1995 JEEP CHEROKEE seat

(5) Coat output shaft thrust washer with petro-
leum jelly. Then install washer in rear clutch hub
(Fig. 149). Use enough petroleum jelly to hold washer
in place.Be sure grooved side of washer faces
rearward (toward output shaft) as shown. Also
note that washer only fits one way in clutch
hub.
(6) Align drive teeth on rear clutch discs with
small screwdriver (Fig. 150). This will make installa-
tion on front planetary easier.
(7) Raise front end of transmission upward as far
as possible and support case with wood blocks. Front/
rear clutch and oil pump assemblies are easier to in-
stall if transmission is as close to upright position as
possible.
(8) Install front and rear clutch units as assembly
(Fig. 151). Align rear clutch with front annulus gear
and install assembly in driving shell.Be sure out-
put shaft thrust washer and thrust plate are
not displaced during installation.
(9) Carefully work assembled clutches back and
forth to engage and seat rear clutch discs on frontannulus gear. Verify that front clutch drive lugs are
fully engaged in slots of driving shell after installa-
tion.
FRONT BAND AND OIL PUMP INSTALLATION
(1) Slide front band over front clutch retainer (Fig.
152).
(2) Insert front band reaction pin part way into
case (Fig. 152).
(3) Install front band lever, strut, lever pin and ad-
justing screw (Fig. 153).
(4) Tighten front band adjusting screw until band
just grips clutch retainer. Verify that front/rear
clutches are still seated before continuing.
(5) Coat band lever pin access plug with sealer and
install plug in converter housing (Fig. 154).
Fig. 149 Installing Output Shaft Thrust Washer
Fig. 150 Aligning Rear Clutch Disc Lugs
Fig. 151 Installing Front/Rear Clutch Assemblies
Fig. 152 Installing Front Band And Reaction Pin
J30RH/32RH TRANSMISSION OVERHAUL 21 - 161

(6) Verify that reaction shaft support hub seal
rings are hooked together (Fig. 155).
(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. 156).
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. 157).
(9) Align and install oil pump gasket (Fig. 157).
(10) Lubricate oil pump seals with Mopar Door-
Ease, or Ru-Glyde, Door Eze, or ATF Plus.
(11) Install oil pump (Fig. 158). 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. 159).
(2) Attach dial indicator to converter housing. Po-
sition indicator plunger against input shaft and zero
indicator.
Fig. 153 Front Band Linkage Installation
Fig. 154 Installing Front Band Pivot Pin Access Plug
Fig. 155 Reaction Shaft Support Seal Rings
Fig. 156 Front Clutch Thrust Washer Installation
Fig. 157 Installing Pilot Studs And Oil Pump Gasket
21 - 162 30RH/32RH TRANSMISSION OVERHAULJ

²On 32RH (4.0L), back adjusting screw off 2
1/4 turns
(d) Hold adjusting screw in position and tighten
locknut to 34 Nzm (25 ft. lbs.).
(2) Adjustrear bandas follows:
(a) Loosen locknut.
(b) Tighten adjusting screw as follows:
²On 32RH, tighten screw to 8 Nzm (72 in. lbs)
torque
²On 30RH, tighten screw to 5 Nzm (41 in. lbs.)
torque.
(c) Back off rear band adjusting screw as follows:
²On 30RH (2.5L), back adjusting screw off 7 turns
²On 32RH (4.0L), back adjusting screw off 4 turns
(d) Hold adjusting screw in place and tighten
locknut to 34 Nzm (25 ft. lbs.) torque.
(3) Install new pan gasket on transmission and in-
stall oil pan. Tighten pan bolts to 17 Nzm (13 ft. lbs.).(4) Turn transmission over.
EXTENSION HOUSING, CONTROL LEVER AND
CONVERTER INSTALLATION
(1) Install throttle valve and manual valve levers
on shaft.
(2) Position new extension adapter housing gasket
on transmission case. Use petroleum jelly to hold
gasket in place.
(3) Install new rear seal in extension housing if re-
quired.
(4) Install extension/adapter housing on transmis-
sion case. Tighten housing fasteners to 33 Nzm (24 ft.
lbs.). Be sure park lock rod is properly engaged in
sprag before tightening fasteners.
(5) Lubricate converter hub with transmission
fluid and carefully install converter. Turn converter
back and forth until seated.
(6) Secure converter in oil pump before mounting
transmission on jack and before moving transmission
back under vehicle. Use metal strapping, C-clamp, or
locking pliers to hold converter in place. Attach hold-
ing tool to converter housing.
CAUTION: The transmission cooler and lines must
be reverse flushed if overhaul corrected a malfunc-
tion that generated sludge, metal particles, or
clutch friction material. The torque converter and
drainback valve should also be replaced as they
will also be contaminated. Debris and residue NOT
flushed from the cooler and lines will flow back into
the transmission and converter. The result will be a
repeat failure and shop comeback.
Fig. 162 Fluid Filter Installation
21 - 164 30RH/32RH TRANSMISSION OVERHAULJ

cushion engagement. The accumulators are all lo-
cated in the transmission case (Fig. 24).
Transmission Valve Body Solenoids
Three solenoids are used (Fig. 25). The No. 1 and 2
solenoids control shift valve operation by applying orreleasing line pressure. The signal to apply or release
pressure is provided by the transmission control
module.
The No. 3 solenoid controls operation of the torque
converter clutch. The solenoid operates in response to
signals from the transmission control module.
When the No. 1 and 2 solenoids are activated, the
solenoid plunger is moved off its seat opening the
drain port to release line pressure. When either sole-
noid is deactivated, the plunger closes the drain port.
The No. 3 solenoid operates in reverse. When the
solenoid is deactivated, the solenoid plunger is moved
off its seat opening the drain port to release line
pressure. When the solenoid is activated, the plunger
closes the drain port.
Fig. 24 Accumulators
Fig. 25 Transmission Valve Body Solenoids
JAW-4 AUTOMATIC TRANSMISSION 21 - 175

PRESSURE TEST ANALYSIS
If pressures in D and Reverse are higher than
specified in test, 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 in test, check for following:
²throttle cable loose, worn, binding or out of adjust-
ment
²throttle valve, downshift plug, or throttle cam
sticking, 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.Stall speeds are
checked in both Drive and Reverse ranges with
the AW-4 transmission.
(1) Before starting test, be sure fluid level is cor-
rect and fluid is at normal operating 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.
(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) Open throttle completely and record maximum
engine rpm registered on tachometer. It takes any-
where from 4 to 10 seconds to reach maximum rpm.
However, once maximum rpm has been achieved,do
not hold wide open throttle for more than 3-4
seconds.CAUTION: Stalling the converter causes a rapid in-
crease in fluid temperature. To avoid fluid overheat-
ing, hold wide open throttle for no more than 4
seconds after reaching peak rpm. In addition, if
more than one stall test is required, run the engine
at 1000 rpm with the transmission in Neutral for at
least 20 seconds to cool the fluid.
(9) Stall speed should be in 2100-2400 rpm range
in Drive.
(10) Release throttle, shift transmission into Neu-
tral, and run engine for 20-30 seconds to cool fluid.
(11) Shift transmission into Reverse.
(12) Repeat stall test described in step (8).
(13) Stall speed in Reverse should also be in 2100-
2400 rpm range.
(14) Release accelerator pedal, shift transmission
into Neutral, and run engine for 20-30 seconds to
cool fluid.
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.
21 - 178 AW-4 TRANSMISSION DIAGNOSISJ

AW-4 IN-VEHICLE SERVICE
INDEX
page page
Accumulator Pistons and Springs............. 189
Adapter Housing Seal Replacement........... 191
Checking Fluid Level and Condition........... 182
Manual Valve Shaft Seal Replacement......... 187
Park Interlock Cable Adjustment............. 195
Park Rod and Pawl Service................. 190
Park/Neutral Position Switch................ 183
Refilling After Overhaul or Fluid/Filter Change . . . 182
Second Coast Brake Servo................. 190
Shift Cable Adjustment.................... 195
Speed Sensor........................... 192Speed Sensor RotorÐSpeedometer Drive Gear . . 193
Throttle Position Sensor (TPS) Service........ 193
Transmission Control Module (TCM) Service.... 183
Transmission Cooler Line Fittings............ 197
Transmission Cooler Service................ 196
Transmission Throttle Cable Adjustment........ 194
Transmission Throttle Cable Replacement...... 193
Transmission Valve Body Installation.......... 187
Transmission Valve Body Removal........... 186
Transmission Valve Body Solenoids........... 184
CHECKING FLUID LEVEL AND CONDITION
Recommended fluid for AW-4 transmissions is Mo-
par Dexron IIE/Mercon.
Mopar Dexron II can also be used but only when
Mercon fluid is not 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 can be used but
only if Mercon is not available.Do not overfill
transmission. Add only enough fluid to bring
level to Full mark.
(9) If too much fluid was added, excess amount can
be removed with suction gun and appropriate diame-
ter plastic tubing. Tubing only has to be long enough
to extend into oil pan.
CHECKING FLUID CONDITION
Inspect the appearance of the fluid during the fluid
level check. Fluid color should range from dark red to
pink and be free of foreign material, or particles. If
the fluid is dark brown or black in color and smells
burnt, the fluid has been overheated and must be
changed.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.
REFILLING AFTER OVERHAUL OR FLUID/FILTER
CHANGE
The best way to refill the transmission after a fluid
change or overhaul is as follows:
(1) If transmission has been overhauled, install
transmission in vehicle.
(2) Remove dipstick and insert clean funnel in
transmission fill tube.
(3) Add following initial quantity of Mopar Dexron
IIE/Mercon to transmission:
(a) If fluid/filter change was performed, add4
pints (2 quarts)of fluid to transmission.
(b) If transmission was completely overhauled
and torque converter was replaced or drained, add
10 pints (5 quarts)of fluid to transmission.
(c) Remove funnel and install dipstick.
(4) Operate vehicle until fluid reaches normal op-
erating temperature.
(5) Apply parking brakes.
Fig. 1 Transmission Fluid Level
21 - 182 AW-4 IN-VEHICLE SERVICEJ

(6) Let engine run at normal curb idle speed, apply
service brakes. Then shift transmission through all
gear ranges and back to PARK (leave engine run-
ning).
(7) Remove dipstick and check fluid level. Add only
enough fluid to bring level to Full mark on dipstick.
Do not overfill.If too much fluid is added, excess
amount can be removed with suction gun and
plastic tubing. Tubing only has to be long
enough to extend into oil pan.
(8) When fluid level is correct, shut engine off, re-
lease park brake, remove funnel, and reseat dipstick
in fill tube.
TRANSMISSION CONTROL MODULE (TCM)
SERVICE
Use the DRB scan tool to diagnose transmission
control module function whenever a fault is sus-
pected. Replace the module only when the scan tool
indicates the module is 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:
²Continuity should exist between terminals B and
C with the transmission in Park and Neutral only
(Fig. 4).²Continuity should exist between terminals A and E
with the transmission in Reverse (Fig. 4).
²Continuity should exist between terminals A and
G with the transmission in third gear (Fig. 4).
²Continuity should exist between terminals A and
H with the transmission in first and/or second gear
(Fig. 4).
²Continuity should not exist in D position.
PARK/NEUTRAL POSITION SWITCH REMOVAL
(1) Raise vehicle.
(2) Disconnect switch wire harness connector.
(3) Pry washer lock tabs upward and remove
switch attaching nut and tabbed washer (Fig. 5).
(4) Remove switch adjusting bolt (Fig. 5).
(5) Slide switch off manual valve shaft.
PARK/NEUTRAL POSITION SWITCH
INSTALLATION AND ADJUSTMENT
(1) Disconnect shift linkage rod from shift lever on
left side of transmission.
Fig. 2 TCM Location (Left Hand Drive)
Fig. 3 TCM Location (Right Hand Drive)
Fig. 4 Park/Neutral Position Switch Terminals And
Testing
JAW-4 IN-VEHICLE SERVICE 21 - 183

(1) Remove park/neutral position switch and dis-
connect transmission shift lever.
(2) Remove oil pan and valve body.
(3) Remove bolts attaching park rod bracket to
case (Fig. 20).
(4) Remove park rod from shift sector (Fig. 21).
(5) Cut spacer sleeve with chisel and remove it
from manual valve shaft (Fig. 22).
(6) Remove pin from shaft and sector with pin
punch.
(7) Remove shaft and sector from case.
(8) Pry shaft seals out of case (Fig. 23).(9) Inspect the manual valve shaft and sector. Re-
place either component if worn or damaged.
(10) Coat replacement shaft seals with petroleum
jelly and seat them in the case (Fig. 24).
(11) Install new spacer sleeve on sector (Fig. 25).
(12) Lubricate manual valve shaft with petroleum
jelly and install it in case.
(13) Lubricate sector and sleeve with petroleum
jelly and install them on shaft.
(14) Align hole in spacer sleeve with notch in sec-
tor. Then install shift sector roll pin. Tap pin into
sector and shaft and stake sleeve to sector and shaft
securely.
Fig. 20 Removing/Installing Park Rod Bracket
Fig. 21 Removing/Installing Park Rod
Fig. 22 Cutting Spacer Sleeve
Fig. 23 Removing Manual Valve Shaft Seals
21 - 188 AW-4 IN-VEHICLE SERVICEJ