1995 JEEP YJ service

bind if misalignment occurs. Remove and repo-
sition governor body if necessary.
(9) Verify that shaft bore in governor body and out-
put shaft are aligned.
(10) Verify that governor valve will be indexed
with spotface in output shaft. Reposition valve, shaft
and body if necessary.
(11) Install an E-clip on one end of governor valve
shaft. Be sure rounded side of E-clip is facing out
(away from weight).
(12) Insert governor valve shaft through governor
weight. Be sure shaft slides freely in bore.
(13) Install governor valve on shaft and in gover-
nor body bore.
(14) Install remaining E-clip on governor valve
shaft. Be sure rounded side of E-clip is facing out
(away from valve).
(15) Install governor body-park gear snap rings
and washer on output shaft as follows:
(a) On models with single snap ring, install snap
ring. Be sure ring is seated in shaft.
(b) On models with thrust washer and two snap
rings, install thin snap ring first. Then install
thrust washer second, and thick snap ring last
(Fig. 14).
16(c) Verify correct position of snap rings.Be
sure flat side of each snap ring is toward gov-
ernor body.(16) Tighten governor body-to-park gear bolts to 11
Nzm (95 in. lbs.).
(17) Install extension housing/adapter and gasket
on transmission. Tighten housing/adapter bolts to 32
Nzm (24 ft. lbs.).
(18) Install transfer case and rear crossmember.
(19) Install speed sensor and speedometer compo-
nents and connect speed sensor wires.
(20) Connect exhaust components and brake cable,
if removed.
(21) Align and connect propeller shafts. Tighten
clamp bolts to 19 Nzm (14 ft. lbs.) torque.
(22) Remove supports and lower vehicle.
(23) Check and adjust transmission fluid level.
PARK LOCK COMPONENT REPLACEMENT
COMPONENT REMOVAL
(1) Raise vehicle and remove transfer case and
adapter housing from transmission.
(2) Slide sprag shaft out of adapter housing and re-
move park sprag and spring (Fig. 22).
(3) Remove snap ring and slide plug and pin as-
sembly out of housing (Fig. 22).
(4) If park rod must be serviced, remove valve
body and remove rod.
Fig. 21 Governor Components (30RH/32RH)
21 - 108 30RH/32RH IN-VEHICLE SERVICEJ

Inspection
Check the sprag shaft for scores and for free move-
ment in the housing and sprag.
Check the sprag and control rod springs for loss of
tension or distortion. Check the square lug on the
sprag for broken edges. Check the lugs on the gover-
nor support (park gear) for broken edges. Replace
any park lock components that are worn or damaged.
Check the knob on the end of the control rod for
nicks, burrs and free turning. Replace the rod if the
knob is grooved, or worn, or if the rod is bent. The
park lock rods used in Chrysler 3-speed transmis-
sions are different lengths. If the rod must be re-
placed, be sure to install the correct length and
shape rod.
COMPONENT INSTALLATION
(1) Install park lock rod on valve body.
(2) Install reaction plug and pin assembly in the
housing and install the snap ring.
(3) Position sprag and spring in housing and in-
stall sprag shaft. Be sure square lug on sprag is fac-
ing park gear and that spring is positioned so it
moves sprag away from park gear.
(4) Install valve body.
(5) Install adapter housing and transfer case.
PARK/NEUTRAL POSITION SWITCH SERVICE
The starter feed circuit of the switch is through the
switch center terminal (Fig. 23). It provides a ground
for the starter solenoid circuit through the gearshift
lever in park and neutral only.
The two outer terminals of the park/neutral posi-
tion switch are for the backup lamp switch circuit.
SWITCH TEST PROCEDURE
(1) Remove wiring connector from switch.
(2) Test continuity between switch center terminal
and transmission case. Continuity should exist onlywhen transmission is in Park or Neutral. Replace
switch if continuity occurs in any gear other than
Park or Neutral.
(3) Shift into reverse and test continuity between
two outside terminals on switch. Continuity should
exist only when transmission is in reverse.
(4) Leave transmission in reverse and test continu-
ity between each switch outer terminal and transmis-
sion case. Continuity should not exist between either
pin and case in reverse.
(5) If switch tests OK, check gearshift linkage ad-
justment or backup light circuit. Replace switch if it
fails continuity tests.
SWITCH REPLACEMENT
(1) Position drain pan under neutral switch.
(2) Disconnect switch wires.
(3) Remove switch from transmission.
(4) Move shift lever to Park and Neutral positions.
Inspect manual lever fingers, lever and shaft for
proper alignment with switch opening in case. Re-
place lever if worn or bent. Do not attempt to
straighten the lever.
(5) Install new switch and seal in case. Tighten
switch to 33 Nzm (24 ft. lbs.) torque.
(6) Adjust transmission fluid level as required.
(7) Verify switch operation.
SPEEDOMETER SERVICE
Rear axle gear ratio and tire size determine speed-
ometer pinion requirements. If the pinion must be re-
placed, refer to the parts catalogue information for
the correct part. It is important for speedometer ac-
curacy that the pinion have the correct number of
teeth.
The speedometer assembly used in XJ models is
the new unit type (one-piece) speed sensor (Fig. 24).
However, YJ models may be equipped with either the
new unit style, or the older style that has a two-piece
Fig. 22 Park Lock ComponentsFig. 23 Park/Neutral Position Switch And Manual
Lever
J30RH/32RH IN-VEHICLE SERVICE 21 - 109

speed sensor and metal adapter (Fig. 25). Service
procedures for both styles are described in the follow-
ing procedures.
SPEEDOMETER ASSEMBLY REMOVAL (WITH
UNIT STYLE SENSOR)
(1) Raise vehicle.
(2) Disconnect wires from vehicle speed sensor.
(3) Remove adapter clamp and screw (Fig. 24).
(4) Remove speed sensor and speedometer adapter
as assembly.
(5) Remove speed sensor retaining screw and re-
move sensor from adapter.
(6) Remove speedometer pinion from adapter.
(7) Inspect sensor and adapter O-rings (Fig. 24).
Remove and discard O-rings if worn or damaged.
(8) Inspect terminal pins in vehicle speed sensor.
Clean pins with Mopar electrical spray cleaner if
dirty or oxidized. Replace sensor if faulty, or pins are
loose, severely corroded, or damaged.
SPEEDOMETER INSTALLATION AND
INDEXING (UNIT STYLE)
(1) Thoroughly clean adapter flange and adapter
mounting surface in housing. Surfaces must be clean
for proper adapter alignment and speedometer oper-
ation.
(2) Install new O-rings on speed sensor and speed-
ometer adapter if necessary (Fig. 25).
(3) Lubricate sensor and adapter O-rings with
transmission fluid.
(4) Install vehicle speed sensor in speedometer
adapter. Tighten sensor attaching screw to 2-3 Nzm
(15-27 in. lbs.) torque.(5) Install speedometer pinion in adapter.
(6) Count number of teeth on speedometer pinion.
Do this before installing assembly in housing. Then
lubricate pinion teeth with transmission fluid.
(7) Note index numbers on adapter body (Fig. 25).
These numbers will correspond to number of teeth on
pinion.
(8) Install speedometer assembly in housing.
(9) Rotate adapter until requiredrange numbers
are at 6 o-clock position. Be sure range index
numbers correspond to number of teeth on pin-
ion gear.
(10) Install speedometer adapter clamp and retain-
ing screw. Tighten clamp screw to 10-12 Nzm (90-110
in. lbs.) torque.
(11) Connect wires to vehicle speed sensor.
(12) Lower vehicle and top off transmission fluid
level if necessary.
SPEEDOMETER COMPONENT REMOVAL
(TWO-PIECE SENSOR)
(1) Raise vehicle.
(2) Disconnect speed sensor wires.
(3) Remove bolt attaching vehicle speed sensor to
sensor adapter. Then slide sensor out of adapter.
(4) Inspect speed sensor mounting area in sensor
adapter. If transmission fluid is found in this area,
oil seal in metal speedometer adapter is leaking and
will have to be replaced.
(5) Remove speedometer adapter clamp bolt and
remove clamp (Fig. 26).
(6) Remove speedometer adapter, sensor adapter
and speedometer pinion as assembly.
Fig. 24 Speedometer Components (With Unit Style Sensor)
21 - 110 30RH/32RH IN-VEHICLE SERVICEJ

SPEEDOMETER COMPONENT INSTALLATION
AND INDEXING (TWO-PIECE SENSOR)
(1) Replace speedometer O-ring if cut, torn, or
worn.
(2) If oil seal in metal speedometer adapter needs
replacement, remove old seal with pointed tool. Then
install new seal with Special Tool C-4004. Push seal
into place with tool until tool bottoms (Fig. 27).
(3) Clean speedometer adapter mounting surface of
transmission, or transfer case thoroughly.
(4) Lubricate adapter seals with transmission
fluid.
(5) Count number of teeth on speedometer pinion.
Do this before installing pinion and adapter.(6) Note range numbers on face of speedometer
adapter (Fig. 27). These numbers correspond to num-
ber of teeth on speedometer pinion.
(7) Install pinion in adapter and install assembled
pinion and adapter in transmission or transfer case.
(8) Rotate speedometer adapter until required
range numbers are at 6 o'clock position (Fig. 28).
Verify that range numbers correspond to num-
ber of teeth on pinion.
(9) Push speedometer adapter into place until
seated.
(10) Install speedometer adapter clamp and bolt.
Tighten bolt to 11 Nzm (100 in. lbs.) torque.
(11) Install sensor adapter on speedometer
adapter. Tighten sensor adapter coupling nut to 17
Nzm (150 in. lbs.) torque.
(12) Carefully align and insert vehicle speed sensor
into sensor adapter.
(13) Install bolt that attaches speed sensor to
adapter. Tighten bolt to 5-8 Nzm (48-72 in. lbs.)
(14) Connect wires to speed sensor.
(15) Lower vehicle.
(16) Check top off transmission fluid level if neces-
sary.
TRANSMISSION COOLER LINE AND FITTING
SERVICE
The transmission cooler lines are attached with
quick connect fittings. Two types of fitting will be
used.
Fig. 25 Location Of Index Numbers On Speedometer
Adapter (Unit Style Sensor)
Fig. 26 Speedometer Components (With Two-Piece
Sensor)
Fig. 27 Installing Speedometer Adapter Seal (With
Two-Piece Sensor And Metal Adapter)
Fig. 28 Indexing Speedometer Adapter (With
Two-Piece Sensor)
J30RH/32RH IN-VEHICLE SERVICE 21 - 111

Early production models will have the type 2 fit-
ting used previously. This fitting requires a release
tool to disconnect the cooler line from the fitting (Fig.
29). Later production models will have a new style
fitting that does not require any type of release tool.
This fitting has a plastic insert with built-in release
tabs (Fig. 30).
Cooler Line And Fitting Service
The cooler lines and fittings are only serviceable as
assemblies. Damaged fittings or cooler lines are to be
replaced. Fittings swedged into cooler line hoses (Fig.
31) are serviced only as part of the entire cooler hose.
DISCONNECTING COOLER LINES WITH TYPE
2 FITTING
(1) If fitting and cooler line are encrusted with
dirt, mud, or grease, clean fitting and cooler line with
Mopar spray type carburetor or brake cleaner. Plastic
release tool will not fit into retainer clip if fitting is
full of foreign material.
(2) Slide small plastic release tool into fitting until
tool bottoms against cooler line flange (Fig. 29).
(3) Push and turn release tool to spread retainer
clip and pull cooler line out of fitting (Fig. 29).
(4) Cover open ends of cooler lines and fittings to
prevent dirt entry.
(5) Inspect condition of fitting. Replace transmis-
sion fitting as an assembly if fitting body or retainerclip is damaged. Replace cooler line as assembly, if
fitting swedged into cooler line hose, is damaged.
DISCONNECTING COOLER LINES WITH NEW
STYLE FITTING
The new style fittingdoes notrequire any kind of
release tool. The fitting inserts have built-in release
tabs that only require finger pressure to release
them.
The new style fitting insert is unique. The insert
does not stay in place inside the fitting when re-
leased. Instead, the insert remains on the line and
does not have to be removed.
To release a new style fitting, simply squeeze the
insert tabs (Fig. 32) and disconnect the line. The in-
sert will remain in place on the line, or fitting and
does not have to be removed (Fig. 33).
Fig. 30 New Style Quick Connect Fitting With Insert
Fig. 29 Disconnecting Cooler Line With Release
Tool (Type 2 fitting)
Fig. 31 Cooler Line Fitting Placement
Fig. 32 Releasing Cooler Line From New Style
Fitting
21 - 112 30RH/32RH IN-VEHICLE SERVICEJ

CONNECTING COOLER LINES AND FITTINGS
(ALL TYPES)
(1) Wipe cooler line and fitting clean with shop
towel.
(2) Insert cooler line into fitting. Then push line
inward until retainer or insert secures line. A snap or
click sound will be heard when the insert tabs or re-
tainer clip seats behind the cooler line flange.
(3)Pull outward on cooler lines/fittings to
verify they are properly secured.
CAUTION: The wire retainer clips or insert release
tabs secure the cooler lines. If the clips or tabs are
deformed, distorted, or not fully seated, normal
fluid pressure could unseat the lines resulting in
fluid loss and transmission damage. Be very sure
the cooler lines are firmly secured as described in
step (3).
CONVERTER DRAINBACK CHECK VALVE SERVICE
The converter drainback check valve is located in
the cooler outlet (pressure) line near the radiator
lower tank. The valve prevents fluid drainback when
the vehicle is parked for lengthy periods. The valve
check ball is spring loaded and has an opening pres-
sure of approximately 2 psi. Refer to the cooler flow
test procedure for valve testing.
The valve is serviced as an assembly; it is not re-
pairable. Do not clean the valve if restricted, or con-
taminated by sludge, or debris. If the valve fails, or if
a transmission malfunction occurs that generates
sludge and/or clutch particles and metal shavings,
the valve must be replaced.
The valve must be removed whenever the cooler
and lines are reverse flushed. The valve can be flow
tested when necessary. The procedure is exactly the
same as for flow testing a cooler.
If the valve is restricted, installed backwards, or in
the wrong line, it will cause an overheat condition
and possible transmission failure.
CAUTION: The drainback valve is a one-way valve.
As such, it must be properly oriented in terms of
flow direction. In addition, the valve must only beinstalled in the pressure line. Otherwise flow will be
blocked causing overheat and eventual transmis-
sion failure.
TRANSMISSION COOLER FLOW TESTING
The transmission main and auxiliary coolers, plus
the drainback valve, should be flow tested whenever
fluid overheating is noted.
Restricted flow caused by contamination, or a
cooler malfunction, reduces lubrication fluid flow
throughout the transmission. This can result in fluid
overheating, fluid breakdown, bushing wear, shift
problems and component failure.
Normal color of transmission fluid varies from
bright red, to light pink. Fluid overheating is indi-
cated when fluid color ranges from orange-brown to
black, and the fluid smells burned, or contains
sludge.
CAUTION: If a transmission malfunction contami-
nates the fluid with clutch disc and metal particles,
the cooler and lines must be reverse flushed thor-
oughly. Flushing will prevent sludge and particles
from flowing back into the transmission and con-
verter after repair.
Cooler flow is tested by measuring the amount of
fluid pumped through the cooler in a specified time
by the transmission oil pump.The same flow test
procedure is used for the drainback valve, main
cooler, and auxiliary cooler.
Cooler And Drainback Valve Flow Test Procedure
(1) Test flow throughdrainback valveas follows:
(a) Add extra quart of ATF Plus to transmission.
(b) Disconnect pressure line at radiator fitting, or
at drainback valve and position hose or valve end
in one quart test container.
(c) Shift transmission into neutral, run engine at
idle speed for 20 seconds, and note flow from valve.
Use stopwatch to check test time.
(d) Replace drainback valve if flow is less than
one quart in 20 seconds, is intermittent, or does
not flow at all.
(e) Connect pressure hose to radiator fitting and
proceed to cooler flow test.
(2) Test flow throughmain cooleras follows:
(a) Disconnect cooler return (rear) line at trans-
mission and place it in one quart test container.
(b) Add extra quart of fluid to transmission.
(c) Shift transmission into neutral, run engine at
idle speed for 20 seconds, and note flow from valve.
Use stopwatch to check test time.
(d) Replace cooler if fluid flow is less than one
quart in 20 seconds, is intermittent, or does not
flow at all.
Fig. 33 New Style Fitting Insert (On Cooler Line)
J30RH/32RH IN-VEHICLE SERVICE 21 - 113

(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

30RH/32RH TRANSMISSION REMOVAL AND INSTALLATION
INDEX
page page
ConverterÐPump SealÐDrive Plate Service.... 116
Transmission and Converter Installation........ 117Transmission and Converter Removal......... 115
TRANSMISSION AND CONVERTER REMOVAL
(1) Remove fan shroud attaching bolts.
(2) Disconnect transmission fill tube at upper
bracket.
(3) Raise vehicle.
(4) Remove inspection cover from converter hous-
ing and remove skid plate for access, if necessary.
(5) Remove transmission fill tube and fill tube O-
ring.
(6) Remove starter motor.
(7) Mark propeller shafts and axle yokes for align-
ment reference.
(8) Disconnect propeller shafts at yokes. Secure
shafts to frame rails with wire.
(9) Disconnect exhaust pipes at exhaust manifolds,
if necessary.
(10) Drain transfer case lubricant, if transfer case
will also be serviced.
(11) Disconnect vehicle speed sensor wires.
(12) Disconnect transfer case shift linkage.
(13) Disconnect gearshift cable/linkage and throttle
valve cable at transmission levers.
(14) Disconnect transfer case vent hose. Then dis-
connect indicator switch wires on XJ, or vacuum
switch harness on YJ.
(15) Remove wire harness from clips on transfer
case.
(16) Remove transfer case attaching nuts and re-
move transfer case. Use transmission jack or helper
to support and remove transfer case.
(17) Disconnect park/neutral position switch wires.
(18) Disconnect and remove crankshaft position
sensor (Figs. 1 and 2). Retain sensor bolt (or bolts)
for reinstallation.
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.
(19) Remove wire harnesses from clips/tie straps
on transmission.
(20) Remove converter housing access cover and
mark drive plate and converter for alignment refer-
ence.
(21) Remove bolts attaching converter to drive
plate.(22) Support engine with support stand.
(23) Support transmission with transmission jack.
Secure transmission to jack with safety chain.
Fig. 1 Crankshaft Position Sensor (2.5L)
Fig. 2 Crankshaft Position Sensor (4.0L YJ)
J30RH/32RH TRANSMISSION REMOVAL AND INSTALLATION 21 - 115