1995 JEEP YJ manual transmission

MANUAL VALVE SHAFT OVERHAUL
(1) Cut shaft spacer sleeve in half with chisel and
remove it from lever and shaft (Fig. 2).
(2) Remove shift sector retaining pin with pin
punch (Fig. 3).
(3) Pull shaft out of case and remove manual lever.
(4) Carefully pry shaft seals from case.
(5) Lubricate new seals with petroleum jelly and
install them in case (Fig. 4).
(6) Install new spacer sleeve on shift sector (Fig.
5).(7) Install sector and sleeve on shaft and install
shaft in case.
(8) Align sector and sleeve and install new retain-
ing pin.
(9) Align notch in sleeve with depression in sector
and stake sleeve in two places. Be sure lever and
shaft rotate smoothly.
Fig. 1 Manual Valve Shaft Components
Fig. 2 Cutting Shaft Spacer Sleeve
Fig. 3 Removing/Installing Sector Retaining Pin
Fig. 4 Installing Manual Shaft Seals
JAW-4 TRANSMISSION OVERHAUL 21 - 215

OIL PUMP OVERHAUL
(1) Remove pump body O-ring (Fig. 1).
(2) Remove pump seal rings (Fig. 1).
(3) Remove bolts attaching stator shaft to pump
body and separate components.
(4) Remove drive gear and driven gear from pump
body (Fig. 1).
(5) Measure inside diameter of pump body bushing
with bore gauge or inside micrometer (Fig. 2). Diameter
should be maximum of 38.19 mm (1.5035 in.). Replace
pump body if bushing I.D. is greater than specified.
(6) Measure inside diameter of stator shaft bush-
ing (Fig. 2). Take measurements at front and rear of
bushing. Diameter should be maximum of 21.58 mm
(0.08496 in.) at front and 27.08 mm (1.0661 in.) at
Fig. 1 Oil Pump Components
Fig. 5 Installing Manual Shaft And Sector
Fig. 2 Checking Pump/Stator Shaft Bushings
21 - 216 AW-4 TRANSMISSION OVERHAULJ

REMOVING UPPER BODY FROM LOWER BODY
(1) Remove two-piece detent spring (Fig. 3). Note
position of spring sections for assembly reference.
(2) Remove manual valve from lower body (Fig. 4).
(3) Remove bolts attaching upper body to lower
body (Fig. 5).
(4) Carefully lift and remove upper body, plate and
gaskets from lower body (Fig. 6).
(5) Disassemble and overhaul upper and lower
body sections as outlined in following procedures.
LOWER BODY DISASSEMBLY
(1) Remove check valve and spring, pressure relief
valve and spring and ball check and seat from lower
body. Note location of each valve for assembly refer-
ence (Fig. 1).
Fig. 3 Removing/Installing Detent Spring
Fig. 4 Removing/Installing Manual Valve
Fig. 5 Valve Body Bolt Locations
Fig. 6 Upper Body, Plate And Gaskets
Fig. 1 Lower Body Check Valve And Strainer
Location
21 - 252 AW-4 TRANSMISSION OVERHAULJ

(6) Install manual valve (Fig. 4).
(7) Install two-piece detent spring (Fig. 5). Tighten
spring attaching bolt to 10 Nzm (7 ft. lbs.) torque.
Fig. 4 Installing Manual Valve
Fig. 5 Installing Detent Spring
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(11) Install second brake piston sleeve (Fig. 8).
Sleeve lip faces up and toward case front as shown.
(12) Install second brake drum gasket with In-
staller Tool 7544 (Fig. 9). Gasket depth is 43.7 mm
(1.720 in.).(13) Install park lock pawl, spring and pin (Fig.
10).
(14) Connect park lock rod to manual valve shift
sector (Fig. 11).
Fig. 8 Installing Second Brake piston Sleeve
Fig. 9 Installing Second Brake Drum Gasket
Fig. 10 Installing Park Lock Pin, Spring And Pawl
Fig. 11 Installing Park Lock Rod
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(73) Assemble and install accumulator pistons and
springs (Fig. 57).
(74) Install new check ball body and spring (Fig.
58).
(75) Position valve body on case (Fig. 59).(76) Install detent spring (Fig. 59).
(77) Align manual valve, detent spring and shift
sector (Fig. 59).
(78) Connect transmission throttle cable to throttle
valve cam (Fig. 60).
(79) Install and tighten valve body-to-case bolts to
10 Nzm (7 ft. lbs.) torque.
(80) Connect valve body solenoid wires to solenoids
(Fig. 61).
(81) Install new O-ring on solenoid harness
adapter and secure adapter to case.
(82) Install valve body oil tubes (Fig. 62). Tap
tubes into place with a plastic mallet. Be sure the
flanged tube ends and straight tube ends are in-
stalled as shown.
Fig. 57 Accumulator Piston And Spring Installation
Fig. 58 Installing Check Ball Body And Spring
Fig. 59 Aligning Manual Valve, Shift Sector And
Detent Spring
Fig. 60 Connecting Transmission Throttle Cable
JAW-4 TRANSMISSION OVERHAUL 21 - 279

(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
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