1995 JEEP YJ automatic transmission

(1) Remove the ignition switch from the steering
column. Refer toGroup 8D Ignition System.
(2) Using a key cylinder, check the turning effort of
the switch.
²If the ignition switch binds look for the following
conditions.
(1) Look for rough areas or flash in the casting and
if found remove with a file (Fig. 2).
(2) Remove the link and slider.
(3) Check the link to see if it has been bent and if
so replace with a new part.
Put the slider in its slot in the sleeve and verify a
loose fit over the length of the slot. If the slider binds
in the slot at any point lightly file the slider until
clearance is achieved.
²If no binding is found.
Lightly file the ramp on the ignition switch, (The
ramp fits into the casting) until binding no longer oc-
curs.
AUTOMATIC TRANSMISSION SHIFTER/IGNITION
INTERLOCK MECHANISM
The automatic transmission Shifter/Ignition Inter-
lock, is a cable operated system. It interconnects the
automatic transmission floor mounted shifter to the
steering column ignition switch (Fig. 1). The system
locks the shifter into the PARK position. The Inter-
lock system is engaged whenever the ignition switch
is in the LOCK or ACCESSORY position. When the
key is in the OFF or RUN position the shifter is un-
locked and will move into any position. The interlock
system also prevents the ignition switch from being
turned to the LOCK or ACCESSORY position (Fig.
2). Unless the shifter is fully locked into the PARK
position.
INTERLOCK CABLE REPLACEMENT
REMOVAL
(1) Lower the steering column. Refer to Column
Assembly Replacement in this group.
Fig. 1 Steering Column Non-Serviceable
Components
Fig. 2 Steering Column Flash Removal And
Non-Serviceable Components
Fig. 3 Observe Cautions
Fig. 4 Observe Cautions
JSTEERING 19 - 55

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

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

Fig. 1 30RH/32RH Automatic Transmission
21 - 68 30RH/32RH AUTOMATIC TRANSMISSIONJ

driven by the torque converter. The converter is con-
nected to the engine crankshaft through the drive-
plate.
The pressure regulator valve maintains line pres-
sure. The regulator valve is located in the valve body.
The amount of line pressure developed is controlled
by throttle pressure, which is dependent on the de-
gree of throttle opening.
The governor valve is operated by the transmission
output shaft. Governor pressure increases approxi-
mately in proportion to vehicle speed.
The throttle valve determines line pressure and
shift speed. The throttle valve also controls upshift
and downshift speeds by regulating pressure in con-
junction with throttle position.
Shift Valves
The manual valve is operated by the gearshift link-
age and provides the operating range selected by the
driver.
The 1-2 shift valve provides automatic 1-2 or 2-1
shifts and the 2-3 shift valve provides automatic 2-3
or 3-2 shifts. The kickdown valve provides forced 3-2
or 3-1 downshifts depending on vehicle speed. Down-
shifts occur when the throttle is opened beyond
downshift detent position which is just before wide
open throttle.
The 2-3 valve throttle pressure plug provides 3-2
downshifts with varying throttle openings and de-
pending on vehicle speed. The 1-2 shift control valve
transmits 1-2 shift pressure to the accumulator pis-
ton to control kickdown band capacity on 1-2 upshifts
and 3-2 downshifts.The shuttle valve has two functions. First is fast
front band release and smooth engagement during
lift-foot 2-3 upshifts. The second is to regulate front
clutch and band application during 3-2 downshifts.
Clutches-Bands-Servos-Accumulator
The front/rear clutch pistons and servo pistons are
actuated by line pressure. When line pressure is re-
moved, the pistons are released by spring tension.
On 2-3 upshifts, the front servo piston is released
by spring tension and hydraulic pressure. The accu-
mulator controls hydraulic pressure on the apply side
of the front servo during 1-2 upshifts and at all
throttle openings.
Converter Clutch Controls
Converter clutch operation is controlled by the
power train control module, and by the solenoid and
clutch module on the valve body. The solenoid is op-
erated by a relay on the engine compartment side of
the dash panel.
Activating the solenoid opens a vent allowing fluid
to flow into the clutch module. When line pressure
exceeds tension of the module valve springs, the
module valves open. This allows fluid to be chan-
neled to the converter clutch through the reaction
shaft support and transmission shaft.
Gearshift And Park Lock Controls
The gearshift lever provides six operating positions:
Park (P), Reverse (R), Neutral (N), and the D, 2 and
1 forward drive ranges.
Manual 1 position provides first gear only. Overrun
braking occurs in 1 range when the throttle is re-
leased. Upshifts are not provided in 1 range.
Manual 2 range provides first and second gear. A
1-2 upshift will take place but a 2-3 upshift will not
occur.
D position provides 1-2, 2-3 upshifts and 3-2 and
3-1 downshifts.
Park position allows the park rod to move the park
pawl into engagement with the park gear. This pre-
vents rotation of the transmission output shaft. The
park lock mechanism is only engaged when the shift
lever is in the Park detent.
A park/neutral position switch controls engine
starting. The switch is designed to allow engine
starts only in park or neutral positions.
Fig. 2 Transmission Identification
J30RH/32RH AUTOMATIC TRANSMISSION 21 - 69

30RH/32RH TRANSMISSION DIAGNOSIS
INDEX
page page
Air Pressure Test......................... 74
Analyzing the Road Test.................... 71
Converter Housing Leak Diagnosis............ 75
Converter Stall Test........................ 74
Diagnosis Guides and Charts................ 77
Effects of Incorrect Fluid Level............... 71
Fluid Level Check......................... 70Gearshift Cable/Linkage Adjustment........... 71
General Information....................... 70
Hydraulic Pressure Test.................... 72
Preliminary Diagnosis...................... 70
Road Test............................... 71
Transmission Throttle Valve Cable Adjustment.... 71
GENERAL INFORMATION
Automatic transmission problems are generally a
result of:
²poor engine performance
²incorrect fluid level
²incorrect throttle valve cable adjustment
²incorrect band adjustment
²incorrect hydraulic control pressure adjustments
²hydraulic component malfunctions
²mechanical component malfunctions.
Begin diagnosis by checking the easily accessible
items such as fluid level, fluid condition and control
linkage adjustment. A road test will determine if fur-
ther diagnosis is necessary.
Procedures outlined in this section should be per-
formed in the following sequence to realize the most
accurate results:
²Preliminary diagnosis
²Check fluid level and condition
²Check control linkage Adjustment
²Road test
²Stall test
²Hydraulic pressure test
²Air pressure tests
²Leak test
²Analyze test results and consult diagnosis charts
PRELIMINARY DIAGNOSIS
Two basic procedures are required. One procedure
for vehicles that are driveable and an alternate pro-
cedure for disabled vehicles (will not back up or move
forward).
Vehicle Is Driveable
(1) Check fluid level and condition.
(2) Adjust throttle cable and gearshift linkage if
complaint was based on delayed, erratic, or harsh
shifts.
(3) Road test vehicle and note transmission operat-
ing characteristics.(4) Perform stall test if complaint is based on slug-
gish, low speed acceleration or abnormal throttle
opening needed to maintain normal speeds with
properly tuned engine.
(5) Perform hydraulic pressure tests.
(6) Perform air pressure test to check clutch-band
operation.
Vehicle Is Disabled
(1) Check fluid level and condition.
(2) Check for broken, disconnected throttle linkage.
(3) Check for cracked, leaking cooler lines, or loose,
missing pressure port plugs.
(4) Raise vehicle, start engine, shift transmission
into gear and note following:
(a) If propeller shafts turn but wheels do not,
problem is with differential or axle shafts.
(b) If propeller shafts do not turn and transmis-
sion is noisy, stop engine. Remove oil pan, and
check for debris. If pan is clear, remove transmis-
sion and check for damaged drive plate, converter,
oil pump or input shaft.
(c) If propeller shafts do not turn and transmis-
sion is not noisy, perform hydraulic pressure test to
determine if problem is a hydraulic or mechanical.
FLUID LEVEL CHECK
Transmission fluid level should be checked monthly
under normal operation. If the vehicle is used for
trailer towing or similar heavy load hauling, check
fluid level and condition weekly.
Fluid level is checked with the engine running at
curb idle speed, the transmission in Neutral and the
transmission fluid at normal operating temperature.
FLUID LEVEL CHECK PROCEDURE
(1) Transmission fluid must be at normal operating
temperature for accurate fluid level check. Drive ve-
hicle if necessary to bring fluid temperature up to
normal hot operating temperature of 82ÉC (180ÉF).
(2) Position vehicle on level surface. This is ex-
tremely important for accurate fluid level check.
(3) Start and run engine at curb idle speed.
21 - 70 30RH/32RH TRANSMISSION DIAGNOSISJ

(3) If vehicle is equipped withauxiliary cooler,
test cooler flow as described in step (2).
TRANSMISSION COOLER REVERSE FLUSHING
The flushing procedure applies to standard and
auxiliary coolers alike. Although pressure equipment
is preferred, reverse flushing can be performed with
hand operated equipment as follows.
(1) Disconnect cooler pressure and return lines at
transmission (Figs. 34 and 35).
(2) Remove and discard drainback valve. Install
fabricated hose and fitting in place of valve.
(3) Position drain pan under cooler pressure line to
catch material flushed through cooler and lines.(4) Reverse flush cooler using hand operated suc-
tion gun filled with mineral spirits. Insert gun nozzle
(or hose) into cooler return line. Then force mineral
spirits into line and through cooler.
(5) Continue reverse flushing until fluid coming
out of cooler pressure line is clear.Replace cooler if
fluid cannot be pumped through.
(6) Clear flushing materials from cooler and lines
with short pulses of compressed air. Insert air gun
nozzle into cooler return line and continue short air
pulses until all fluid is cleared from cooler and lines.
(7) Pump one quart of fresh automatic transmis-
sion fluid through cooler and lines before reconnect-
ing lines.
(8) Install new drainback valve in pressure line.
(9) Check and adjust transmission fluid level as
described in this section.
Fig. 34 Cooler Line Fitting Identification (30RH/
32RH)
Fig. 35 Cooler Line Routing (YJ)
21 - 114 30RH/32RH IN-VEHICLE SERVICEJ

AW-4 AUTOMATIC TRANSMISSION
CONTENTS
page page
AW-4 AUTOMATIC TRANSMISSION........ 165
AW-4 IN-VEHICLE SERVICE.............. 182
AW-4 TRANSMISSION DIAGNOSIS......... 176
AW-4 TRANSMISSION OVERHAUL......... 201AW-4 TRANSMISSION REMOVAL AND
INSTALLATION....................... 198
GENERAL INFORMATION................ 165
GENERAL INFORMATION
INDEX
page page
Components and Operation................. 166
Description............................. 165
First/Second/Third/Reverse Components....... 168
Fourth Gear Overdrive Components.......... 167
Geartrain Operation and Application Charts..... 169Hydraulic System........................ 169
Recommended Fluid and Capacity........... 166
Torque Converter........................ 167
Transmission Identification.................. 166
Transmission Ranges and Shift Lever Positions . . 166
DESCRIPTION
AW-4 Transmission Overhaul
The AW-4 is a 4-speed, electronically controlled au-
tomatic transmission (Fig. 1). The AW-4 is used in XJ
models with a 4.0L engine.
Running gear consists of an oil pump, planetary
gear sets, clutch and brake units, hydraulic accumu-
lators, a valve body with electrical solenoids and a
transmission control module (TCM). Cables are usedfor shift and throttle pressure control. A park/neutral
position switch permits engine starting in Park and
Neutral range only.
The valve body solenoids are controlled by signals
from the transmission control module (TCM). Signal
sequence is determined by vehicle speed and throttle
position.
Fourth gear is an 0.75:1 ratio overdrive range.
First, second, third and reverse gear are conventional
Fig. 1 AW-4 Automatic Transmission
JAW-4 AUTOMATIC TRANSMISSION 21 - 165