1994 JEEP CHEROKEE length

feed hole used for checking piston operation.
(6) Remove reaction sleeve with Sleeve Remover
Tool 7542 (Fig. 5). Insert tool flanges under sleeve
and lift tool and sleeve out of case.
(7) Remove No. 1 first/reverse brake piston with
Piston Puller 7543 (Fig. 6). Slip tool under piston and
lift tool and piston out of case.
(8) Measure free length of piston return springs
with springs mounted in retainer. Length should be
18.382 mm (0.724 in.). Replace springs if length is
less than this.(9) Clean transmission case thoroughly with sol-
vent and dry it with compressed air. Blow com-
pressed air through oil feed passages to remove
solvent residue and ensure that passages are clear.
Inspect the case for wear or damage. Replace case if
necessary.
ASSEMBLING FIRST/REVERSE BRAKE
PISTON
(1) Lubricate and install new O-rings on No. 1
first/reverse brake piston and on reaction sleeve (Fig.
7). Then install piston in sleeve.
(2) Lubricate and install new O-ring on No. 2
brake piston.
(3) Install assembled No. 1 piston and reaction
sleeve on No. 2 piston (Fig. 8).
Fig. 2 Removing/Installing Bearing And Race
Assembly
Fig. 3 Checking First-Reverse Brake Piston
Operation
Fig. 4 Removing/Installing Piston Snap Ring
Fig. 5 Removing/Installing Reaction Sleeve
21 - 238 AW-4 TRANSMISSION OVERHAULJ

roded. Replace valves, plugs or sleeves that are
scored or worn. Replace oil strainers if cut, torn or
damaged in any way.
(14) Inspect valve body springs. Replace any spring
having rusted, distorted, or collapsed coils. Measure
length of each valve body spring. Replace any spring
if free length is less than length specified in following
chart (Fig. 11).
LOWER BODY ASSEMBLY
(1) Lubricate lower body components with auto-
matic transmission fluid.
(2) Install spring and accumulator control valve in
sleeve (Fig. 11). Then install assembled components
in lower body (Fig. 9).
(3) Press accumulator control valve assembly into
valve bore and install retainer (Fig. 9).
(4) Install pressure reducing plug in plug bore.
Then secure plug with retaining clip (Fig. 8).
(5) Install washer on primary regulator valve
plunger (Fig. 12).
(6) Install primary regulator valve plunger in valve
sleeve (Fig. 7).(7) Install valve spring and regulator valve sleeve
and plunger.
Fig. 11 Lower Body Valve Spring Dimensions
Fig. 10 Accumulator Control Valve Components
Fig. 12 Installing Washer On Regulator Valve
Plunger
JAW-4 TRANSMISSION OVERHAUL 21 - 245

(8) Press regulator valve sleeve into bore and in-
stall retainer (Fig. 5 and 6). Be sure retainer is posi-
tioned in sleeve lugs as shown.
(9) Install 1-2 shift valve, spring and plug (Fig. 4).
Then press valve assembly into bore and install re-
tainer.
(10) Install replacement O-rings on solenoids and
install solenoids on valve body. Tighten solenoid at-
taching bolts to 10 Nzm (7 ft-lbs) torque.
(11) Install oil strainers (Fig. 13).Identify strain-
ers before installation. The three strainers are
all the same diameter but are different lengths.
Two strainers are 11.0 mm (0.443 in.) long while
one strainer is 19.5 mm (0.76 in.) long (Fig. 14).
(12) Install check valve and spring (Fig. 13).
(13) Install check ball and seat (Fig. 13).
(14) Install pressure relief valve and spring (Fig.
13).UPPER BODY DISASSEMBLY AND INSPECTION
(1) Remove valve body plate and gaskets (Fig. 1).
Discard gaskets.
(2) Remove strainer and eight check balls (Fig. 2).
Note check ball and strainer position for assembly
reference.
Fig. 1 Removing/Installing Upper Body Plate And
Gaskets
Fig. 2 Check Ball And Strainer Location/Identification
Fig. 13 Oil Strainer And Check Valve Installation
21 - 246 AW-4 TRANSMISSION OVERHAULJ

(16) Inspect the valve body springs. Replace any
spring having rusted, distorted, or collapsed coils.
Measure length of each spring. Replace any spring if
free length is less than specified in the chart (Fig.
14).
UPPER BODY ASSEMBLY
(1) Lubricate the valves, springs, plugs, sleeves
and the valve bores in the upper body with automatic
transmission fluid.
(2) Note position of the valve retainers (A) and
stop (B) for assembly reference (Fig. 15).
(3) Install low coast modulator valve, spring and
plug in valve bore. Press valve plug inward and in-
stall retainer (Fig. 13).(4) Install 2-3 shift valve, spring and plug in valve
bore. Press plug inward and install retainer (Fig. 12).
(5) Install cut-back valve spring, valve and plug
(Fig. 11). Press plug inward and install retainer.
(6) Install secondary regulator valve spring, valve
and plug in valve bore. Press plug inward and install
retainer (Fig. 10).
(7) Assemble lock-up relay valve. Install spring
and plunger in valve sleeve (Fig. 9). Then install as-
sembled valve in sleeve.
(8) Install assembled lock-up relay valve in valve
bore and install retainer (Fig. 8).
(9) Install second coast modulator valve, spring
and plug in valve bore. Press plug inward and install
retainer (Fig. 7).
(10) Install 3-4 shift valve, spring and plug in bore.
Press plug inward and install retainer (Fig. 6).
Fig. 14 Upper Body Spring/Valve Identification
21 - 250 AW-4 TRANSMISSION OVERHAULJ

(16) Install spring on cam (Fig. 20). Hook curved
end of spring through hole in cam as shown.
(17) Mount cam on upper body and install cam at-
taching bolt and spacer (Fig. 20). Tighten bolt to 10
Nzm (7 ft. lbs.) torque.
(18) Be sure straight end of spring is seated in up-
per body slot as shown (Fig. 20).
(19) Install check balls in upper body (Fig. 2).
(20) Install oil strainer (Fig. 2).
INSTALLING UPPER BODY ON LOWER BODY
If valve body was equipped with gaskets, start at
step (1). However, if valve body is not equipped with
gaskets, start at step (4).
(1) Position new No. 1 gasket (Fig. 1) on upper
body.(2) Position valve body plate on No. 1 gasket.
(3) Position new No. 2 gasket (Fig. 2) on valve
body plate and align gaskets and plate using bolt
holes as guides.
(4) Install valve body bolts.Three different
length bolts are used. Refer to the Figure 3 for
bolt locations. Chart symbols indicate bolt loca-
tion and length in millimeters.
(5) Tighten valve body bolts to 6.4 Nzm (56 in. lbs.)
torque.
(6) Install manual valve (Fig. 4).
(7) Install two-piece detent spring (Fig. 5). Tighten
spring attaching bolt to 10 Nzm (7 ft. lbs.) torque.
Fig. 20 Installing Throttle Cam
Fig. 1 Valve Body Gasket No. 1
Fig. 2 Valve Body Gasket No. 2
Fig. 3 Valve Body Bolt Location/Size
21 - 252 AW-4 TRANSMISSION OVERHAULJ

(37) Check clearance between sun gear input drum
and direct clutch drum (Fig. 30). Clearance should be
9.8 - 11.8 mm (0.386 - 0.465 in.). If clearance is in-
correct, planetary gear/forward-direct clutch assem-
bly is not seated or is improperly assembled. Remove,
and correct if necessary.
(38) Coat thrust bearing and race assembly with
petroleum jelly and install it on clutch shaft. Bearing
faces up and toward case front as shown (Fig. 31).
Verify bearing/race size. Bearing and race outer di-
ameter is 47.8 mm (1.882 in.) and inside diameter is
33.6 mm (1.301 in.).
(39) Assemble second coast brake piston compo-
nents (Fig. 32).(40) Install assembled second coast brake piston in
case.
(41) Install replacement seals on second coast
brake piston cover and install cover in case.
(42) Install second coast brake piston snap ring
with snap ring plier tool (Fig. 33).
(43) Check second coast brake piston stroke as fol-
lows:
(a) Make reference mark on brake piston rod
(Fig. 34).
(b) Apply 57-114 psi air pressure through feed
hole (Fig. 34). Alternately apply and release air
pressure to operate piston.
(c) Check stroke with gauge 7552 (Fig. 35).
(d) If stroke length is incorrect, piston, cover or
snap ring is not seated. Reassemble and check
stroke again if necessary.
(44) Coat thrust race and tabbed washer with pe-
troleum jelly and install them on overdrive support
(Fig. 36). Verify race size. Race outer diameter is 50.9
mm (2.004 in.) and inside diameter is 36.2 mm (1.426
in.).
Fig. 30 Checking Input Drum-To-Direct Clutch Drum
Clearance
Fig. 31 Installing Clutch Shaft Thrust Bearing And
Race Assembly
Fig. 32 Assembling Second Coast Brake Piston
Fig. 33 Installing Second Coast Brake Piston Snap
Ring
21 - 262 AW-4 TRANSMISSION OVERHAULJ

(52) Check overdrive brake piston stroke as fol-
lows:(a) Mount Gauge 7546 in dial indicator and posi-
tion gauge tool against overdrive brake piston (Fig.
43).
(b) Apply and release overdrive brake piston
with compressed air and note piston stroke length
on dial indicator. Apply air pressure through feed
hole in case (Fig. 44).
(c) Piston stroke length should be 1.40 - 1.70 mm
(0.55 - 0.66 in.).
(d) If stroke is incorrect, brake pack or piston is
installed incorrectly. Check and correct as neces-
sary and measure piston stroke again.
(53) Remove dial indicator and gauge tool.
Fig. 38 Installing Overdrive Support Snap Ring
Fig. 39 Installing Overdrive Support Bolts
Fig. 40 Checking Output Shaft End Play
Fig. 41 Install Overdrive Clutch Pack
Fig. 42 installing Overdrive Brake Snap Ring
21 - 264 AW-4 TRANSMISSION OVERHAULJ

(2) Install the hinge nuts on the studs. Tighten the
restraint cable nut to 4 Nzm (38 in-lbs) torque.
Tighten the remaining nuts to 9 Nzm (77 in-lbs)
torque.
If a replacement hinge seal is being installed,
position it around the hinge arm, force it
against the hinge base.
(3) Position the hinge seal around the hinge arm
and on hinge base.
(4) Install the hood.
(5) Adjust the hood as necessary.
HOOD LATCH REPLACEMENT
REMOVAL
(1) Remove the screw that attaches the latch to the
hood inner panel (Fig. 15).
(2) Disconnect the latch from the hood and latch
connecting rod. Remove the latch from the hood.
INSTALLATION
(1) Connect the latch to the latch connecting rod
and position it on the hood inner panel.
(2) Install the screw that attaches the latch to the
hood inner panel.
(3) Tighten the screw to 9 Nzm (77 in-lbs) torque.
(4) Test the operation of the latch release cable and
latch.
HOOD LATCH STRIKER REPLACEMENT
REMOVE
(1) Remove the grille opening panel (GOP).
(2) Remove the screws that attach the striker to
the radiator baffle (Fig. 19).
(3) Remove the striker and shims from the baffle.
INSTALLATION
(1) Position the shims and striker on the radiator
baffle and install the screws.
(2) Tighten the screws to 21 Nzm (15 ft-lbs) torque.
(3) Test the striker/hood alignment by opening and
closing the hood several times. Adjust the striker, if
necessary.
LATCH RELEASE CABLE REPLACEMENT
REMOVAL
(1) Drill out the bellcrank to hood rivet heads and
remove the rivets (Fig. 14).
(2) Disconnect the bellcrank from the latch rod and
the latch release cable. Remove the bellcrank from
the hood.
(3) Disconnect the latch release cable from the
clips on the hood.
(4) Remove the left cowl side trim panel.
(5) Remove the cable bracket screws from the cowl
side panel.(6) Pull the cable through the dash panel and re-
move it from under the instrument panel.
INSTALLATION
(1) Insert the replacement cable end through the
hole in the dash panel into the engine compartment.
(2) Pull the cable forward and seat the grommet in
the dash panel.
(3) Position the cable bracket on the cowl side
panel and install the screws. Tighten the screws to
13 Nzm (111 in-lbs) torque.
(4) Install the left cowl side trim panel.
(5) Connect the cable and latch rod to the
bellcrank (Fig. 14).
(6) Position the bellcrank on the hood and install
the rivets.
(7) Attach the cable to the clips.
(8) Test release the cable for proper operation.
SAFETY LATCH STRIKER REPLACEMENT
REMOVAL
(1) Remove the striker screws from the radiator
support crossmember (Fig. 21).
(2) Remove the striker from the crossmember.
INSTALLATION
(1) Position the striker on the radiator support
crossmember and install the screws. Tighten the
screws to 9 Nzm (77 in-lbs) torque.
(2) Test the safety latch operation.
COWL WEATHERSTRIP SEAL/CROSSMEMBER AIR
DEFLECTOR
WEATHERSTRIP SEAL REPLACEMENT
(1) Pry upward along the length of seal (Fig. 22).
(2) Detach the seal retainers from the cowl panel.
(3) Remove the seal from cowl panel.
Fig. 21 Hood Safety Latch StrikerÐ2.5L Engine
(Typical)
23 - 10 BODY COMPONENTSÐXJ VEHICLESJ