1995 JEEP CHEROKEE sensor

(7) Disconnect transfer case shift linkage at trans-
fer case.
(8) Disconnect vehicle speed sensor wires and
transfer case vent hose.
(9) Remove slave cylinder from clutch housing.
(10) Disconnect transmission shift lever as follows:
(a) Lower transmission-transfer case assembly
approximately 7-8 cm (3 in.) for access to shift le-
ver.
(b) Reach up and around transmission case and
unseat shift lever dust boot from transmission shift
tower (Fig. 6). Move boot upward on shift lever for
access to retainer that secures lever in shift tower.
(c) Reach up and around transmission case and
press shift lever retainer downward with your fin-
gers. Turn retainer counterclockwise to release it.
(d) Lift lever and retainer out of shift tower (Fig.
6).Do not remove the shift lever from the
floorpan boots. Leave the lever in place for
later transmission installation.
(11) Mark front and rear propeller shafts for in-
stallation alignment (Fig. 7). Then remove both
shafts.
(12) Remove crankshaft position position sensor
(Figs. 8, 9).
CAUTION: It is important that the crankshaft posi-
tion sensor be removed prior to transmission re-
moval. The sensor can easily be damaged if left in
place during removal operations.
(13) Unclip wire harnesses from transmission and
transfer case.
(14) Remove slave cylinder from clutch housing.
(15) Support transmission with transmission jack.
(16) Remove nuts attaching transfer case to trans-
mission and remove transfer case.
(17) Secure transmission to jack with safety
chains.
(18) Remove clutch housing brace rod.(19) Remove clutch housing-to-engine bolts.
(20) Pull transmission jack rearward until input
shaft clears clutch. Then slide transmission out from
under vehicle.
Fig. 6 Removing/Installing Shift Lever
Fig. 7 Marking Propeller Shaft And Axle Yokes
Fig. 8 Crankshaft Position Sensor (2.5L)
Fig. 9 Crankshaft Position Sensor (4.0L)
21 - 4 AX 4/5 MANUAL TRANSMISSIONJ

(21) Remove clutch release bearing, release fork
and retainer clip.
(22) Remove clutch housing from transmission.
TRANSMISSION INSTALLATION
(1) Install clutch housing on transmission. Tighten
housing bolts to 37 Nzm (27 ft. lbs.) torque.
(2) Lubricate contact surfaces of release fork pivot
ball stud and release fork with high temp grease.
Then install release bearing, fork and retainer clip.
(3) Mount transmission on transmission jack.
(4) Lightly lubricate pilot bearing and transmis-
sion input shaft splines with Mopar high temp
grease.
(5) Align transmission input shaft, release bearing,
and clutch disc splines. Then slide transmission into
place.
(6) Install and tighten clutch housing-to-engine
bolts to 38 Nzm (28 ft. lbs.) torque.Be sure the
housing is properly seated on engine block be-
fore tightening bolts.
(7) Lower transmission approximately 7-8 cm (3
in.) for access to shift tower. Be sure transmission is
in first or third gear.
(8) Reach up and around transmission and insert
shift lever in shift tower. Press lever retainer down-
ward and turn it clockwise to lock it in place. Then
install lever dust boot on shift tower.
(9) Install slave cylinder in clutch housing.
(10) Align and install transfer case on and trans-
mission. Tighten transfer case-to-transmission nuts
to 35 Nzm (26 ft. lbs.) torque.
(11) Connect transfer case vent hose and shift link-
age. Check and adjust linkage if necessary.
(12) Connect transfer case vent hose.
(13) Secure wire harnesses in clips/tie straps on
transmission and transfer case.
(14) Connect backup light switch wires.
(15) Connect vehicle speed sensor wires.
(16) Install and connect crankshaft position sensor.
(17) Install rear crossmember (Fig. 5). On XJ,
tighten crossmember-to-frame bolts to 41 Nzm (31 ft.
lbs.) torque. Then tighten transmission-to-rear sup-
port bolts/nuts to 45 Nzm (33 ft. lbs.) torque. On YJ,
tighten bolts/nuts to indicated torque (Fig. 5).
(18) Remove jack stand.
(19) Align and install front/rear propeller shafts.
Tighten shaft U-joint clamp bolts to 19 Nzm (170 in.
lbs.) torque.
(20) Install skid plate, if equipped. Tighten bolts to
42 Nzm (31 ft. lbs.) torque. Tighten stud nuts to 17
Nzm (150 in. lbs.) torque.
(21) Top off transmission and transfer case lubri-
cant levels.
(22) Lower vehicle.
TRANSMISSION DISASSEMBLY AND OVERHAUL
ADAPTER HOUSING AND FRONT BEARING
RETAINER REMOVAL
(1) Drain transmission lubricant.
(2) Remove release bearing and lever.
(3) Remove clutch housing bolts and remove hous-
ing.
(4) On 2-wheel drive models, remove vehicle speed
sensor, speedometer adapter and speedometer driven
gear. Then remove extension housing seal (Fig. 1).
(5) Remove detent spring and ball. Remove detent
plug (Fig. 2) and remove detent spring and ball with
pencil magnet.
Fig. 1 Removing 2-Wheel Drive Extension Housing
Seal
Fig. 2 Detent Ball Plug Location
JAX 4/5 MANUAL TRANSMISSION 21 - 5

(10) Install lock ball and spring in housing. Then
apply sealer to ball plug and install plug (Fig. 91).
Tighten plug to 19 Nzm (14 ft. lbs.) torque.
(11) Install reverse pins in housing (Fig. 92).
Tighten pins to 27 Nzm (20 ft. lbs.) torque.(12) Install shift tower and new gasket on housing
(Fig. 93). Tighten tower bolts to 18 Nzm (13 ft. lbs.)
torque.
(13) Install backup lamp switch (Fig. 93). Tighten
switch to 37 Nzm (27 ft. lbs.) torque.
(14) On 2-wheel drive models, install new seal in
extension housing (Fig. 94).
(15) Install vehicle speed sensor. Refer to proce-
dure in In-Vehicle Service section.
(16) Install clutch housing, release bearing, release
fork and retainer clip.
Fig. 91 Installing Ball Plug
Fig. 92 Install Reverse Pins
Fig. 93 Installing Shift Tower And Backup Lamp
Switch
Fig. 94 Extension Housing Seal InstallationÐ2WD
Models
21 - 32 AX 4/5 MANUAL TRANSMISSIONJ

(6) On XJ, remove rear crossmember. On YJ, re-
move skid plate (Fig. 1).
(7) Disconnect transmission shift linkage, speed-
ometer cable, transfer case vacuum lines and clutch
hydraulic lines.
(8) Lower transmission-transfer case assembly no
more than 7.6 cm (3 in.) for access to shift lever.
(9) Reach up and around transmission case and
unseat shift lever dust boot from transmission shift
tower (Fig. 2). Move boot upward on shift lever for
access to lever retainer.
(10) Disengage shift lever as follows:
(a) Reach up and around transmission case and
press shift lever retainer downward with your fin-
gers.
(b) Turn retainer counterclockwise to release it.
(c) Lift lever and retainer out of shift tower (Fig.
2).It is not necessary to remove shift lever
from floorpan boot. Simply leave lever in
place for later installation.(11) Mark front and rear propeller shafts for in-
stallation alignment (Fig. 2). Then remove both
shafts.
(12) Remove crankshaft position sensor (Fig. 4).
(13) Disconnect transmission and transfer case
vent hoses.
(14) Remove slave cylinder from clutch housing.
(15) Remove wire harnesses from clips/tie straps
on transmission and transfer case.
(16) Support transmission-transfer case assembly
with transmission jack. Secure assembly to jack with
safety chains.
(17) Reposition adjustable jack stand under engine.
Be sure to place wood block between jack and oil
pan.
(18) Remove clutch housing brace rod.
(19) Remove clutch housing-to-engine bolts and re-
move transmission-transfer case assembly.
(20) Remove bolts attaching transmission to trans-
fer case and separate components.
(21) Remove release bearing, fork and retainer
clip.
(22) Remove clutch housing from transmission.
TRANSMISSION INSTALLATION
(1) Install clutch housing on transmission. Tighten
housing bolts to 37 Nzm (27 ft-lbs) torque.
(2) Lubricate contact surfaces of release fork, lever
and pivot ball stud. Then install bearing, fork and
clip in clutch housing.
(3) Mount transmission on transmission jack. Se-
cure transmission with safety chains.
(4) Lightly lubricate pilot bearing and transmis-
sion input shaft splines with Mopar high tempera-
ture grease.
(5) Align transmission input shaft and clutch disc
splines and install transmission.
Fig. 2 Removing/Installing Shift Lever
Fig. 3 Marking Propeller Shaft And Axle Yoke
Fig. 4 Crankshaft Position Sensor Location
21 - 36 AX 15 MANUAL TRANSMISSIONJ

(6) Install and tighten clutch housing-to-engine
bolts to 38 Nzm (28 ft. lbs.) torque.Be sure housing
is properly seated on engine before tightening
bolts.
(7) Lower transmission no more than 7.6 cm (3 in.)
for access to the shift tower.
(8) Reach up and around the transmission and in-
sert shift lever in shift tower. Press lever retainer
downward and turn it clockwise to lock it in place.
Then install lever dust boot on shift tower.
(9) Install and connect crankshaft position sensor.
(10) Align and install transfer case on transmis-
sion. Tighten transfer case attaching nuts to 35 Nzm
(26 ft. lbs.) torque.
(11) Connect transfer case vacuum and vent hoses.
(12) Install and connect transfer case shift linkage.
Check and adjust linkage if necessary.
(13) Secure wire harnesses to clips/tie straps on
transmission and transfer case.
(14) Connect backup light switch wires.
(15) Install clutch slave cylinder.
(16) Connect vehicle speed sensor wires.
(17) On XJ, install rear crossmember and attach
cushion and bracket. Tighten crossmember-to-frame
bolts to 41 Nzm (30 ft. lbs.) torque. Tighten transmis-
sion-to-rear cushion and bracket bolts/nuts to 45 Nzm
(33 ft. lbs.) torque.
(18) On YJ, install rear cushion and bracket and
skid plate. Tighten attaching bolts/nuts to indicated
torque (Fig. 1).
(19) Align and install front/rear propeller shafts.
Tighten shaft U-joint clamp bolts to 19 Nzm (170 in.
lbs.) torque.
(20) On XJ, install skid plate if removed. Tighten
bolts to 42 Nzm (31 ft. lbs.) torque. Tighten stud nuts
to 17 Nzm (150 in. lbs.) torque.
(21) Top off transmission and transfer lubricant
levels.
(22) Remove supports and lower vehicle.
TRANSMISSION DISASSEMBLY AND OVERHAUL
ADAPTER HOUSING REMOVAL
(1) Remove release bearing, release lever and re-
lease fork from clutch housing. Then remove clutch
housing from transmission.
(2) Remove backup light switch. Then remove
drain plug (Fig. 1) and drain transmission lubricant
into pan.
(3) Remove shift tower bolts and remove tower
from adapter or extension housing (Fig. 2).
(4) Remove gasket from shift tower (Fig. 3).
Fig. 1 Drain Plug And Backup Light Switch Location
Fig. 2 Shift Tower Removal/Installation
Fig. 3 Shift Tower Gasket Removal/Installation
JAX 15 MANUAL TRANSMISSION 21 - 37

(28) Position new shift tower gasket on adapter
housing (Fig 127).
(29) Install shift tower (Fig. 128). Tighten tower
attaching bolts to 18 Nzm (13 ft. lbs.) torque.(30) Install new gasket on backup light switch and
install switch. Tighten switch to 37 Nzm (27 ft. lbs.)
torque.
(31) Install new washer on drain plug. Then install
and tighten plug to 37 Nzm (27 ft. lbs.) torque.
(32) If transmission will be filled with gear lubri-
cant before installation, place transmission in a level
position. Then fill with Mopar 75W-90, grade GL-5
gear lubricant.
(33) Install new washer on fill plug. Then install
and tighten plug to 37 Nzm (27 ft. lbs.) torque.
(34) Install clutch housing and hydraulic concen-
tric bearing.
(35) On models with extension housing, install new
seal in housing with suitable size installer tool (Fig.
129). Lubricate seal lips with petroleum jelly before
installation.
(36) On models with extension housing, install
speedometer driven gear, speedometer adapter and
speed sensor.
Fig. 127 Shift Tower Gasket Installation
Fig. 128 Shift Tower Installation
Fig. 129 Installing Extension Housing Seal
21 - 66 AX 15 MANUAL TRANSMISSIONJ

(7) Align valve body and seat it on case. Be sure
manual lever shaft and accumulator spring are prop-
erly seated.
(8) Hold valve body in position and install one or
two attaching bolts to hold valve body in place.
(9) Install remaining valve body bolts. Tighten all
bolts evenly in a diagonal pattern to 12 Nzm (105 in-
lbs) torque.
(10) Install new oil filter and tighten filter screws
to4Nzm (35 in. lbs.) torque.
(11) Connect converter solenoid wire to case con-
nector.
(12) Install manual and throttle levers on throttle
lever shaft. Tighten lever clamp screws and check for
free operation. Shaft and levers must operate freely
without any bind.
(13) Install oil pan and new gasket. Tighten pan
bolts to 17 Nzm (13 ft. lbs.) torque.
(14) Install seal on neutral switch, install switch in
case, and connect switch wires.
(15) Lower vehicle.
(16) Fill transmission with Mopar ATF Plus, Type
7176 fluid.
(17) Adjust gearshift linkage and throttle valve
(kickdown) cable if necessary.
GOVERNOR AND PARK GEAR SERVICE
GOVERNOR/PARK GEAR REMOVAL
(1) Raise vehicle.
(2) Mark both propeller shaft yokes for assembly
reference and disconnect propeller shafts at transfer
case.
(3) Disconnect speed sensor wires and remove
speedometer adapter and sensor.
(4) Position support stand under transmission con-
verter housing.
(5) Remove rear crossmember.
(6) Disconnect parking brake cable at equalizer
and disconnect exhaust components as necessary.
(7) Support transfer case with jack.
(8) Remove bolts attaching transfer case to trans-
mission adapter housing and remove transfer case.
(9) Remove bolts attaching adapter, or extension
housing to transmission and remove adapter/housing.
(10) Loosen but do not remove bolts that attach
governor body to park gear.
(11) Rotate transmission output shaft until gover-
nor weight assembly is accessible. Then remove
E-clip at this end of governor shaft.
(12) Remove governor valve and shaft from gover-
nor body (Fig. 13).
(13) Remove snap rings and washers that retain
governor body and park gear assembly on output
shaft (Fig. 14).
(14) Remove governor body-park gear assembly
from output shaft (Fig. 15).
GOVERNOR BODY/PARK GEAR DISASSEMBLY
(1) Remove bolts attaching governor body to park
gear; then separate body from gear.
Fig. 13 Governor Valve And Shaft Removal
Fig. 14 Governor Body/Park Gear Retaining Snap
Rings And Thrust Washer Position
Fig. 15 Governor Body And Park Gear Removal/
Installation
J30RH/32RH IN-VEHICLE SERVICE 21 - 105

bind if misalignment occurs. Remove and repo-
sition governor body if necessary.
(9) Verify that shaft bore in governor body and out-
put shaft are aligned.
(10) Verify that governor valve will be indexed
with spotface in output shaft. Reposition valve, shaft
and body if necessary.
(11) Install an E-clip on one end of governor valve
shaft. Be sure rounded side of E-clip is facing out
(away from weight).
(12) Insert governor valve shaft through governor
weight. Be sure shaft slides freely in bore.
(13) Install governor valve on shaft and in gover-
nor body bore.
(14) Install remaining E-clip on governor valve
shaft. Be sure rounded side of E-clip is facing out
(away from valve).
(15) Install governor body-park gear snap rings
and washer on output shaft as follows:
(a) On models with single snap ring, install snap
ring. Be sure ring is seated in shaft.
(b) On models with thrust washer and two snap
rings, install thin snap ring first. Then install
thrust washer second, and thick snap ring last
(Fig. 14).
16(c) Verify correct position of snap rings.Be
sure flat side of each snap ring is toward gov-
ernor body.(16) Tighten governor body-to-park gear bolts to 11
Nzm (95 in. lbs.).
(17) Install extension housing/adapter and gasket
on transmission. Tighten housing/adapter bolts to 32
Nzm (24 ft. lbs.).
(18) Install transfer case and rear crossmember.
(19) Install speed sensor and speedometer compo-
nents and connect speed sensor wires.
(20) Connect exhaust components and brake cable,
if removed.
(21) Align and connect propeller shafts. Tighten
clamp bolts to 19 Nzm (14 ft. lbs.) torque.
(22) Remove supports and lower vehicle.
(23) Check and adjust transmission fluid level.
PARK LOCK COMPONENT REPLACEMENT
COMPONENT REMOVAL
(1) Raise vehicle and remove transfer case and
adapter housing from transmission.
(2) Slide sprag shaft out of adapter housing and re-
move park sprag and spring (Fig. 22).
(3) Remove snap ring and slide plug and pin as-
sembly out of housing (Fig. 22).
(4) If park rod must be serviced, remove valve
body and remove rod.
Fig. 21 Governor Components (30RH/32RH)
21 - 108 30RH/32RH IN-VEHICLE SERVICEJ