1995 JEEP CHEROKEE engine

TRANSMISSION AND TRANSFER CASE
CONTENTS
page page
30RH/32RH AUTOMATIC TRANSMISSION.... 67
AW 4 AUTOMATIC TRANSMISSION........ 165
AX 15 MANUAL TRANSMISSION........... 33
AX 4/5 MANUAL TRANSMISSION............ 1NP231 TRANSFER CASE................. 283
NP242 TRANSFER CASE................. 306
TRANSMISSION/TRANSFER CASE
SPECIFICATIONS..................... 333
AX 4/5 MANUAL TRANSMISSION
INDEX
page page
Cleaning and Inspection.................... 13
Gear Ratios.............................. 2
General Information........................ 1
Recommended Lubricant.................... 2
Service Diagnosis.......................... 2
Shift Pattern.............................. 2Transmission Assembly and Adjustment......... 16
Transmission Disassembly and Overhaul......... 5
Transmission Identification................... 2
Transmission Installation..................... 5
Transmission Removal...................... 3
GENERAL INFORMATION
The AX 4 is a four speed manual transmission. The
AX 5 is a five speed manual transmission. Fifth gear
in the AX 5 is an overdrive range. The shift mecha-
nism in both models is integral and mounted in theshift tower portion of the adapter housing (Fig. 1).
The AX 4/5 is used for 2.5L engine applications.
Fig. 1 AX 4/5 Manual Transmission
JTRANSMISSION AND TRANSFER CASE 21 - 1

happens when the container delivery mechanism is im-
properly calibrated. Always check the lubricant level af-
ter filling to avoid an under fill condition.
A correct lubricant level check can only be made
when the vehicle is level; use a drive-on hoist to en-
sure this. Also allow the lubricant to settle for a
minute or so before checking. These recommenda-
tions will ensure an accurate check and avoid an un-
der-or-overfill condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants, compo-
nent damage, incorrect clutch adjustment, or by a
damaged clutch pressure plate or disc.
Substantial lubricant leaks can result in gear, shift
rail, synchro and bearing damage. If a leak goes un-
detected for an extended period, the first indications
of a problem are usually hard shifting and noise.
Incorrect or contaminated lubricants can also con-
tribute to hard shifting. The consequence of using
non-recommended lubricants is noise, excessive wear,
internal bind and hard shifting.
Improper clutch release is a frequent cause of hard
shifting. Incorrect adjustment or a worn, damaged
pressure plate or disc can cause incorrect release. If
the clutch problem is advanced, gear clash during
shifts can result.
Worn or damaged synchro rings can cause gear clash
when shifting into any forward gear. In some new or re-
built transmissions, new synchro rings may tend to
stick slightly causing hard or noisy shifts. In most
cases, this condition will decline as the rings wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears generate a mild
whine that is audible but only at extreme speeds.
Severe, highly audible transmission noise is gener-
ally the result of a lubricant problem. Insufficient,
improper, or contaminated lubricant will promote
rapid wear of gears, synchros, shift rails, forks and
bearings. The overheating caused by a lubricant
problem, can also lead to gear breakage.
TRANSMISSION REMOVAL
(1) Shift transmission into first or third gear. Then
raise vehicle on hoist.
(2) Support engine with adjustable jack stand. Po-
sition wood block between jack and oil pan to avoid
damaging pan.
(3) Disconnect necessary exhaust system components.
(4) Remove skid plate.
(5) Disconnect rear cushion and bracket from
transmission (Fig. 5).
(6) Remove rear crossmember.
Fig. 5 Rear Mount Components (YJ Shown)
JAX 4/5 MANUAL TRANSMISSION 21 - 3

(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

AX 15 MANUAL TRANSMISSION
INDEX
page page
General Information....................... 33
Service Diagnosis......................... 34
Transmission Assembly and Adjustment......... 52
Transmission Disassembly and Overhaul........ 37
Transmission Gear Ratios................... 34
Transmission Identification.................. 33Transmission Installation.................... 36
Transmission Lubricant..................... 34
Transmission Removal..................... 35
Transmission Shift Pattern................... 34
Transmission Switch and Plug Locations........ 34
GENERAL INFORMATION
The AX 15 is a 5-speed, synchromesh, manual
transmission. Fifth gear is an overdrive range with a
ratio of 0.79:1. The shift mechanism is integral and
mounted in the shift tower portion of the adapter
housing (Fig. 1).
An adapter housing is used to attach the transmis-
sion to the transfer case on 4-wheel drive models. A
standard extension housing is used on 2-wheel drive
models.
The AX 15 is used in XJ and YJ models with a 4.0L
engine. The AX 15 is used for two and four-wheel
drive applications.
TRANSMISSION IDENTIFICATION
The AX 15 identification code numbers are on the
bottom surface of the transmission gear case (Fig. 2).
Fig. 1 AX 15 Manual Transmission
Fig. 2 Identification Code Number Location
JAX 15 MANUAL TRANSMISSION 21 - 33

(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

30RH/32RH AUTOMATIC TRANSMISSION
GENERAL INFORMATION
INDEX
page page
Recommended Fluid....................... 67
Torque Converter......................... 67
Transmission Application.................... 67
Transmission Changes and Parts Interchangeability.. 67
Transmission Controls and Components........ 67
Transmission Identification.................. 67
TRANSMISSION APPLICATION
Chrysler 30RH and 32RH automatic transmissions
are used in XJ/YJ models. Both are 3-speed auto-
matic transmissions with a gear-type oil pump, two
clutches and bands and a planetary gear system (Fig.
1).
The 30RH is used in XJ/YJ models with a 2.5L en-
gine. The 32RH is used in YJ models with a 4.0L en-
gine.
TORQUE CONVERTER
A three element, torque converter is used for all
applications. The converter consists of an impeller,
stator, and turbine.
The converter used with 30RH/32RH transmissions
has a converter clutch. The clutch is engaged by an
electrical solenoid and mechanical module on the
valve body. The solenoid is operated by the power-
train control module.
The torque converter is a welded assembly and is
not a repairable component. The converter is serviced
as an assembly.
RECOMMENDED FLUID
The recommended and preferred fluid for 30RH/
32RH transmissions is Mopar ATF Plus, Type 7176.
Dexron II is not really recommended and should
only be used when ATF Plus is not available.
TRANSMISSION IDENTIFICATION
The transmission identification numbers are
stamped on the left side of the case just above the oil
pan gasket surface (Fig. 2). The first set of numbers
is the transmission part number. The next set of code
numbers set is the date of build. The final set of code
numbers represents the transmission serial number.
TRANSMISSION CHANGES AND PARTS
INTERCHANGEABILITY
1995 transmissions are similar to previous models
but only in appearance. Current transmissions are
dimensionally different. Do not interchange new/oldparts. Different dimensions, fluid passages, input/
output shafts, cases, bands, valve bodies and gover-
nor assemblies are just a few of the changed items.
CAUTION: Special bolts are used to attach the
driveplate to the crankshaft on models with a 2.5L
engine and 30RH transmission,. These bolts have a
smaller hex head for torque converter clearance.
DO NOT interchange these bolts with similar size
bolts for any reason.
Different governor weight assemblies are used in
30RH/32RH transmissions. The 30RH weight assem-
bly is much the same as in previous years. However,
the 32RH has a three stage governor weight assem-
bly consisting of the outer weight, a smaller weight
spring, and a new intermediate weight. Refer to the
overhaul and in-vehicle service sections for more de-
tailed information.
Plastic check balls are now used in many 30RH/
32RH valve bodies. The new check balls entered pro-
duction as a running change. Plastic and steel check
balls are not interchangeable.
A converter drainback check valve has been added
to the fluid cooler system. The one-way valve is lo-
cated in the transmission outlet (pressure) line. The
valve prevents fluid drainback when the vehicle is
parked for lengthy periods.
TRANSMISSION CONTROLS AND COMPONENTS
The transmission hydraulic control system per-
forms five basic functions, which are:
²pressure supply
²pressure regulation
²flow control
²clutch/band apply and release
²lubrication
Pressure Supply And Regulation
The oil pump generates the fluid working pressure
needed for operation and lubrication. The pump is
J30RH/32RH AUTOMATIC TRANSMISSION 21 - 67