1995 JEEP YJ transmission

(a) Install 4.0 mm (0.157 in.) thick plate first.
Rounded edge of plate must face upward.
(b) Install a disc followed by a plate until the re-
quired number of discs and plates are installed. Be
sure to install the stepped plate last with the flat
side of the plate facing the disc (Fig. 51).
(c) Confirm that four discs and three plates have
been installed.
(64) Install clutch pack snap ring (Fig. 52).(65) Coat thrust bearing race with petroleum jelly
and install it in oil pump (Fig. 53). Bearing race
outer diameter is 47.2 mm (1.858 in.) and inside di-
ameter is 28.1 mm (1.106 in.).
(66) Lubricate and install replacement O-ring on
oil pump body.
(67) Install oil pump in case. Align pump and case
bolt holes and carefully ease pump into place (Fig.
54).
CAUTION: Do not use force to seat the pump. The
seal rings on the stator shaft could be damaged if
they bind or stick to the direct clutch drum.
(68) Tighten oil pump bolts to 22 Nzm (16 ft. lbs.)
torque.
Fig. 49 Installing Overdrive Planetary And Clutch
Assembly
Fig. 50 Installing Input Shaft Thrust Bearing And
Race Assembly
Fig. 51 Installing Overdrive Clutch Pack
Fig. 52 Installing Clutch Pack Snap Ring
JAW-4 TRANSMISSION OVERHAUL 21 - 277

(69) Verify input shaft rotation. Shaft should rotate
smoothly and not bind.
(70) Lubricate and install new O-ring on transmis-
sion throttle cable adapter and install cable in case
(Fig. 55).
(71) Check clutch and brake operation. Operate
clutches and brakes with compressed air applied
through feed holes in case (Fig. 56). Listen for clutch
and brake application. If you do not hear a clutch or
brake apply, disassemble transmission and repair
fault before proceeding.It is necessary to block
the overdrive clutch accumulator feed hole No.
8 (Fig. 56) in order to check direct clutch oper-
ation.
(72) Lubricate and install new O-rings on accumu-
lator pistons (Fig. 57).
Fig. 53 Installing Oil Pump Thrust Race
Fig. 54 Installing Oil Pump
Fig. 55 Installing Transmission Throttle Cable
Fig. 56 Clutch And Brake Feed Hole Locations
21 - 278 AW-4 TRANSMISSION OVERHAULJ

(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
JAW-4 TRANSMISSION OVERHAUL 21 - 281

(99) Install retaining clamp for wire harness and
throttle cable (Fig. 69).
(100) Install torque converter.
(101) Verify that converter is seated by measuring
distance between converter housing flange and one of
the converter mounting pads (Fig. 70). Use straight-
edge and vernier calipers to measure distance. On
6-cyl. transmissions, distance should be 16.5 mm
(0.650 in.).
(102) Secure converter in transmission with
C-clamp or metal strapping. Do this before mounting
transmission on jack or moving transmission under
vehicle.(103) Install lower half of transmission fill tube (in-
stall upper half after transmission is in vehicle).
CAUTION: The transmission cooler and lines must
be reverse flushed if overhaul corrected a malfunc-
tion that generated sludge, metal particles, or
clutch friction material. The torque converter should
also be replaced if contaminated by the same mal-
function. Debris and residue not flushed from the
cooler and lines will flow back into the transmission
and converter. The result will be a repeat failure and
shop comeback.
Fig. 69 Installing Cable/Harness Clamps
Fig. 70 Checking Converter Installation
21 - 282 AW-4 TRANSMISSION OVERHAULJ

SHIFT LINKAGE ADJUSTMENT
(1) Shift transfer case into 4L position.
(2) Raise vehicle.
(3) Loosen lock bolt on adjusting trunnion (Figs. 3
and 4).
4) Be sure linkage rod slides freely in trunnion.
Clean rod and apply spray lube if necessary.
(5) Verify that transfer case range lever is fully en-
gaged in 4L position.
(6) Tighten adjusting trunnion lock bolt.
(7) Lower vehicle.
SHIFT LEVER REMOVAL (XJ)
(1) Shift transfer case into 4L.
(2) Raise vehicle.
(3) Loosen adjusting trunnion locknut and slide
shift rod out of trunnion (Fig. 4). If rod lacks enough
travel to come out of trunnion, push trunnion out of
torque shaft.
(4) Lower vehicle.
(5) Remove console. Refer to park brake section in
Group 5 for procedures.
(6) Remove screws attaching lever assembly to
floorpan and remove assembly and shift rod (if left
attached).
SHIFT LEVER INSTALLATION (XJ)
(1) If shift rod was not removed from lever assem-
bly, work rod down through floorpan opening. Then
position lever assembly on floorpan and install as-
sembly attaching screws.
(2) Install console.
(3) Raise vehicle.
(4) Connect trunnion to torque shaft arm. Or, slide
shift rod into trunnion on range lever. Be sure shift
rod slides freely in trunnion.
(5) Verify that range lever is in 4L position. Then
tighten trunnion lock bolt.(6) Lower vehicle and check transfer case shift op-
eration.
SHIFT LEVER REMOVAL (YJ)
(1) Shift transfer case into neutral.
(2) Remove shift lever knob and retaining nut.
Then remove shift lever boot and bezel.
(3) Raise vehicle
(4) Loosen lock bolt in adjusting trunnion and slide
shift rod out of trunnion (Fig. 3).
(5) Remove bolts/nuts attaching bracket and brace
assembly to transmission (Fig. 5).
(6) Remove shift lever and bracket as assembly.
(7) YJ shift lever assembly is serviceable. If any
assembly part must be replaced, remove pivot bolt,
lever pin E-clip, and lever pin and spring. Then dis-
assemble and replace necessary part (Fig. 6).
SHIFT LEVER INSTALLATION (YJ)
(1) Assemble lever components, if necessary. Lube
pivot bolt and pin with Mopar multi-mileage grease
before installation.
(2) Work shift lever upward into vehicle interior.
Then position lever and bracket assembly on trans-
mission and install attaching bolts/nuts.
(3) Place transfer case range lever in 4L position.
Then slide shift rod into trunnion and tighten lock
bolt.
Fig. 3 Adjusting Trunnion And Lock Bolt (YJ)
Fig. 4 Shift Linkage (XJ)
21 - 286 NP231 TRANSFER CASEJ

(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