JEEP XJ 1995 Service And Repair Manual

(3) Apply parking brakes and turn off air condi-
tioning unit.
(4) Shift transfer case into 2H range.
(5) Start engine and check curb idle speed. Adjust
speed if necessary. Curb idle must be correct to en-
sure accurate test results.
(6) Shift transmission into Neutral and set stop
watch.
(7) During following test steps, start stop watch as
soon as shift lever reaches D and Reverse ranges.
(8) Shift transmission into D range and record
time it takes for engagement. Repeat test two more
times.
(9) Reset stop watch and shift transmission back to
Neutral.
(10) Shift transmission into Reverse and record
time it takes for engagement. Repeat test two more
times.(11) Engagement time in D range should be a max-
imum of 1.2 seconds. Engagement time for Reverse
should be a maximum of 1.5 seconds.
TIME LAG TEST ANALYSIS
If engagement time is longer than specified for D
range, check for the following:
²shift cable misadjusted
²line pressure low
²forward clutch worn
²overdrive clutch worn or damaged
If engagement time is longer than specified for Re-
verse, check for the following:
²shift cable misadjusted
²line pressure low
²direct clutch worn
²first/reverse brake worn
²overdrive clutch worn or damaged
JAW-4 TRANSMISSION DIAGNOSIS 21 - 179

SERVICE DIAGNOSIS
21 - 180 AW-4 TRANSMISSION DIAGNOSISJ

SERVICE DIAGNOSIS
JAW-4 TRANSMISSION DIAGNOSIS 21 - 181

AW-4 IN-VEHICLE SERVICE
INDEX
page page
Accumulator Pistons and Springs............. 189
Adapter Housing Seal Replacement........... 191
Checking Fluid Level and Condition........... 182
Manual Valve Shaft Seal Replacement......... 187
Park Interlock Cable Adjustment............. 195
Park Rod and Pawl Service................. 190
Park/Neutral Position Switch................ 183
Refilling After Overhaul or Fluid/Filter Change . . . 182
Second Coast Brake Servo................. 190
Shift Cable Adjustment.................... 195
Speed Sensor........................... 192Speed Sensor RotorÐSpeedometer Drive Gear . . 193
Throttle Position Sensor (TPS) Service........ 193
Transmission Control Module (TCM) Service.... 183
Transmission Cooler Line Fittings............ 197
Transmission Cooler Service................ 196
Transmission Throttle Cable Adjustment........ 194
Transmission Throttle Cable Replacement...... 193
Transmission Valve Body Installation.......... 187
Transmission Valve Body Removal........... 186
Transmission Valve Body Solenoids........... 184
CHECKING FLUID LEVEL AND CONDITION
Recommended fluid for AW-4 transmissions is Mo-
par Dexron IIE/Mercon.
Mopar Dexron II can also be used but only when
Mercon fluid is not available.
CHECKING FLUID LEVEL
(1) Be sure transmission fluid is at normal operat-
ing temperature. Normal operating temperature is
reached after approximately 15 miles (25 km) of op-
eration.
(2) Position vehicle on level surface. This is impor-
tant for an accurate fluid level check.
(3) Shift transmission through all gear ranges and
back to Park.
(4) Apply parking brakes.
(5) Verify that transmission is in Park.
(6) Wipe off dipstick handle to prevent dirt from
entering fill tube. Then remove dipstick and check
fluid level and condition.
(7) Correct fluid level isto FULL mark on dip-
stick when fluid is at normal operating temper-
ature(Fig. 1).
(8) If fluid level is low, top off level with Mopar
Dexron IIE/Mercon. Mopar Dexron II can be used but
only if Mercon is not available.Do not overfill
transmission. Add only enough fluid to bring
level to Full mark.
(9) If too much fluid was added, excess amount can
be removed with suction gun and appropriate diame-
ter plastic tubing. Tubing only has to be long enough
to extend into oil pan.
CHECKING FLUID CONDITION
Inspect the appearance of the fluid during the fluid
level check. Fluid color should range from dark red to
pink and be free of foreign material, or particles. If
the fluid is dark brown or black in color and smells
burnt, the fluid has been overheated and must be
changed.Transmission operation should also be checked if
the fluid is severely discolored and contains quanti-
ties of foreign material, metal particles, or clutch disc
friction material.
A small quantity of friction material or metal
particles in the oil pan is normal. The particles
are usually generated during the break-in pe-
riod and indicate normal seating of the various
transmission components.
REFILLING AFTER OVERHAUL OR FLUID/FILTER
CHANGE
The best way to refill the transmission after a fluid
change or overhaul is as follows:
(1) If transmission has been overhauled, install
transmission in vehicle.
(2) Remove dipstick and insert clean funnel in
transmission fill tube.
(3) Add following initial quantity of Mopar Dexron
IIE/Mercon to transmission:
(a) If fluid/filter change was performed, add4
pints (2 quarts)of fluid to transmission.
(b) If transmission was completely overhauled
and torque converter was replaced or drained, add
10 pints (5 quarts)of fluid to transmission.
(c) Remove funnel and install dipstick.
(4) Operate vehicle until fluid reaches normal op-
erating temperature.
(5) Apply parking brakes.
Fig. 1 Transmission Fluid Level
21 - 182 AW-4 IN-VEHICLE SERVICEJ

(6) Let engine run at normal curb idle speed, apply
service brakes. Then shift transmission through all
gear ranges and back to PARK (leave engine run-
ning).
(7) Remove dipstick and check fluid level. Add only
enough fluid to bring level to Full mark on dipstick.
Do not overfill.If too much fluid is added, excess
amount can be removed with suction gun and
plastic tubing. Tubing only has to be long
enough to extend into oil pan.
(8) When fluid level is correct, shut engine off, re-
lease park brake, remove funnel, and reseat dipstick
in fill tube.
TRANSMISSION CONTROL MODULE (TCM)
SERVICE
Use the DRB scan tool to diagnose transmission
control module function whenever a fault is sus-
pected. Replace the module only when the scan tool
indicates the module is actually faulty.
TRANSMISSION CONTROL MODULE
REPLACEMENT
The transmission control module is mounted under
the instrument panel. On left hand drive models, it is
at the driver side of the lower finish panel (Fig. 2).
On right hand drive models, it is at the passenger
side of the lower finish panel (Fig. 3).
To remove the module, disconnect the wire harness,
remove the mounting screws and remove the module
from the finish panel. Tighten the module mounting
screws securely after installation. Also be sure the
wire harness is not twisted, kinked or touching any
body panels.
PARK/NEUTRAL POSITION SWITCH
SWITCH TESTING
Test switch continuity with an ohmmeter. Discon-
nect the switch and check continuity at the connector
terminal positions and in the gear ranges indicated
in Figure 3. Switch continuity should be as follows:
²Continuity should exist between terminals B and
C with the transmission in Park and Neutral only
(Fig. 4).²Continuity should exist between terminals A and E
with the transmission in Reverse (Fig. 4).
²Continuity should exist between terminals A and
G with the transmission in third gear (Fig. 4).
²Continuity should exist between terminals A and
H with the transmission in first and/or second gear
(Fig. 4).
²Continuity should not exist in D position.
PARK/NEUTRAL POSITION SWITCH REMOVAL
(1) Raise vehicle.
(2) Disconnect switch wire harness connector.
(3) Pry washer lock tabs upward and remove
switch attaching nut and tabbed washer (Fig. 5).
(4) Remove switch adjusting bolt (Fig. 5).
(5) Slide switch off manual valve shaft.
PARK/NEUTRAL POSITION SWITCH
INSTALLATION AND ADJUSTMENT
(1) Disconnect shift linkage rod from shift lever on
left side of transmission.
Fig. 2 TCM Location (Left Hand Drive)
Fig. 3 TCM Location (Right Hand Drive)
Fig. 4 Park/Neutral Position Switch Terminals And
Testing
JAW-4 IN-VEHICLE SERVICE 21 - 183

(2) Rotate manual shift lever all the way rearward.
Then rotate lever forward two detent positions to
Neutral.
(3) Install switch on manual valve shaft and in-
stall switch adjusting bolt finger tight. Do not tighten
bolt at this time.
(4) Install tabbed washer on manual valve shaft
and install switch attaching nut. Tighten nut to 6.9
Nzm (61 in. lbs.) torque but do not bend washer lock
tabs over nut at this time.
(5) Verify that transmission is in Neutral.
(6) Rotate switch to align neutral standard line
with vertical groove on manual valve shaft (Fig. 6).
(7) Align switch standard line with groove or flat
on manual valve shaft.
(8) Tighten switch adjusting bolt to 13 Nzm(9ft.
lbs.) torque.
(9) Bend at least two washer lock tabs over switch
attaching nut to secure it.
(10) Connect shift linkage rod to shift lever on left
side of case.
(11) Connect switch wires to harness and lower ve-
hicle.
(12) Check switch operation. Engine should start
in Park and Neutral only.
TRANSMISSION VALVE BODY SOLENOIDS
SOLENOID REMOVAL
(1) Remove transmission oil pan drain plug and
drain fluid.
(2) Remove pan bolts and remove oil pan.(3) Remove oil screen bolts and remove screen (Fig.
7) and gasket. Discard the gasket.
(4) Disconnect solenoid wire connector (Fig. 8).
(5) If all solenoids are being removed, mark or tag
wires for assembly reference before disconnecting
them.
(6) Remove bolt attaching solenoids to valve body
and remove solenoids (Fig. 9). Do not allow any valve
body components to fall out when solenoids are re-
moved.
(7) Clean oil filter and pan with solvent and dry
with compressed air.
(8) Remove old sealer material from oil pan and
transmission case.
Fig. 5 Park/Neutral Position Switch Removal/
Installation
Fig. 6 Park/Neutral Position Switch Adjustment
Fig. 7 Oil Screen Removal/Installation
21 - 184 AW-4 IN-VEHICLE SERVICEJ

Solenoid Testing
Test solenoid resistance with an ohmmeter. Con-
nect the ohmmeter leads to the solenoid mounting
bracket and to the solenoid wire terminal (Fig. 10).
Solenoid resistance should be 11-15 ohms. Replace
the solenoid if resistance is above or below the spec-
ified range.
SOLENOID INSTALLATION
(1) Position solenoids on valve body and install so-
lenoid bolts. Tighten bolts to 10 Nzm (7 ft. lbs.)
torque.
(2) Connect feed wires to solenoids.
(3) Install new gaskets on oil screen and install
screen. Tighten screen bolts to 10 Nzm (7 ft. lbs.)
torque.
(4) Apply bead of Loctite 599 sealer to oil pan seal-
ing surface. Sealer bead should be at least 3.0 mm
(1/8 in.) wide.(5) Install oil pan on transmission. Tighten pan
bolts to 7 Nzm (65 in. lbs.) torque.
(6) Install and tighten oil pan drain plug to 20 Nzm
(15 ft. lbs.) torque.
(7) Fill transmission with Mopar Dexron IIE/Mer-
con.
SOLENOID HARNESS ADAPTER SEAL
REPLACEMENT
(1) Remove oil pan and oil screen. Refer to Sole-
noid Removal procedure.
(2) Disconnect solenoid wire connectors (Fig. 8).
(3) Remove bracket securing solenoid harness
adaptor (Fig. 11) to case.
(4) Pull harness adapter and wires out of case.
(5) Remove and discard adapter O-ring.
Fig. 10 Testing Transmission Valve Body Solenoid
Fig. 11 Harness Adapter Removal/Installation
Fig. 8 Solenoid Wire Connectors
Fig. 9 Transmission Valve Body Solenoids
JAW-4 IN-VEHICLE SERVICE 21 - 185

(6) Lubricate new O-ring and install it on adapter.
(7) Install solenoid wire harness and adapter in
case.
(8) Install adapter bracket and bracket bolt.
(9) Connect wires to solenoids.
(10) Install oil screen and oil pan.
TRANSMISSION VALVE BODY REMOVAL
Removal and installation are the only valve body
service procedures covered in this section. Refer to
the transmission overhaul section for valve body dis-
assembly, cleaning, inspection and reassembly.
(1) Remove oil pan plug and drain transmission
fluid.
(2) Remove oil pan and oil screen. Clean pan and
screen in solvent and dry them with compressed air.
(3) Disconnect solenoid wire connectors (Fig. 8).
Mark wires for assembly reference.
(4) Remove valve body oil tubes (Fig. 12). Carefully
pry tubes out of valve body with screwdriver.
(5) Disconnect throttle cable from throttle cam
(Fig. 13).
(6) Remove valve body bolts. Bolt locations are out-
lined in Figure 14.
(7) Lower valve body and remove overdrive clutch
accumulator springs, direct clutch accumulator
springs and second brake accumulator spring (Fig.
15)
(8) Remove valve body and check ball and spring
(Fig. 16).
Fig. 13 Removing/Installing Throttle Cable
Fig. 14 Transmission Valve Body Bolt Locations
Fig. 15 Accumulator Springs
Fig. 12 Removing Transmission Valve Body Oil
Tubes
21 - 186 AW-4 IN-VEHICLE SERVICEJ

TRANSMISSION VALVE BODY INSTALLATION
(1) Connect cable to throttle cam (Fig. 13).
(2) Install check ball and spring (Fig. 16).
(3) Position accumulator springs and spacers on
valve body.
(4) Align valve body manual valve with shift sector
(Fig. 17) and carefully position valve body on case.
(5) Install valve body bolts (Fig. 14). Tighten bolts
evenly to 10 Nzm (7 ft. lbs.) torque.
(6) Install valve body oil tubes. Be sure tube ends
(L) and (M) are installed as shown in Figure 18.
(7) Remove old sealer material from oil pan and
transmission case.(8) Clean oil screen and oil pan with solvent (if not
done previously). Dry both components with com-
pressed air only. Do not use shop towels.
(9) Install new gaskets on oil screen and install
screen on case. Tighten screen attaching bolts to 10
Nzm (7 ft. lbs.) torque.
(10) Apply bead of Mopar or Loctite 599 sealer to
sealing surface of oil pan. Sealer bead should be at
least 3 mm (1/8 in.) wide. Then install oil pan and
tighten pan bolts to 7.4 Nzm (65 in. lbs.) torque.
(11) Install new gasket on oil pan drain plug and
install plug in pan. Tighten plug to 20 Nzm (15 ft.
lbs.) torque.
(12) Fill transmission with Mopar Dexron IIE/Mer-
con.
MANUAL VALVE SHAFT SEAL REPLACEMENT
Fig. 16 Removing/Installing Check Ball And Spring
Fig. 17 Shift Sector And Manual Valve Alignment
Fig. 18 Installing Transmission Valve Body Oil Tubes
Fig. 19 Manual Valve Shaft And Seals
JAW-4 IN-VEHICLE SERVICE 21 - 187

(1) Remove park/neutral position switch and dis-
connect transmission shift lever.
(2) Remove oil pan and valve body.
(3) Remove bolts attaching park rod bracket to
case (Fig. 20).
(4) Remove park rod from shift sector (Fig. 21).
(5) Cut spacer sleeve with chisel and remove it
from manual valve shaft (Fig. 22).
(6) Remove pin from shaft and sector with pin
punch.
(7) Remove shaft and sector from case.
(8) Pry shaft seals out of case (Fig. 23).(9) Inspect the manual valve shaft and sector. Re-
place either component if worn or damaged.
(10) Coat replacement shaft seals with petroleum
jelly and seat them in the case (Fig. 24).
(11) Install new spacer sleeve on sector (Fig. 25).
(12) Lubricate manual valve shaft with petroleum
jelly and install it in case.
(13) Lubricate sector and sleeve with petroleum
jelly and install them on shaft.
(14) Align hole in spacer sleeve with notch in sec-
tor. Then install shift sector roll pin. Tap pin into
sector and shaft and stake sleeve to sector and shaft
securely.
Fig. 20 Removing/Installing Park Rod Bracket
Fig. 21 Removing/Installing Park Rod
Fig. 22 Cutting Spacer Sleeve
Fig. 23 Removing Manual Valve Shaft Seals
21 - 188 AW-4 IN-VEHICLE SERVICEJ