1994 JEEP CHEROKEE check transmission fluid

(2) Mark location of non threaded hole in clutch
cam and blank area of case with paint stripe (Fig.
123).
(3) Align and install overrunning clutch cam in
case (Fig. 123).Be sure cam is correctly installed.
Bolt holes in cam are slightly countersunk on
one side. This side of cam faces rearward (to-
ward rear support).
(4) Partially install overrunning clutch in cam
(Fig. 123).
(5) Verify that non threaded hole in clutch cam is
properly aligned (Fig. 123). Check alignment by
threading a clutch cam bolt into each hole. Adjust
cam position if necessary before proceeding.
(6) Seat overrunning clutch in clutch cam after
verifying correct cam alignment.
(7) Install overrunning clutch cam bolts.Clutch
cam bolts are shorter than rear support bolts.
Tighten cam bolts to 17 Nzm (150 in. lbs. or 13 ft.
lbs.) torque.(8) Lubricate overrunning clutch rollers, springs
and cam with ATF Plus transmission fluid.
REAR BAND, LOW-REVERSE DRUM AND REAR
SUPPORT INSTALLATION
A different rear band and linkage is used in 30RH
and 32RH transmissions.
The 30RH transmission has a single wrap band,
one pivot pin and a band link to connect the lever
(Fig. 124). The lever adjusting screw is in direct con-
tact with the servo piston. A strut is used to connect
the lever to the band lug.
The 32RH transmission has a double wrap band, a
pivot pin, and a reaction pin (Fig. 125). The band le-
ver pivots against a lug on the band. A strut is not
used. The reaction pin functions as the stop, or locat-
ing mechanism for the band lower lug.
Rear Band Installation Procedure
(1) On 32RH transmission, install band compo-
nents and low-reverse drum as follows:
(a) Install reaction pin in case (Fig. 126).
(b) Position band in case and seat band lug
against reaction pin.
(c) Slide low-reverse drum through band (Fig.
127). Then tilt drum slightly and start clutch race
into overrunning clutch rollers.
(d) Rotate drum in clockwise direction and push
drum inward until race is seated in overrunning
clutch.
(e) Install rear band lever (Fig. 128). Be sure le-
ver pivot pin is fully seated in case afterward.
(2) On 30RH transmission, install band compo-
nents and low-reverse drum as follows:
Fig. 123 Overrunning Clutch Cam Alignment
Fig. 121 Location Of Non-Threaded Hole In Clutch
Cam
Fig. 122 Location Of Blank Area In Clutch Cam Seat
Of Case
J30RH/32RH TRANSMISSION OVERHAUL 21 - 147

(6) Verify that reaction shaft support hub seal
rings are hooked together (Fig. 150).
(7) Coat front clutch thrust washer with petroleum
jelly to hold it in place. Then install washer over re-
action shaft hub and seat it on pump (Fig. 151).CAUTION: The thrust washer bore (I.D.), is cham-
fered on one side. Make sure the chamfered side is
installed so it faces the pump.
(8) Thread two Pilot Stud Tools C-3288-B into bolt
holes in oil pump flange (Fig. 152).
(9) Align and install oil pump gasket (Fig. 152).
(10) Lubricate oil pump seals with Ru-Glyde, Door
Eze, or transmission fluid.
(11) Install oil pump (Fig. 153). Align and position
pump on pilot studs. Slide pump down studs and
work it into front clutch hub and case by hand. Then
install two or three pump bolts to hold pump in
place.
(12) Remove pilot stud tools and install remaining
oil pump bolts. Tighten bolts alternately in diagonal
pattern to 20 Nzm (15 ft-lbs).
CHECKING INPUT SHAFT END PLAY
(1) Measure input shaft end play (Fig. 154).
Fig. 148 Front Band Linkage Installation
Fig. 149 Installing Front Band Pivot Pin Access
Plug
Fig. 150 Reaction Shaft Support Seal Rings
Fig. 151 Front Clutch Thrust Washer Installation
Fig. 152 Installing Pilot Studs And Oil Pump Gasket
J30RH/32RH TRANSMISSION OVERHAUL 21 - 153

(2) Attach dial indicator to converter housing. Po-
sition indicator plunger against input shaft and zero
indicator.
(3) Move input shaft in and out and record read-
ing. End play should be 0.56 - 2.31 mm (0.022 - 0.091
in.).
(4) If end play is incorrect, transmission is incor-
rectly assembled, or output shaft thrust washer
and/or thrust plate are worn and need to be changed.
VALVE BODY INSTALLATION
(1) Install new manual lever shaft seal in case.
Use 15/16 deep well socket to install seal.
(2) Make sure neutral switch hasnotbeen in-
stalled in case. Remove switch if necessary as it will
interfere with valve body installation.
(3) Install new seal rings on accumulator piston
(Fig. 155). Lubricate accumulator piston, seals and
accumulator bore with transmission fluid.(4) Install accumulator piston and spring (Fig. 155)
in case.
(5) Place valve body manual lever in low to move
park lock rod rearward.
(6) Position valve body on case. Work park rod past
sprag and install valve body-to-case bolts finger
tight.
(7) Install park/neutral position switch in case.
Tighten switch to 34 Nzm (25 ft. lbs.) torque.
(8) Align valve body on case (Fig. 156).
(9) Install and tighten valve body-to-case bolts al-
ternately and evenly to 12 Nzm (105 in. lbs.) torque.
Start at center and work outward when tightening
bolts.Do not overtighten valve body bolts. This
could result in distortion and cross leakage af-
ter installation..
(10) Connect converter clutch solenoid wire to case
connector (Fig. 156).
(11) Install new filter on valve body (Fig. 157).
Tighten filter screws to 4 Nzm (35 in. lbs.).
BAND ADJUSTMENT AND OIL PAN
INSTALLATION
(1) Adjustfront bandas follows:
(a) Loosen locknut.
(b) Tighten adjusting screw to 72 in. lbs. torque.
Fig. 153 Installing Oil Pump And Reaction Shaft
Support
Fig. 154 Checking Input Shaft End Play
Fig. 155 Installing Accumulator Piston And Spring
Fig. 156 Valve Body Installation
21 - 154 30RH/32RH TRANSMISSION OVERHAULJ

(2) Verify transmission throttle cable operation.
Repair or replace cable if necessary.
(3) Check engine throttle operation. Operate accel-
erator pedal and observe injector throttle plate move-
ment. Adjust linkage if throttle plate does not reach
wide open position.
(4) Check transmission fluid level when fluid is at
normal operating temperature. Start engine. Shift
transmission through all gear ranges then back to
Neutral. Correct level is to Full or Add mark on dip-
stick with engine at curb idle speed.
(5) Check and adjust park/neutral position switch
if necessary.
(6) Check throttle position sensor adjustment and
operation. Adjust the sensor if necessary.
MANUAL SHIFTING TEST
(1) This test determines if problem is related to
mechanical or electrical component.
(2) Stop engine and disconnect transmission con-
trol module or module fuse.
(3) Road test vehicle. Shift transmission into each
gear range. Transmission should operate as follows:
²lock in Park
²back up in Reverse
²not move in Neutral
²provide first gear only with shift lever in 1-2 posi-
tion
²operate in third gear only with shift lever in 3 po-
sition
²operate in overdrive fourth gear in D position
(4) If transmission operates as described, proceed
to next step. However, if forward gear ranges were
difficult to distinguish (all feel the same), or vehicle
would not back up, refer to diagnosis charts. Do not
perform stall or time lag tests.
CAUTION: Do not overspeed the engine during the
next test step. Ease off the throttle and allow the
vehicle to slow before downshifting.
(5) Continue road test. Manually downshift trans-
mission from D to 3, and from 3 to 1-2 position. Then
manually upshift transmission through forward
ranges again.
(6) If transmission operation is OK, perform stall,
time lag and pressure tests. If transmission shifting
problem is encountered, refer to diagnosis charts.
(7) If a problem still exists, continue testing with
DRB II scan tool.
HYDRAULIC PRESSURE TEST
PRESSURE TEST PROCEDURE
(1) Connect pressure test gauge to test port on pas-
senger side of transmission. Use Adapter 7554 to con-
nect gauge. Be sure test gauge has minimum
capacity of 300 psi (2100 kPa).(2) Be sure transmission fluid is at normal operat-
ing temperature.
(3) Apply parking brakes and block wheels.
WARNING: DO NOT ALLOW ANYONE TO STAND AT
THE FRONT OR REAR OF THE VEHICLE WHILE
PERFORMING THE FOLLOWING STEPS IN THE
PRESSURE TEST.
(4) Check and adjust engine curb idle speed.
(5) Apply service brakes.
(6) Shift transmission into D range and note line
pressure with engine at curb idle speed. Pressure
should be 61-to-70 psi (421-to-481 kPa).
(7) Press accelerator pedal to wide open throttle
position and note line pressure. Pressure should be
173-to-209 psi (1196-to-1442 kPa).
CAUTION: Do not maintain wide open throttle for
more than three or four seconds at a time.
(8) Shift transmission into Reverse and note line
pressure with engine at curb idle speed. Pressure
should be 75-to-90 psi (519-to-618 kPa).
(9) Press accelerator to wide open throttle position
and note line pressure in Reverse. Pressure should
be 213-to-263 psi (1471-to-1814 kPa).
CAUTION: Do not maintain wide open throttle for
more than three or four seconds at a time.
(10) If line pressure is not within specifications,
adjust transmission throttle cable and repeat pres-
sure test.
Fig. 27 Pressure Test Gauge Connection
21 - 168 AW-4 TRANSMISSION DIAGNOSISJ

PRESSURE TEST ANALYSIS
If pressures in D and Reverse are higher than
specified, check for the following:
²throttle cable loose, worn, binding or out of adjust-
ment
²throttle valve, downshift plug, throttle cam, or pri-
mary regulator valve are sticking, worn or damaged
If pressures in D and Reverse are lower than spec-
ified, check for following:
²throttle cable loose, worn, binding or out of adjust-
ment
²throttle valve, downshift plug, throttle cam stick-
ing, worn or damaged
²primary regulator valve sticking, worn, or dam-
aged
²oil pump gears or housing worn or damaged
²overdrive clutch worn or damaged
If pressures are low in D range only, check for fol-
lowing:
²forward clutch worn or damaged
²fluid leakage in D range circuit (component seal
and O-rings)
If pressures are low in Reverse only, check for fol-
lowing:
²shift cable and manual valve out of adjustment
²fluid leakage in reverse circuit (component seal
and O-rings)
²direct clutch worn or damaged
²first/reverse brake worn or damaged
TORQUE CONVERTER STALL TEST
Stall testing checks the holding ability of the trans-
mission clutches and brakes and of the torque con-
verter stator overrunning clutch.
(1) Be sure transmission fluid is at normal operat-
ing temperature.
(2) Connect tachometer to engine. Position tachom-
eter so it can be viewed from drivers seat.
(3) Apply parking brakes and block wheels.
(4) Apply and hold service brakes.
(5) Shift transfer case into 2H position. On models
with NP249 transfer case, leave transfer case in 4H
position.
(6) Start engine.
WARNING: DO NOT ALLOW ANYONE TO STAND AT
THE FRONT OR REAR OF THE VEHICLE DURING
THE TEST.
(7) Shift transmission into D range.
(8) Press accelerator pedal to wide open throttle
position and note maximum engine rpm. Stall speed
should be 2100 to 2400 rpm in D range.
CAUTION: Do not maintain wide open throttle for
more than 3-4 seconds at a time.(9) Release throttle and shift transmission into
Neutral. Allow transmission fluid to cool for 15-20
seconds.
(10) Shift transmission into Reverse.
(11) Press accelerator down to wide open throttle
position and note maximum engine rpm. Stall speed
should be 2100-to-2400 rpm in Reverse.
STALL SPEED TEST ANALYSIS
If engine rpm is lower than specified in D and Re-
verse, check for the following:
²engine output/performance insufficient
²stator overrunning clutch in torque converter not
holding if engine speed was 1500 rpm or less.
If stall speed in D range is higher than specified,
check for the following:
²line pressure low
²forward clutch slipping
²No. 2 one-way clutch not holding
²overdrive one-way clutch not holding
If stall speed in Reverse was higher than specified,
check for the following:
²line pressure low
²direct clutch slipping
²first/ reverse brake slipping
²overdrive one-way clutch not holding
If stall speeds were higher than specified in both D
and Reverse, check for the following:
²low fluid level
²line pressure low
²overdrive one-way clutch not holding
TIME LAG TEST
This test checks general condition of the overdrive
clutch, forward clutch, rear clutch and first/reverse
brake. Condition is indicated by the amount of time
required for clutch/brake engagement with the en-
gine at curb idle speed. Engagement time is mea-
sured for D and Reverse positions. A stop watch is
recommended for test accuracy.
TEST PROCEDURE
(1) Check and adjust transmission fluid level if
necessary.
(2) Bring transmission to normal operating tem-
perature.
(3) Apply parking brakes and turn off air condi-
tioning unit.
(4) Shift transfer case into 2H range. On models
with NP249 transfer case, leave transfer case in 4H
range.
(5) Start engine and check curb idle speed. Adjust
speed if necessary. Curb idle must be correct to en-
sure accurate test results.
(6) Shift transmission into Neutral and set stop
watch.
(7) During following test steps, start stop watch as
soon as shift lever reaches D and Reverse ranges.
JAW-4 TRANSMISSION DIAGNOSIS 21 - 169

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

(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

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