1995 JEEP XJ sensor

(4) Install new O-ring on speed sensor and install
sensor in transmission case.
(5) Install sensor bracket and retainer bolt.
Tighten bolt to 7.4 Nzm (65 in. lbs.) torque.
(6) Connect sensor wire harness connector.
SPEED SENSOR ROTORÐSPEEDOMETER DRIVE
GEAR
ROTORÐDRIVE GEAR REMOVAL
(1) Raise vehicle.
(2) Remove components necessary to gain access to
rotor and drive gear such as propeller shaft, transfer
case, crossmember, and shift linkage.
(3) Disconnect speedometer cable and/or speed sen-
sor.
(4) Remove adaptor housing.
(5) Remove speedometer drive gear snap ring (Fig.
39).
(6) Remove the speedometer drive gear and spacer
(if equipped).
(7) Remove rotor by carefully prying it off output
shaft with wood dowel or hammer handle (Fig. 40).
(8) Clean sealing surfaces of transmission case and
extension/adaptor housing.
ROTOR AND DRIVE GEAR INSTALLATION
(1) Install rotor, spacer (if equipped) and drive gear
on output shaft. Then install drive gear snap ring
(Fig. 39).
(2) Apply bead of Loctite 599 sealer, to transmis-
sion case sealing surface and install extension/
adapter housing on case.(3) Tighten adaptor housing bolts to 34 Nzm (25 ft.
lbs.) torque.
(4) Install components removed to gain access to
rotor and drive gear.
THROTTLE POSITION SENSOR (TPS) SERVICE
A separate throttle position sensor is used for au-
tomatic transmission applications. The sensor is at-
tached to the base of the throttle body. Refer to
Group 14 for TPS service and adjustment.
TRANSMISSION THROTTLE CABLE REPLACEMENT
THROTTLE CABLE REMOVAL
(1) In engine compartment, disconnect cable from
throttle linkage. Then compress cable mounting ears
and remove cable from engine bracket (Fig. 41).
(2) Raise vehicle.
(3) Remove transmission oil pan.
(4) Disengage cable from throttle valve cam (Fig.
42).
(5) Remove cable bracket bolt and remove cable
and bracket from case (Fig. 43).
(6) Remove and discard cable seal.
THROTTLE CABLE INSTALLATION
(1) Lubricate and install new seal on cable.
(2) Insert cable in transmission case.
(3) Attach cable to throttle cam (Fig. 42).
(4) Install cable bracket on case and tighten at-
taching bolt to 10 Nzm (7 ft-lbs) torque (Fig. 43).
(5) Remove old sealer material from oil pan and
transmission case. Clean oil pan with solvent and dry
it with compressed air.
Fig. 40 Removing Speed Sensor Rotor
Fig. 39 Removing/Installation Speedometer Drive
Gear
JAW-4 IN-VEHICLE SERVICE 21 - 193

AW-4 TRANSMISSION REMOVAL AND INSTALLATION
INDEX
page page
Oil Pump Seal Replacement................ 199
Torque Converter Stator Clutch Inspection...... 199Transmission and Torque Converter Installation . . 199
Transmission and Torque Converter Removal.... 198
TRANSMISSION AND TORQUE CONVERTER
REMOVAL
(1) Raise vehicle.
(2) Drain transmission fluid and reinstall oil pan
drain plug.
(3) On models with 2-piece fill tube, remove upper
half of tube (Fig. 1).
(4) Disconnect cooler lines at transmission. Cooler
lines have quick-disconnect fittings. Press fitting re-
lease tabs and pull cooler lines and fittings out of
case or use Special Tool 7555 to disconnect them.
(5) Support engine with safety stand and support
transmission with jack.
(6) Disconnect transmission and transfer case shift
linkage.
(7) Remove necessary exhaust components.
(8) Disconnect vehicle speed sensor wires
(9) Mark position of front and rear propeller shafts
for alignment reference. Then remove shafts from ve-
hicle.(10) Remove rear crossmember.
(11) Disconnect transmission shift cable at trans-
mission. Then disconnect transmission throttle valve
cable at engine.
(12) Disconnect necessary vacuum and fluid hoses.
(13) Remove transfer case from transmission.
(14) Disconnect and remove crankshaft position
sensor (Fig. 2).
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.
(15) Remove starter motor.
(16) Remove bolts attaching converter to drive
plate.
(17) Remove bolts attaching converter housing to
engine.
(18) Secure transmission to jack with safety
chains.
(19) Pull transmission rearward for access to con-
verter. Then secure converter in pump with C-clamp
or strap bolted to converter housing.
(20) Remove transmission from under vehicle.
(21) Remove torque converter if converter or oil
pump seal are to be serviced.
Fig. 1 Transmission Fill Tube (Two-Piece)Fig. 2 Crankshaft Position Sensor
21 - 198 AW-4 TRANSMISSION REMOVAL AND INSTALLATIONJ

TORQUE CONVERTER STATOR CLUTCH
INSPECTION
(1) Insert Rotating Tool 7547 into converter hub
and seat tool in one-way clutch (Fig. 3).
(2) Insert Stopper Tool 7548 in one converter hub
notch and into outer race of rotating tool.
(3) Turn rotating tool clockwise. Converter clutch
should rotate freely and smoothly. Less than 2.5 Nzm
(22 in. lbs.) of torque should be required to rotate
clutch in clockwise direction.
(4) Turn rotating tool in counterclockwise direction.
Converter clutch should lock.
(5) Replace converter if clutch binds or will not
lock.
OIL PUMP SEAL REPLACEMENT
(1) Remove converter.
(2) Remove old seal. Use blunt punch to collapse
seal and pry seal out of pump housing. Do not
scratch or damage seal bore.
(3) Lubricate lip of new seal with transmission
fluid and install seal in pump with tool 7549 (Fig. 4).
(4) Lubricate converter drive hub with transmis-
sion fluid.
(5) Align and install converter in oil pump.
TRANSMISSION AND TORQUE CONVERTER
INSTALLATION
(1) Mount transmission on transmission jack. Then
secure transmission to jack with safety chains.
(2) Lubricate converter drive hub and oil pump
seal lip with transmission fluid. Then install con-
verter. Be sure converter is fully seated in oil pump
gears before proceeding. Hold converter in place with
C-clamp or strap attached to converter housing.
(3) Align and position transmission and converter
on engine.
(4) Remove clamp or strap used to hold torque con-
verter in place.
(5) Move transmission forward seat and it on en-
gine. Be sure torque converter hub is fully seated.
(6) Install converter housing-to-engine bolts (Fig.
5).
(7) Install converter-to-drive plate bolts.
(8) Install and connect starter motor.
(9) Install and connect crankshaft position sensor.
(10) Install transfer case on transmission. Tighten
transfer case attaching nuts to 41 Nzm (30 ft. lbs.)
torque
(11) Connect transfer case shift linkage and vac-
uum hoses.
(12) Connect exhaust components.
(13) Install rear crossmember and remove jack
used to support transmission assembly.
(14) Connect speed sensor wire harness to sensor.
(15) Connect wire harness to park/neutral position
switch.(16) Align and connect front and rear propeller
shafts.
Fig. 3 Checking Operation Of Torque Converter
Stator One-Way Clutch
JAW-4 TRANSMISSION REMOVAL AND INSTALLATION 21 - 199

AW-4 TRANSMISSION OVERHAUL
INDEX
page page
Cleaning and Inspection................... 214
Direct Clutch Overhaul.................... 228
First-Reverse Brake Piston and Transmission Case
Overhaul............................. 247
Forward Clutch Overhaul................... 232
Front Planetary Gear Overhaul.............. 237
Manual Valve Shaft Overhaul............... 215
Oil Pump Overhaul....................... 216
Overdrive Planetary Gear and Clutch Overhaul . . 218Overdrive Support Overhaul................ 226
Overhaul Service Tools.................... 201
Rear Planetary, No. 2 One-Way Clutch and Output
Shaft Overhaul......................... 244
Second Brake Overhaul................... 241
Sun Gear and No. 1 One-Way Clutch Overhaul . . 238
Transmission Assembly and Adjustment........ 265
Transmission Disassembly................. 201
Transmission Valve Body Overhaul........... 250
OVERHAUL SERVICE TOOLS
The special tools needed to overhaul the AW-4
transmission are provided in Tool Kit 6294. However,
Pressure Test Port Adapter 7554 is not included in
this kit and must be ordered separately. The over-
haul tool kit and test port adapter are available
through the parts division and dealer special tool
program.
TRANSMISSION DISASSEMBLY
(1) Remove torque converter.
(2) Remove lower half of filler tube if not previ-
ously removed.
(3) Remove clamps attaching wire harness and
throttle cable (Fig. 1) to transmission.(4) Remove shift lever from manual valve shaft at
left side of transmission.
(5) Remove park/neutral position switch.
(6) Remove speed sensor (Fig. 2).
Fig. 1 Typical Harness And Cable Clamp Attachment
Fig. 2 Speed Sensor Removal
JAW-4 TRANSMISSION OVERHAUL 21 - 201

(7) Remove converter housing bolts and remove
housing (Fig. 3) from case.
(8) Remove adapter housing.
(9) Remove speedometer drive gear snap ring and
remove gear and gear spacer if equipped (Fig. 4).(10) Remove speed sensor rotor and key. Use wood
dowel or hammer handle to loosen and remove rotor
(Fig. 5).
(11) Remove transmission oil pan, oil screen and
screen gaskets (Fig. 6). Then mount transmission in
holding fixture.
Fig. 3 Converter Housing Removal
Fig. 4 Removing Speed Sensor And Speedometer
Drive Gear
Fig. 5 Removing Transmission Speed Sensor Rotor
Fig. 6 Removing Oil Screen
21 - 202 AW-4 TRANSMISSION OVERHAULJ

(83) Install new gaskets on oil screen and install
screen on valve body. Tighten screen bolts to 10 Nzm
(7 ft. lbs.) torque.
(84) Install magnet in oil pan. Be sure magnet
does not interfere with valve body oil tubes.
(85) Apply Loctite 599 to sealing surface of oil pan.
Sealer bead should be at least 3 mm (1/8 in.) wide.
Install pan on case and tighten pan bolts to 7 Nzm
(65 in. lbs.) torque.
(86) Install transmission speed sensor rotor and
key on output shaft (Fig. 63).
(87) Install spacer and speedometer drive gear on
output shaft. Then install retaining snap ring (Fig.
64).
(88) Apply bead of Loctite 599 sealer to sealing
surface at rear of case (Fig. 65).(89) Install adapter housing on transmission.
Tighten adapter bolts to 34 Nzm (25 ft. lbs.) torque.
(90) Install transmission speed sensor (Fig. 66).
Tighten sensor bolt to 7.4 Nzm (65 in. lbs.) torque
and connect sensor wire harness connector.
(91) Install converter housing (Fig. 67). Tighten 12
mm diameter housing bolts to 57 Nzm (42 ft. lbs.)
torque. Tighten 10 mm diameter housing bolts to 34
Nzm (25 ft. lbs.) torque.
(92) Install transmission shift lever on manual
valve shaft. Do not install lever attaching nut at this
time.
(93) Move transmission shift lever fully rearward.
Then move lever two detent positions forward.
Fig. 61 Connecting Valve Body Solenoid Wires
Fig. 62 Installing Valve Body Oil Tubes
Fig. 63 Installing Transmission Speed Sensor Rotor
And Key
Fig. 64 Installing Spacer And Speedometer Drive
Gear
21 - 280 AW-4 TRANSMISSION OVERHAULJ

(94) Mount park/neutral position switch on manual
valve shaft and tighten switch adjusting bolt just
enough to keep switch from moving (Fig. 68).
(95) Install park/neutral position switch tabbed
washer and retaining nut (Fig. 68). Tighten nut to
6.9 Nzm (61 in. lbs.) torque, but do not bend any of
the washer tabs against the nut at this time.
(96) Align park/neutral position switch standard
line with groove or flat on manual shaft (Fig. 68).(97) Tighten park/neutral position switch adjusting
bolt to 13 Nzm (9 ft. lbs.) torque.
(98) Install transmission shift lever on manual
valve shaft. Tighten lever attaching nut to 16 Nzm
(12 ft. lbs.) torque.
Fig. 65 Applying Sealer To Case Rear Flange
Fig. 66 Installing Transmission Speed Sensor
Fig. 67 Installing Converter Housing
Fig. 68 Park/Neutral Position Switch Installation/
Adjustment
JAW-4 TRANSMISSION OVERHAUL 21 - 281

(4) Lower vehicle.
(5) Install shift lever bezel and boot (Fig. 7). Then
install retaining nut and shift knob on lever.
SPEEDOMETER SERVICE
Speedometer service is covered in the 30RH/32RH,
or AW-4 automatic transmission sections in this
group. Refer to the appropriate section as needed.
TRANSFER CASE REMOVAL
(1) Shift transfer case into Neutral.
(2) Raise vehicle.
(3) Drain transfer case lubricant.
(4) Mark front and rear propeller shaft yokes for
alignment reference.
(5) Support transmission with jack stand.
(6) Remove rear crossmember, or skid plate.
(7) Disconnect front/rear propeller shafts at trans-
fer case.
(8) Disconnect vehicle speed sensor wires.
(9) Disconnect transfer case linkage rod from range
lever.
(10) Disconnect transfer case vent hose, and indi-
cator or vacuum switch harness.
(11) Support transfer case with transmission jack.
(12) Remove nuts attaching transfer case to trans-
mission.
(13) Secure transfer case to jack with chains.
Fig. 5 Shift Linkage Mounting (YJ)
Fig. 6 Shift Linkage (YJ)
JNP231 TRANSFER CASE 21 - 287