JEEP CHEROKEE 1988 Service Repair Manual

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TR AN SM IS SIO N R EM OVA L & IN STA LLA TIO N - A /T

1988 J e ep C hero ke e
1988 Automatic Transmission Removal
JEEP
TRANSMISSION
ALL MODELS
Removal
1) Disconnect fan shroud and transmission fill tube upper
bracket. Raise vehicle. Remove converter inspection cover and fill
tube. Remove starter.
2) Mark drive shafts for reassembly. Disconnect shafts at
transfer case and wire to frame rails. DO NOT allow shafts to hang
free as damage to universal joints may result. On V8 models,
disconnect exhaust pipes from exhaust manifolds. Drain transfer case
lubricant. Disconnect speedometer cable from transmission.
3) Disconnect all shift and throttle linkages and wiring
from transmission and transfer case. Mark converter drive plate and
converter for reassembly and remove torque converter-to-drive plate
bolts. Rotate crankshaft to gain access to bolts.
4) Support transmission/transfer case assembly with jack and
secure with chain. Remove bolts and rear transmission crossmember.
Lower transmission enough to disconnect cooler lines at transmission.
Remove transmission-to-engine retaining bolts and slowly slide
transmission assembly away from engine.
5) Hold converter in position while lowering transmission
assembly from vehicle. Separate transmission from transfer case.
Installation
To install, reverse removal procedures. DO NOT tighten
exhaust pipe attaching bolts until crossmember has been installed and
transmission jack has been removed. Make sure all index marks made at
removal are aligned. Tighten all bolts to specification and fill
transmission and transfer case with fluid.
TORQUE SPECIFICATIONS
TIGHTENING SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Cooler Line Nuts ........................................... 25 (34)\
Torque Converter-to-Drive Plate Bolts ...................... 22 (30)\
Transfer Case-to-Transmission Bolts ........................ 40 (54)\
Transmission-to-Engine Bolts ............................... 30 (41)\









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\003
TR AN SM IS SIO N R EM OVA L & IN STA LLA TIO N - M /T

1988 J e ep C hero ke e
1988 MANUAL TRANSMISSION REMOVAL
Jeep
Cherokee, Comanche, Grand Wagoneer, Pickup, Wagoneer,
Wrangler
REMOVAL & INSTALLATION
TRANSMISSION
Removal
1) Remove screws attaching shift lever boot to floorpan.
Slide boot over lever. On models with T-176 transmission, press and
turn shift lever retainer counterclockwise to release lever.
2) Remove lever, boot, spring and seat as an assembly. On all
models, raise vehicle and support with safety stands. Disconnect rear
drive shaft from transfer case and wire out of way.
3) DO NOT allow shaft to hang free, as damage to universal
joint may result. Disconnect front parking brake cable at equalizer.
Remove rear cable clip from crossmember.
4) Place a jack under clutch housing to support engine.
Remove rear crossmember from frame. Disconnect speedometer cable,
back-up light switch wire and 4WD indicator switch wire.
5) Disconnect transfer case vent hose. Disconnect front drive
shaft and wire out of way. On Wrangler, remove transfer case shift
lever by removing shifter shaft retaining nut.
6) Remove cotter pins retaining shift control link pins in
shift rods and remove pins. Remove shifter shaft and disengage shift
lever from shift control links. Move lever out of the way.
NOTE: On some models, shifter shaft must be unthreaded from shift
lever in order to be removed. On other models, shaft can be
removed by sliding it out of lever.
7) Remove cotter pin and washers connecting link to shift
lever. Separate link from lever. Support transmission and transfer
case with jack.
8) Remove bolts securing transmission to clutch housing and
remove transmission and transfer case. Separate transfer case and
transmission.
Installation
1) Install pilot bushing lubricating wick and align throw out
bearing with splines in driven plate hub. Shift transmission into gear
using shift lever or a long screwdriver. This prevents clutch shaft
from rotating during installation and makes clutch shaft-to-driven
plate spline alignment easier.
2) Mount transmission on transmission jack. Raise
transmission and align transmission clutch shaft with splines in
driven plate hub.
3) When transmission is seated on clutch housing, install and
tighten transmission-to-clutch housing bolts. Apply Permatex No. 3
sealer to both sides of replacement transmission output shaft and
transfer case input shaft splines.
4) To install transmission, reverse removal procedure. Adjust
clutch and shift linkage.
TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS TABLE








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Application Ft. Lbs. (N.m)
Transmission-to-Clutch Housing ..................... 55 (75)
Transmission Cover Bolts ..................... 55-65 (75-88)
Housing-to-Transmission Case ................. 40-45 (54-61)
Crossmember Attaching Bolts .................. 34-40 (46-54)
Filler Plug .................................. 13-15 (18-20)









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TR AN SM IS SIO N S ER VIC IN G - A /T

1988 J e ep C hero ke e
1988 Automatic Transmission Servicing
JEEP
LUBRICATION
SERVICE INTERVALS
Transmission
Check fluid level and condition of fluid at each engine oil
change. Under normal, light duty operating conditions, change fluid,
replace filter and adjust bands every 2 yrs. or 25,000 miles. Under
heavy duty service, change fluid, replace filter and adjust bands
every 12 months or 12,500 miles.
Transfer Case
Check transfer case fluid every 12,000 miles and replace
fluid every 30,000 miles.
CHECKING FLUID LEVEL
Transmission
Park vehicle on a level surface and apply parking brake.
With engine idling at normal operating temperature, move transmission
selector lever through all gears, ending in "N" ("P" for AW-4
transmission). Check fluid level. Fluid level should be between
"FULL" and "ADD ONE PINT" mark on dipstick. Add fluid as needed. DO
NOT overfill.
Transfer Case
Remove fill plug. Check oil level. If level is not up to
fill plug opening, add lubricant until it is.
RECOMMENDED FLUID
Both transmissions and transfer cases use DEXRON-II ATF.
FLUID CAPACITY
NOTE: Transmission and converter capacities are approximate. Fluid
level should always be determined by reading on dipstick,
rather than amount of fluid added.
TRANSMISSION REFILL CAPACITIES









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Application Quantity
All Models
Including Converter ................................ 8.5 qts. (8.0L)\
Without Converter .................................. 4.3 qts. (4.0L)\









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TRANSFER CASE REFILL CAPACITIES








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Application Capacity
Model 207 ............................................ 4.5 pts. (2.1L)\
Model 208 ............................................ 6.0 pts. (2.8L)\

Model 228 ............................................ 7.0 pts. (3.3L)\
Model 229 ............................................ 6.0 pts. (3.8L)\









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DRAINING & REFILLING
Transmission
1) Loosen oil pan bolts, tap pan to break it loose and allow
fluid to drain. Remove pan. Install new filter on bottom of valve
body and tighten retaining screws. Install new "O" ring on fluid
pick-up pipe (if needed). Clean oil pan and install with new gasket.
2) Refill transmission with fluid. Start engine and allow to
run at curb idle for a few minutes. With vehicle on level surface,
engine idling and parking brake applied, move shift selector lever
through all gear ranges, ending in "N" ("P" for AW-4 transmission).
Add fluid up to "ADD ONE PINT" mark on dipstick.
3) Recheck fluid level when transmission reaches normal
operating temperature. Fluid should be between "ADD ONE PINT" and
"FULL" marks on dipstick. Transmission must NOT be overfilled.
Transfer Case
Remove drain plug from transfer case. Remove fill plug for
easier draining. With fluid fully drained, reinstall drain plug. Fill
transfer case to fill plug opening with Dexron II.
ADJUSTMENT
NOTE: Bands on the AW-4 (4-speed overdrive) transmission are not
adjustable. If slippage occurs, bands must be replaced.
KICKDOWN (FRONT) BAND
1) Locate kickdown band adjusting screw on left side of case
(near throttle lever shaft). Loosen adjusting screw lock nut and back
off approximately 5 turns. Ensure adjusting screw turns freely in
case.
2) Using Adapter (J-24063) and 5/16" square socket, tighten
screw to 36 INCH lbs. (4 N.m). If adapter is not used, tighten screw
to 72 INCH lbs. (8 N.m). Back off adjusting screw. See KICKDOWN
(FRONT) BAND ADJUSTMENT table. Hold adjusting screw in position and
tighten lock nut to 35 ft. lbs. (48 N.m).
KICKDOWN (FRONT) BAND ADJUSTMENT









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Application (1) Back Off Screw\
All Models ............................................... 2 1/2 Turns
(1) - Tighten screw to 72 INCH lbs. (8 N.m) and back off indicated
number of turns.









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LOW-REVERSE (REAR) BAND
1) Raise vehicle, drain transmission fluid and remove oil
pan. Locate adjusting screw on rear servo lever. Loosen adjusting
screw lock nut and back off about 5 turns.
2) Tighten screw to 41 INCH lbs. (4.6 N.m) and back off
screw at indicated number of turns. See LOW-REVERSE (REAR) BAND
ADJUSTMENT table. Hold adjusting screw in position and tighten lock
nut to 35 ft. lbs. (48 N.m). Install oil pan and fill transmission

with fluid.
LOW-REVERSE (REAR) BAND ADJUSTMENT









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Tighten Screw to Back Off
Application INCH Lbs. (N.m) Screw\
Model 727 ................. 41 (4.6 N.m.) .................... 2 Turns\
Model 904 ................. 41 (4.6 N.m.) .................... 7 Turns\
Model 999 ................. 41 (4.6 N.m.) .................... 4 Turns\









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TRANSMISSION THROTTLE CABLE/LINKAGE
NOTE: A special Idle Speed Actuator (ISA) Exerciser Box Tool is
required to initially set ISA motor and adjust transmission
throttle linkage on vehicles with transmission model 999
with 4-cylinder engines.
727 Transmission with 6-Cylinder Engines
1) Disconnect throttle control rod spring. Use spring to
hold transmission throttle control lever forward, against stop. Block
choke open and release fast idle cam.
2) On carburetors equipped with throttle operated solenoid
valve, turn key to "ON" position to energize solenoid. Open throttle
halfway to allow solenoid to lock. Return throttle to idle position.
3) Loosen retaining bolt on throttle control adjusting link.
DO NOT remove spring clip or nylon washer. Pull on end of link to
eliminate lash. Tighten link retaining bolt. Reconnect throttle
control rod spring.
727 Transmission with V8 engines
1) Disconnect throttle control rod spring. Use spring to
hold transmission throttle valve control lever against forward stop.
Block choke open and release fast idle cam.
2) On carburetors equipped with throttle operated solenoid
valve, turn key to "ON" position to energize solenoid. Open throttle
halfway to allow solenoid to lock. Return throttle to idle position.
3) Loosen retaining bolt on throttle control rod adjusting
link. Remove spring clip and slide nylon washer to rear of link. Push
on end of link to eliminate lash and tighten retaining bolt. Install
nylon washer and spring clip. Reconnect throttle control rod spring.
904 Transmission with 6-Cylinder Engines
1) Remove air cleaner. Hold throttle control lever rearward
against its stop. Block choke plate open and set carburetor linkage
completely off fast idle cam.
2) Unlock throttle control cable by lifting "T" shaped
adjuster clamp with small screwdriver. Move cable outer sheath
forward to remove any cable load on throttle cable bellcrank.
3) Adjust cable by moving cable and sheath rearward until
there is no lash between cable and throttle linkage. Lock cable by
pressing "T" shaped clamp downward until clamp snaps into place.
Install and reconnect any parts removed and/or disconnected.
999 Transmission with 4-Cylinder Engines
1) Raise vehicle. Using a spring, hook one end on throttle
control lever and other end on torque converter housing. Lower
vehicle.
2) Disconnect the ISA motor and connect Exerciser Box to
ISA. Adjustment light should turn off and ready light should turn on.
Press retrack button. Wait until ISA adjusts, ready light goes off
and adjust light goes on.

3) Loosen bolt on throttle control link. Pull on link end to
eliminate lash. Tighten adjusting bolt. Press extend button on
Exerciser Box. When ISA retracts, release button and disconnect
Exerciser Box. Connect ISA wiring and remove spring from throttle
control lever. Install and reconnect any parts removed and/or
disconnected.
999 Transmission with 6-Cylinder Engines
1) Disconnect throttle control rod spring. Use spring to
hold adjusting link in forward position, against nylon washer. Block
choke open and release fast idle cam.
2) Raise vehicle. Loosen both retaining bolts on adjusting
link clamp. DO NOT remove spring clip or nylon washer. Use a spare
spring to hold transmission throttle lever against forward stop.
3) Push adjusting link to eliminate lash and pull clamp to
rear so that bolt in rod bottoms in rear of slot in rod. Tighten
forward clamp retaining bolt.
4) Pull throttle control rod to the rear so that bolt in
rod bottoms in front of slot and tighten rear retaining bolt. Remove
spare spring. Lower vehicle and reconnect throttle control rod spring.
AW-4 Transmission with All Engines
1) With ignition off, retract cable self-adjusting mechanism
fully. Press cable button down and push cable plunger inward.
2) Rotate throttle lever to wide open throttle position.
While holding throttle lever in position, allow cable plunger to
extend. When plunger is fully extended, release throttle lever. Cable
is now adjusted.
SHIFT LINKAGE
Cable Linkage
1) Place gearshift lever in "P" position and raise vehicle.
Using a small screwdriver, unlock shift control cable by releasing
U-shaped cable adjuster clamp. Remove cable from mounting bracket.
2) Move transmission shift lever rearward until fully
seated into "P" detent. Ensure that driveshaft cannot be rotated.
Snap control cable into cable mounting bracket and replace U-shaped
cable adjuster clamp.
3) Lower vehicle and verify engine starting. Engine should
start only with shifter in "P" or "N" position.
Rod Linkage
1) Loosen shift rod trunnion jam nuts at transmission lever.
Remove shift rod-to-bellcrank lock pin. Disengage trunnion and shift
rod. Place selector lever in "P" position and lock steering column.
Move transmission shift lever to full rear Park position.
2) Adjust shift rod trunnion to obtain free pin fit in
bellcrank arm. Tighten jam nuts. On vehicles with shift lever on
column, make sure linkage lash is eliminated by pulling down on shift
rod and pushing up on outer bellcrank when tightening jam nuts.
3) Check steering column lock for ease of operation. Ensure
engine starts in "N" or "P", only. If starter engages in any drive
gear, or does not work in "N" or "P", check for proper shift linkage
adjustment or faulty neutral safety switch.
NEUTRAL SAFETY SWITCH
1) Switch combines functions of neutral safety switch and
back-up light switch. With transmission linkage properly adjusted,
switch should allow starter operation in "P" and "N" only.
2) To test switch, remove wire connector and test for
continuity between center pin of switch and case. Continuity should

only exist when transmission is in "P" or "N".
3) Check for continuity between 2 outer pins. Continuity
should exist with transmission in "R" only. There should be no
continuity between either outer pin and transmission case. If any of
these conditions are not met, the switch should be replaced.
4) To replace switch, unscrew from case. Move selector lever
to "P" and "N" positions and check that switch operating fingers are
centered in switch opening. Install switch and new seal in case.
Check fluid level and add as needed.

\003
TR AN SM IS SIO N S ER VIC IN G - M /T

1988 J e ep C hero ke e
1988 MANUAL TRANSMISSION SERVICING
Jeep
Cherokee, Comanche, Grand Wagoneer, Pickup, Wagoneer,
Wrangler
LUBRICATION
SERVICE INTERVALS
Transmission
Under normal driving conditions, check fluid level every 5000
miles or when serviced. Under severe driving conditions, check fluid
level every 3000 miles. Transmission lubricant should be changed at
27,500 mile intervals.
Transfer Case
Check transfer case fluid every 12,000 miles and replace
fluid every 30,000 miles.
CHECKING FLUID LEVEL
Transmission
Check lubricant level at transmission filler plug hole.
Lubricant should be level with bottom of hole. Add lubricant as
needed.
Transfer Case
Remove fill plug. Check oil level. If level is not up to fill
plug opening, add lubricant until it is.
RECOMMENDED FLUID
Transmission
Recommended lubricant for Jeep with manual transmission is
AMC/Jeep Manual Transmission Fluid (89 83 000 000) or 75W-90 GL-5 gear\
lubricant.
Transfer Cases
Transfer cases use DEXRON-II ATF.
FLUID CAPACITY
NOTE: Capacities given are approximate. Correct fluid level should
be determined by level at filler plug hole.
TRANSMISSION REFILL CAPACITIES









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Application Quantity
4-Speed
AX4 .......................... 7.4 pts. (3.5L)
T176 ......................... 3.5 pts. (1.7L)
5-Speed
AX5 .......................... 7.0 pts. (3.3L)
BA 10/5 ...................... 3.5 pts. (1.6L)









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TRANSFER CASE REFILL CAPACITIES