1995 JEEP CHEROKEE sensor

Inspection
Check the sprag shaft for scores and for free move-
ment in the housing and sprag.
Check the sprag and control rod springs for loss of
tension or distortion. Check the square lug on the
sprag for broken edges. Check the lugs on the gover-
nor support (park gear) for broken edges. Replace
any park lock components that are worn or damaged.
Check the knob on the end of the control rod for
nicks, burrs and free turning. Replace the rod if the
knob is grooved, or worn, or if the rod is bent. The
park lock rods used in Chrysler 3-speed transmis-
sions are different lengths. If the rod must be re-
placed, be sure to install the correct length and
shape rod.
COMPONENT INSTALLATION
(1) Install park lock rod on valve body.
(2) Install reaction plug and pin assembly in the
housing and install the snap ring.
(3) Position sprag and spring in housing and in-
stall sprag shaft. Be sure square lug on sprag is fac-
ing park gear and that spring is positioned so it
moves sprag away from park gear.
(4) Install valve body.
(5) Install adapter housing and transfer case.
PARK/NEUTRAL POSITION SWITCH SERVICE
The starter feed circuit of the switch is through the
switch center terminal (Fig. 23). It provides a ground
for the starter solenoid circuit through the gearshift
lever in park and neutral only.
The two outer terminals of the park/neutral posi-
tion switch are for the backup lamp switch circuit.
SWITCH TEST PROCEDURE
(1) Remove wiring connector from switch.
(2) Test continuity between switch center terminal
and transmission case. Continuity should exist onlywhen transmission is in Park or Neutral. Replace
switch if continuity occurs in any gear other than
Park or Neutral.
(3) Shift into reverse and test continuity between
two outside terminals on switch. Continuity should
exist only when transmission is in reverse.
(4) Leave transmission in reverse and test continu-
ity between each switch outer terminal and transmis-
sion case. Continuity should not exist between either
pin and case in reverse.
(5) If switch tests OK, check gearshift linkage ad-
justment or backup light circuit. Replace switch if it
fails continuity tests.
SWITCH REPLACEMENT
(1) Position drain pan under neutral switch.
(2) Disconnect switch wires.
(3) Remove switch from transmission.
(4) Move shift lever to Park and Neutral positions.
Inspect manual lever fingers, lever and shaft for
proper alignment with switch opening in case. Re-
place lever if worn or bent. Do not attempt to
straighten the lever.
(5) Install new switch and seal in case. Tighten
switch to 33 Nzm (24 ft. lbs.) torque.
(6) Adjust transmission fluid level as required.
(7) Verify switch operation.
SPEEDOMETER SERVICE
Rear axle gear ratio and tire size determine speed-
ometer pinion requirements. If the pinion must be re-
placed, refer to the parts catalogue information for
the correct part. It is important for speedometer ac-
curacy that the pinion have the correct number of
teeth.
The speedometer assembly used in XJ models is
the new unit type (one-piece) speed sensor (Fig. 24).
However, YJ models may be equipped with either the
new unit style, or the older style that has a two-piece
Fig. 22 Park Lock ComponentsFig. 23 Park/Neutral Position Switch And Manual
Lever
J30RH/32RH IN-VEHICLE SERVICE 21 - 109

speed sensor and metal adapter (Fig. 25). Service
procedures for both styles are described in the follow-
ing procedures.
SPEEDOMETER ASSEMBLY REMOVAL (WITH
UNIT STYLE SENSOR)
(1) Raise vehicle.
(2) Disconnect wires from vehicle speed sensor.
(3) Remove adapter clamp and screw (Fig. 24).
(4) Remove speed sensor and speedometer adapter
as assembly.
(5) Remove speed sensor retaining screw and re-
move sensor from adapter.
(6) Remove speedometer pinion from adapter.
(7) Inspect sensor and adapter O-rings (Fig. 24).
Remove and discard O-rings if worn or damaged.
(8) Inspect terminal pins in vehicle speed sensor.
Clean pins with Mopar electrical spray cleaner if
dirty or oxidized. Replace sensor if faulty, or pins are
loose, severely corroded, or damaged.
SPEEDOMETER INSTALLATION AND
INDEXING (UNIT STYLE)
(1) Thoroughly clean adapter flange and adapter
mounting surface in housing. Surfaces must be clean
for proper adapter alignment and speedometer oper-
ation.
(2) Install new O-rings on speed sensor and speed-
ometer adapter if necessary (Fig. 25).
(3) Lubricate sensor and adapter O-rings with
transmission fluid.
(4) Install vehicle speed sensor in speedometer
adapter. Tighten sensor attaching screw to 2-3 Nzm
(15-27 in. lbs.) torque.(5) Install speedometer pinion in adapter.
(6) Count number of teeth on speedometer pinion.
Do this before installing assembly in housing. Then
lubricate pinion teeth with transmission fluid.
(7) Note index numbers on adapter body (Fig. 25).
These numbers will correspond to number of teeth on
pinion.
(8) Install speedometer assembly in housing.
(9) Rotate adapter until requiredrange numbers
are at 6 o-clock position. Be sure range index
numbers correspond to number of teeth on pin-
ion gear.
(10) Install speedometer adapter clamp and retain-
ing screw. Tighten clamp screw to 10-12 Nzm (90-110
in. lbs.) torque.
(11) Connect wires to vehicle speed sensor.
(12) Lower vehicle and top off transmission fluid
level if necessary.
SPEEDOMETER COMPONENT REMOVAL
(TWO-PIECE SENSOR)
(1) Raise vehicle.
(2) Disconnect speed sensor wires.
(3) Remove bolt attaching vehicle speed sensor to
sensor adapter. Then slide sensor out of adapter.
(4) Inspect speed sensor mounting area in sensor
adapter. If transmission fluid is found in this area,
oil seal in metal speedometer adapter is leaking and
will have to be replaced.
(5) Remove speedometer adapter clamp bolt and
remove clamp (Fig. 26).
(6) Remove speedometer adapter, sensor adapter
and speedometer pinion as assembly.
Fig. 24 Speedometer Components (With Unit Style Sensor)
21 - 110 30RH/32RH IN-VEHICLE SERVICEJ

SPEEDOMETER COMPONENT INSTALLATION
AND INDEXING (TWO-PIECE SENSOR)
(1) Replace speedometer O-ring if cut, torn, or
worn.
(2) If oil seal in metal speedometer adapter needs
replacement, remove old seal with pointed tool. Then
install new seal with Special Tool C-4004. Push seal
into place with tool until tool bottoms (Fig. 27).
(3) Clean speedometer adapter mounting surface of
transmission, or transfer case thoroughly.
(4) Lubricate adapter seals with transmission
fluid.
(5) Count number of teeth on speedometer pinion.
Do this before installing pinion and adapter.(6) Note range numbers on face of speedometer
adapter (Fig. 27). These numbers correspond to num-
ber of teeth on speedometer pinion.
(7) Install pinion in adapter and install assembled
pinion and adapter in transmission or transfer case.
(8) Rotate speedometer adapter until required
range numbers are at 6 o'clock position (Fig. 28).
Verify that range numbers correspond to num-
ber of teeth on pinion.
(9) Push speedometer adapter into place until
seated.
(10) Install speedometer adapter clamp and bolt.
Tighten bolt to 11 Nzm (100 in. lbs.) torque.
(11) Install sensor adapter on speedometer
adapter. Tighten sensor adapter coupling nut to 17
Nzm (150 in. lbs.) torque.
(12) Carefully align and insert vehicle speed sensor
into sensor adapter.
(13) Install bolt that attaches speed sensor to
adapter. Tighten bolt to 5-8 Nzm (48-72 in. lbs.)
(14) Connect wires to speed sensor.
(15) Lower vehicle.
(16) Check top off transmission fluid level if neces-
sary.
TRANSMISSION COOLER LINE AND FITTING
SERVICE
The transmission cooler lines are attached with
quick connect fittings. Two types of fitting will be
used.
Fig. 25 Location Of Index Numbers On Speedometer
Adapter (Unit Style Sensor)
Fig. 26 Speedometer Components (With Two-Piece
Sensor)
Fig. 27 Installing Speedometer Adapter Seal (With
Two-Piece Sensor And Metal Adapter)
Fig. 28 Indexing Speedometer Adapter (With
Two-Piece Sensor)
J30RH/32RH IN-VEHICLE SERVICE 21 - 111

30RH/32RH TRANSMISSION REMOVAL AND INSTALLATION
INDEX
page page
ConverterÐPump SealÐDrive Plate Service.... 116
Transmission and Converter Installation........ 117Transmission and Converter Removal......... 115
TRANSMISSION AND CONVERTER REMOVAL
(1) Remove fan shroud attaching bolts.
(2) Disconnect transmission fill tube at upper
bracket.
(3) Raise vehicle.
(4) Remove inspection cover from converter hous-
ing and remove skid plate for access, if necessary.
(5) Remove transmission fill tube and fill tube O-
ring.
(6) Remove starter motor.
(7) Mark propeller shafts and axle yokes for align-
ment reference.
(8) Disconnect propeller shafts at yokes. Secure
shafts to frame rails with wire.
(9) Disconnect exhaust pipes at exhaust manifolds,
if necessary.
(10) Drain transfer case lubricant, if transfer case
will also be serviced.
(11) Disconnect vehicle speed sensor wires.
(12) Disconnect transfer case shift linkage.
(13) Disconnect gearshift cable/linkage and throttle
valve cable at transmission levers.
(14) Disconnect transfer case vent hose. Then dis-
connect indicator switch wires on XJ, or vacuum
switch harness on YJ.
(15) Remove wire harness from clips on transfer
case.
(16) Remove transfer case attaching nuts and re-
move transfer case. Use transmission jack or helper
to support and remove transfer case.
(17) Disconnect park/neutral position switch wires.
(18) Disconnect and remove crankshaft position
sensor (Figs. 1 and 2). Retain sensor bolt (or bolts)
for reinstallation.
CAUTION: The crankshaft position sensor can be
damaged during transmission removal (or installa-
tion) if the sensor is still bolted to the engine block.
To avoid damage, remove the sensor before remov-
ing the transmission.
(19) Remove wire harnesses from clips/tie straps
on transmission.
(20) Remove converter housing access cover and
mark drive plate and converter for alignment refer-
ence.
(21) Remove bolts attaching converter to drive
plate.(22) Support engine with support stand.
(23) Support transmission with transmission jack.
Secure transmission to jack with safety chain.
Fig. 1 Crankshaft Position Sensor (2.5L)
Fig. 2 Crankshaft Position Sensor (4.0L YJ)
J30RH/32RH TRANSMISSION REMOVAL AND INSTALLATION 21 - 115

grip the metal part of the seal. Then tighten the tool
puller screw to withdraw the seal from the pump
body.
Use Special Tool C-4193-A to install the seal (Fig.
6). Be sure to lubricate the pump seal and converter
hub with transmission fluid before installation.
TRANSMISSION AND CONVERTER INSTALLATION
CAUTION: If the transmission was repaired to cor-
rect a problem that generated sludge and debris,
the fluid cooler and lines must be reverse flushed
and the torque converter and drainback valve re-
placed. Sludge and metal or friction particles must
be removed from the cooler system before reinstall-
ing the transmission. This avoids re-contaminating
the repaired transmission. Failure to flush the sys-
tem will result in repeat failure and a shop come-
back.
(1) Lubricate converter drive hub and pump seal
with Mopar ATF Plus transmission fluid. Then in-
stall converter. Turn converter back and forth toalign drive slots in converter hub with pump gear
lugs. Be sure converter is fully seated in pump (Fig.
7).
(2) Temporarily secure converter with C-clamp or
metal strap attached across converter housing.
(3) Position transmission on jack and secure it
with safety chains.
(4) Raise transmission and align converter with
drive plate.
(5) Move transmission forward. Then raise, lower
or tilt transmission to align converter housing with
engine block dowels.
(6) Install two transmission attaching bolts.
Tighten bolts just enough to hold transmission con-
verter housing in place on block.
(7) Install torque converter attaching bolts.
Tighten bolts to following torque.
²54 Nzm (40 ft. lbs.) with 9.5 in. 3-lug converter
²74 Nzm (55 ft. lbs.) with 9.5 in. 4-lug converter
²74 Nzm (55 ft. lbs.) with 10.0 in. 4-lug converter
²31 Nzm (270 in. lbs.) with 10.75 in. 4-lug converter
(8) Install and tighten remaining bolts that attach
transmission converter housing to engine block (Fig.
8).
CAUTION: Be sure the converter housing is fully
seated on the engine block dowels before tighten-
ing any bolts.
(9) Install crankshaft position sensor.
(10) Install transmission fill tube and O-ring (Fig.
5).
(11) Connect transmission cooler lines to fittings.
Refer to Figure 9 for cooler line identification.
Fig. 5 Pump Seal Removal
Fig. 6 Pump Seal Installation
Fig. 7 Checking Torque Converter Seating
J30RH/32RH TRANSMISSION REMOVAL AND INSTALLATION 21 - 117

(12) Install transfer case on transmission. Tighten
attaching nuts to 47 Nzm (35 ft. lbs.) torque if case
has 3/8 studs, or 35 Nzm (26 ft. lbs.) if case has 5/16
studs.
(13) Install rear crossmember and attach transmis-
sion rear support to crossmember.
(14) Remove transmission jack.
(15) Connect vehicle speed sensor wires.
(16) Install inspection cover on converter housing.(17) Install exhaust pipes and support brackets, if
removed.
(18) Install starter motor.
(19) Connect wires to park/neutral position switch.
(20) Connect gearshift and linkage and throttle ca-
ble.
(21) Connect transfer case shift linkage.
(22) Connect propeller shafts to transfer case
yokes.
(23) Connect front exhaust pipes and catalytic con-
verter support bracket bolts (if removed).
(24) Install skid plate, rear cushion and bracket, if
removed.
(25) Fill transfer case to bottom edge of fill plug
hole with Mopar Dexron II.
(26) Lower vehicle and fill transmission to correct
level with ATF Plus, type 7176 fluid.
(27) Install fan shroud and bolts (if removed).
(28) Check and adjust gearshift cable or linkage if
necessary. Then check and adjust throttle valve cable
if necessary.
Fig. 8 Transmission Attachment
Fig. 9 Transmission Cooler Line Location And
Identification
21 - 118 30RH/32RH TRANSMISSION REMOVAL AND INSTALLATIONJ

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.
RECOMMENDED FLUID AND CAPACITY
Recommended and preferred fluid for the AW-4
transmission is Mopar Dexron IIE/Mercon.
Mopar Dexron II can be used but only in emer-
gency situations where Mercon fluid is not available.
Approximate refill capacity for the AW-4 is 8.0 li-
ters (16.9 pints or 8.45 quarts).
COMPONENTS AND OPERATION
ELECTRONIC CONTROLS
The AW-4 is electronically controlled in 1, 2, 3 and
D ranges. Controls consist of the transmission control
module (TCM), valve body solenoids and various sen-
sors. The sensors monitor vehicle speed, throttle
opening, shift lever position and brake pedal applica-
tion.
TRANSMISSION CONTROL MODULE (TCM)
The module determines shift and converter clutch
engagement timing based on signals from sensors.
The valve body solenoids are activated, or deacti-
vated accordingly.
The TCM has a self diagnostic program. Compo-
nent and circuitry malfunctions can be diagnosed
with the DRB scan tool. Once a malfunction is noted
and stored in control module memory, it is retained
even after the problem has been corrected. To cancel
a stored malfunction, disconnect and reconnect the
9Trans.9fuse in the module harness.
TRANSMISSION VALVE BODY SOLENOIDS
The solenoids are mounted on the valve body and
operated by the TCM. The solenoids control operation
of the converter clutch and shift valves in response to
input signals from the module.
SENSORS
Sensors include:
²throttle position sensor (TPS)
²transmission speed sensor
²vehicle speed sensor
²park/neutral position switch
²brake 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.
Fig. 2 AW-4 Shift Lever Positions And Transmission
Ranges
Fig. 3 Transmission Identification
21 - 166 AW-4 AUTOMATIC TRANSMISSIONJ

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-
net complete one revolution. Sensor signals are sent
to the transmission control module.
The park/neutral position switch is mounted on the
valve body manual shaft. The switch signals shift
linkage and manual valve position to the transmis-
sion control module through an interconnecting har-
ness. The switch prevents engine starting in all gears
other than Park or Neutral.
The brake switch is in circuit with the torque con-
verter clutch solenoid. The switch disengages the
converter clutch whenever the brakes are applied.
The switch is mounted on the brake pedal bracket
and signals the transmission control module when
the pedal is pressed or released.
TORQUE CONVERTER
A three element torque converter is used for all ap-
plications. The converter contains an impeller, stator,
and turbine.
The AW-4 converters are all equipped with a con-
verter clutch mechanism. The clutch consists of a
sliding clutch piston, clutch springs and the clutch
disc material (Fig. 4). The clutch provides optimum
torque transfer and economy when engaged.
The clutch disc is attached to the converter front
cover. The clutch piston and clutch springs are at-
tached to the turbine hub. The springs dampen en-
gine firing impulses and loads during the initial
phase of converter clutch engagement.
Clutch engagement is controlled by transmission
valve body solenoid number three and by the con-
verter clutch relay valve. The solenoid channels line
pressure to the clutch through the relay valve at
clutch engagement speeds.Torque converter clutch engagement occurs in sec-
ond gear in 1-2 position; third gear in 3 position and
third and fourth gear in D position.
FOURTH GEAR OVERDRIVE COMPONENTS
The overdrive system consists of the input shaft,
one-way clutch, planetary sun gear, ring gear, plane-
tary carrier, clutch and overdrive brake (Fig. 5). The
overdrive elements are controlled and applied
through transmission valve body solenoid number
two.
In overdrive fourth gear, the brake prevents the
overdrive sun gear from turning. During operation,
the overdrive elements operate as follows:
Fig. 4 Torque Converter (With Clutch)
Fig. 5 Fourth Gear Overdrive Components
JAW-4 AUTOMATIC TRANSMISSION 21 - 167