JEEP CHEROKEE 1994 Service Repair Manual

(16) Inspect the valve body springs. Replace any
spring having rusted, distorted, or collapsed coils.
Measure length of each spring. Replace any spring if
free length is less than specified in the chart (Fig.
14).
UPPER BODY ASSEMBLY
(1) Lubricate the valves, springs, plugs, sleeves
and the valve bores in the upper body with automatic
transmission fluid.
(2) Note position of the valve retainers (A) and
stop (B) for assembly reference (Fig. 15).
(3) Install low coast modulator valve, spring and
plug in valve bore. Press valve plug inward and in-
stall retainer (Fig. 13).(4) Install 2-3 shift valve, spring and plug in valve
bore. Press plug inward and install retainer (Fig. 12).
(5) Install cut-back valve spring, valve and plug
(Fig. 11). Press plug inward and install retainer.
(6) Install secondary regulator valve spring, valve
and plug in valve bore. Press plug inward and install
retainer (Fig. 10).
(7) Assemble lock-up relay valve. Install spring
and plunger in valve sleeve (Fig. 9). Then install as-
sembled valve in sleeve.
(8) Install assembled lock-up relay valve in valve
bore and install retainer (Fig. 8).
(9) Install second coast modulator valve, spring
and plug in valve bore. Press plug inward and install
retainer (Fig. 7).
(10) Install 3-4 shift valve, spring and plug in bore.
Press plug inward and install retainer (Fig. 6).
Fig. 14 Upper Body Spring/Valve Identification
21 - 250 AW-4 TRANSMISSION OVERHAULJ

(11) Install throttle valve in valve bore. Push valve
into place and install valve stop (Fig. 16).
(12) On models with adjusting rings, turn upper
body over and install adjusting rings (Fig. 17). Be
sure to install same number of rings as were re-
moved.
(13) Install throttle valve adjusting spring in bore
and onto end of throttle valve (Fig. 18).
(14) Install downshift spring and plug in throttle
valve bore. Press plug inward against throttle valve
and spring and install retainer pin (Fig. 19).
(15) Install sleeve in throttle cam (Fig. 20).
Fig. 15 Valve Retainer And Stop Locations
Fig. 16 Installing Throttle Valve And Stop
Fig. 17 Install Throttle Valve Adjusting Rings (If
Equipped)
Fig. 18 Installing Throttle Valve Adjusting Spring
Fig. 19 Installing Downshift Plug
JAW-4 TRANSMISSION OVERHAUL 21 - 251

(16) Install spring on cam (Fig. 20). Hook curved
end of spring through hole in cam as shown.
(17) Mount cam on upper body and install cam at-
taching bolt and spacer (Fig. 20). Tighten bolt to 10
Nzm (7 ft. lbs.) torque.
(18) Be sure straight end of spring is seated in up-
per body slot as shown (Fig. 20).
(19) Install check balls in upper body (Fig. 2).
(20) Install oil strainer (Fig. 2).
INSTALLING UPPER BODY ON LOWER BODY
If valve body was equipped with gaskets, start at
step (1). However, if valve body is not equipped with
gaskets, start at step (4).
(1) Position new No. 1 gasket (Fig. 1) on upper
body.(2) Position valve body plate on No. 1 gasket.
(3) Position new No. 2 gasket (Fig. 2) on valve
body plate and align gaskets and plate using bolt
holes as guides.
(4) Install valve body bolts.Three different
length bolts are used. Refer to the Figure 3 for
bolt locations. Chart symbols indicate bolt loca-
tion and length in millimeters.
(5) Tighten valve body bolts to 6.4 Nzm (56 in. lbs.)
torque.
(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. 20 Installing Throttle Cam
Fig. 1 Valve Body Gasket No. 1
Fig. 2 Valve Body Gasket No. 2
Fig. 3 Valve Body Bolt Location/Size
21 - 252 AW-4 TRANSMISSION OVERHAULJ

Fig. 5 Installing Detent Spring
Fig. 4 Installing Manual Valve
JAW-4 TRANSMISSION OVERHAUL 21 - 253

Fig. 1 AW-4 Transmission Components
21 - 254 AW-4 TRANSMISSION OVERHAULJ

TRANSMISSION ASSEMBLY AND ADJUSTMENT
(1) During assembly, lubricate components with
transmission fluid or petroleum jelly as indicated.
(2) If any of the transmission components are still
assembled after overhaul checking procedures, disas-
semble as necessary in preparation for transmission
assembly.
(3) Verify thrust bearing and race installation dur-
ing assembly. Refer to the Thrust Bearing Chart (Fig.
2) for bearing and race location and correct position-
ing.
Fig. 2 Thrust Bearing Chart
JAW-4 TRANSMISSION OVERHAUL 21 - 255

(4) Install rear planetary gear, second brake drum
and output shaft as outlined in following steps:
(5) Verify No. 10 thrust bearing and race (Fig. 2).
Bearing and race outer diameter is 57.7 mm (2.272
in.) and inside diameter is 39.2 mm (1.543 in.).
(6) Coat thrust bearing and race assembly with pe-
troleum jelly and install in case (Fig. 3). Race faces
down. Bearing rollers face up.
(7) Align teeth of second brake drum and clutch
pack (Fig. 4).(8) Align rear planetary-output shaft assembly
teeth with case slots and install assembly in case
(Fig. 5).
(9) Install rear planetary snap ring with snap ring
pliers. Chamfered side of snap ring faces up and to-
ward case front (Fig. 6).
(10) Check first-reverse brake pack clearance with
feeler gauge. Clearance should be 0.70 - 1.20 mm
(0.028 - 0.047 in.). If clearance is incorrect, planetary
assembly, thrust bearing or snap ring is not properly
seated in case. Remove and reinstall components if
necessary.
(11) Install second brake piston sleeve (Fig. 8).
Sleeve lip faces up and toward case front as shown.
Fig. 3 Installing Thrust Bearing And Race (No. 10)
Fig. 4 Aligning Second Brake Drum And Clutch
Pack Teeth
Fig. 5 Installing Output Shaft And Rear Planetary
Assembly
Fig. 6 Installing Planetary Snap Ring
21 - 256 AW-4 TRANSMISSION OVERHAULJ

(12) Install second brake drum gasket with Installer
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).
(15) Position park lock rod bracket on case and
tighten bracket attaching bolts to 10 Nzm (7 ft. lbs.)
torque (Fig. 12).
(16) Verify park lock operation. Move shift sector
to Park position. Park pawl should be firmly engaged
(locked) in planetary ring gear (Fig. 13).
Fig. 7 Checking First-Reverse Brake Pack Clearance
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
JAW-4 TRANSMISSION OVERHAUL 21 - 257

(17) Install No. 1 one-way clutch (Fig. 14). Short
flanged side of clutch faces up and toward case front.
(18) Install second brake pack (Fig. 15). Install
disc then plate. Continue installation sequence until
correct number of discs-plates are installed. Use five
discs and five plates.
(19) Install second brake pack retainer with
rounded edge of retainer facing disc.
(20) Install second brake pack snap ring.
(21) Check brake pack clearance with feeler gauge
(Fig. 16). Clearance should be 0.062 - 1.98 mm (0.024
- 0.078 in.). If brake pack clearance is not correct,
brake pack components are not seated. Reassemble
brake pack if necessary.
Fig. 14 Installing No. 1 One-Way Clutch
Fig. 12 Installing Park Rod Bracket
Fig. 13 Checking Park Pawl Engagement
Fig. 15 Installing Second Brake Pack
Fig. 16 Checking Second Brake Pack Clearance
21 - 258 AW-4 TRANSMISSION OVERHAULJ

(22) Install planetary sun gear and input drum
(Fig. 17). Be sure drum thrust washer tabs are
seated in drum. Use petroleum jelly to hold thrust
washer in position if necessary.
(23) Install front planetary gear on sun gear (Fig.
18).
(24) Support output shaft with wood blocks (Fig.
19).
(25) Install planetary snap ring on sun gear with
snap ring plier tool 7541 (Fig. 20).(26) Install tabbed thrust race on front planetary
gear (Fig. 21). Washer tabs face down and toward
gear. Race outer diameter is 47.8 mm (1.882 in.). In-
side diameter is 34.3 mm (1.350 in.).
(27) Install second coast brake band (Fig. 22).
(28) Install pin in second coast brake band. Then
install retaining ring on pin (Fig. 23).
(29) Install thrust bearing and race in forward-di-
rect clutch (Fig. 24). Coat bearing/race with petro-
leum jelly to hold them in place.
(30) Verify forward-direct clutch thrust bearing
size.
Fig. 17 Installing Sun Gear And Input Drum
Fig. 18 Installing Front Planetary Gear
Fig. 19 Supporting Output Shaft
Fig. 20 Installing Front Planetary Snap Ring
JAW-4 TRANSMISSION OVERHAUL 21 - 259