the valve body components.
Lint will interfere with valve operation and may
clog filters and fluid passages.
Inspect the throttle and manual valve levers and
shafts. Do not attempt to straighten a bent shaft or
correct a loose lever. Replace these components if
worn, bent, loose or damaged in any way.
Inspect all of the valve body mating surfaces for
scratches, nicks, burrs, or distortion. Use a straight-
edge to check surface flatness. Minor scratches may
be removed with crocus cloth using only very light
pressure.
Minor distortion of a valve body mating surface
may be corrected by smoothing the surface with cro-
cus cloth. The cloth should be in sheet form and be
positioned on a surface plate, sheet of plate glass, or
equally flat surface. However, if distortion is severe
or any surfaces are heavily scored, the valve body
will have to be replaced.
CAUTION: The throttle valve, shuttle valve plug, 1-2
shift valve and 1-2 governor plug are made of
coated aluminum. These components are identified
in Figure 114 with the abbreviation (Alum.). Alumi-
num components can be identified by the dark
color of the special coating applied to the surface
(or by testing with a magnet). DO NOT polish or
sand aluminum valves or plugs with any type of
material, or under any circumstances. This practice
might damage the special coating and cause the
valves and plugs to stick and bind.
Fig. 113 Shift Valves And Pressure Regulator Plugs
J30RH/32RH TRANSMISSION OVERHAUL 21 - 141

AW-4 AUTOMATIC TRANSMISSION
CONTENTS
page page
AW-4 IN-VEHICLE SERVICE............. 173
AW-4 TRANSMISSION DIAGNOSIS........ 167
AW-4 TRANSMISSION OVERHAUL........ 192
AW-4 TRANSMISSION REMOVAL AND
INSTALLATION....................... 189GENERAL INFORMATION................ 156
TRANSMISSION/TRANSFER CASE
SPECIFICATIONS..................... 320
GENERAL INFORMATION
INDEX
page page
Components and Operation................ 157
Description............................ 156
FirstÐThirdÐReverse Gear Components...... 159
Fourth Gear Overdrive Components......... 158
Geartrain Operation and Application Charts.... 159Hydraulic System........................ 160
Torque Converter........................ 158
Transmission Identification................. 157
Transmission Ranges and Shift Lever Positions . 157
DESCRIPTION
The AW-4 is a 4-speed, electronically controlled au-
tomatic transmission (Fig. 1). Running gear consists
of a torque converter, oil pump, three planetary gear
sets, clutch and brake units, hydraulic accumulators,
a valve body with electrical solenoids and a transmis-sion control module (TCM). The AW-4 is used in XJ
models with a 4.0L engine.
Cables are used for shifting and transmission
throttle pressure control. A park/neutral position
switch permits engine starting in Park and Neutral
range only.
Fig. 1 AW-4 Automatic Transmission
21 - 156 TRANSMISSION AND TRANSFER CASEJ

The valve body solenoids are controlled by signals
from the transmission control module (TCM). Signal
sequence is determined by vehicle speed and throttle
position.
Fourth gear is an 0.75:1 ratio overdrive range.
First, second, third and reverse gear are conventional
ranges. Third gear ratio is 1:1. A separate planetary
gear set provides overdrive operation in fourth gear.
TRANSMISSION RANGES AND SHIFT LEVER
POSITIONS
The AW-4 transmission has six ranges and shift le-
ver positions. Park, Reverse and Neutral are conven-
tional and mechanically operated. The 1-2, 3 and D
ranges provide electronically controlled shifting.
The 1-2 position provides first and second gear
only. The 3 position provides first, second and third
gear.
The D range provides first through fourth gear.
Overdrive fourth gear range is available only when
the shift lever is in D position (Fig. 2).
TRANSMISSION IDENTIFICATION
The transmission I.D. plate is attached to the case
(Fig. 3). The plate contains the transmission serial
and model numbers. Refer to the information on this
plate when ordering service parts.
COMPONENTS AND OPERATION
ELECTRONIC CONTROLS
The AW-4 is electronically controlled in the 1, 2, 3
and D ranges. Controls consist of the transmission
control module (TCM), valve body solenoids and var-ious sensors. The sensors monitor vehicle speed,
throttle opening, shift lever position and brake pedal
application.
TRANSMISSION CONTROL MODULE (TCM)
The module determines shift and converter clutch
engagement timing based on signals from the sen-
sors. The valve body solenoids are activated, or deac-
tivated accordingly.
The module has a self diagnostic program. Compo-
nent and circuitry malfunctions can be diagnosed
with the DRB II scan tool. Once a malfunction is
noted and stored in control module memory, it is re-
tained even after the problem has been corrected. To
cancel a stored malfunction, simply disconnect and
reconnect the9Trans.9fuse in the module harness.
TRANSMISSION VALVE BODY SOLENOIDS
The solenoids are mounted on the valve body and
operated by the transmission control module. The so-
lenoids control operation of the converter clutch and
shift valves in response to input signals from the
module.
SENSORS
The sensors include the throttle position sensor
(TPS), transmission output speed sensor, vehicle
speed sensor, park/neutral position switch and brake
switch.
The throttle position sensor is mounted on the
throttle body. It electronically determines throttle po-
sition and relays this information to the transmission
control module to determine shift points and con-
verter clutch engagement.
The transmission speed sensor consists of a rotor
and magnet on the transmission output shaft and a
switch in the extension housing or adapter. The sen-
sor switch is activated each time the rotor and mag-
Fig. 2 AW-4 Shift Lever Positions And Transmission
Ranges
Fig. 3 Transmission Identification
JAW-4 AUTOMATIC TRANSMISSION 21 - 157