ABS JEEP CHEROKEE 1994 Service Repair Manual

(26) Press the tilt spring guide retainer inward.
Turn it counterclockwise until the tabs disengage
from the key/lock cylinder housing lugs. Ensure that
the screwdriver blade properly fits the retainer slot.
Remove the tilt spring guide retainer, the guide and
the spring from the housing (Fig. 9).
(27) Position the steering column in the center,
non-tilt position.
(28) Remove the support pivot pins with Pivot Pin
Remover C-4016 (J-21854-01) (Fig. 10).(29) Lift the tilt-release lever to release the lock
shoes. Pull the key/lock cylinder housing upward to
disengage the shoes. Turn the housing clockwise to
separate the lock rack from the remote rod. Remove
the cylinder housing from the support (Fig. 11).
(30) Remove the tilt-release lever from the key/
lock cylinder housing.
(31) Remove the lock sector spring retaining screw
and then remove the spring (Fig. 12). Rotate the
spring in a clockwise direction to remove it from the
lock bolt.
(32) Remove the lock bolt, the lock rack, the rack
preload spring and the remote rod from the cylinder
housing.
(33) Insert a wedge between the lock shoes and the
key/lock cylinder housing (Fig. 13). This will relieve
spring tension on the tilt-release lever pin and lock
shoe pin.
Fig. 7 Ignition Switch & Dimmer Switch
Fig. 8 Steering Shaft Bearing Race & Seat
Fig. 9 Retainer/Guide/Spring Removal
Fig. 10 Pivot Pin Removal
JSTEERING 19 - 61

(13) Install all support attaching screws finger-
tight. Next, tighten the screws alternately and evenly
to7Nzm (60 in. lbs.) torque.
(14) Install the remote rod in the support. Route
the rod through the upper end of the shroud and in-
sert it into the rod slot located in the support.
(15) Install the dimmer switch and ignition switch.
(16) Install the steering shaft in the steering col-
umn.
(17) Install replacement races and bearings in the
key/lock cylinder, if removed.Ensure that the bear-
ings are lubricated with chassis lubricant be-
fore installation.
(18) Install the lock shoes, the lock shoe springs
and the lock shoe pin the key/lock cylinder housing.
Use a 4.5-mm (0.18-in) diameter rod to align the
shoes and the pin during installation.
(19) Install the tilt-release lever, the lever spring
and the lever pin in the key/lock cylinder housing.
Insert a wedge between the housing and the lever to
relieve the spring tension. This will allow easier re-
lease lever pin installation.
(20) Install the lock bolt in the key/lock cylinder
housing and engage it in the lock sector cam surface.
(21) Install the lock rack, the rack preload spring
and a replacement shim in the key/lock cylinder
housing. Align and mate the square block tooth on
the lock rack and the lock sector.
(22) Install the lock spring and the spring retain-
ing screw. Tighten the screw to 4 Nzm (35 in. lbs.)
torque.
(23) Align and install the assembled key/lock cylin-
der housing on the support. Retain the lock shoes in
the disengaged position for easier housing installa-
tion.(24) Align the pivot pin holes in the housing with
those in the support. Insert the pivot pins.Press the
housing firmly downward when inserting the
pivot pins. This prevents damaging the holes in
the support.When the pivot pins are within both
the housing and the support holes, seat them fully
with a punch and a hammer.
(25) Insert tilt-release lever in key/lock cylinder
housing and place housing in the full-upward tilt po-
sition.
(26) Lubricate the tilt spring guide and the tilt
spring liberally with chassis lubricant and position
the spring on the guide.
(27) Insert the tilt spring guide and the spring into
the key/lock cylinder housing. Install the guide re-
tainer over the spring. Engage the retainer lock tabs
with the housing lugs by pressing the retainer down-
ward and turning clockwise with a screwdriver.
(28) Place the cover on the key/lock cylinder hous-
ing. Align and install the cover retaining screws.
Tighten the screws to 7 Nzm (60 in. lbs.) torque.
(29) Install the gear selector indicator lamp mount-
ing bracket screw.
(30) Install the gear selector indicator cover and
retaining screws.
(31) Route the dimmer switch wire harness and
gear selector indicator down through the steering col-
umn.
(32) To install ignition switch lock, turn the key to
the LOCK position and remove the key. This will
cause the buzzer operating lever to retract in the
key/lock cylinder. Now insert the key/lock cylinder
into the housing far enough to contact the drive
shaft. Force it inward and move the ignition switch
actuator rod up and down to align the components.
When the components align, the key/lock cylinder
will move inward and the spring-loaded retainer will
snap and lock it in place (Fig. 23).
(33) Insert the ignition key in the cylinder and
turn it to the ON position. Install the key warning
buzzer switch.
(34) Install the turn signal switch. Fold the wires
against the connector. Route the wire harness and
connector down through the steering column. Posi-
tion the switch in the key/lock cylinder housing.Do
notinstall the switch retaining screws at this time.
(35) Install the windshield wiper wire harness and
switch. Route the wire harness down through steer-
ing column jacket.
(36) If equipped, install the cruise control wire har-
ness. Install the turn signal stalk by pushing it
straight into the column.
(37) Insert the hazard warning knob in the hazard
warning switch and press it inward. Align and install
the turn signal switch retaining screws. Ensure that
the turn signal switch is properly seated before tight-
ening the screws. Tighten the screws to 4 Nzm
Fig. 22 Shift Tube Installation
JSTEERING 19 - 65

(9) Install replacement races and bearings in the
key/lock cylinder, if removed.Ensure that the bear-
ings are lubricated with chassis lubricant be-
fore installation.
(10) Install the lock shoes, the lock shoe springs
and the lock shoe pin the key/lock cylinder housing.
Use a 4.5-mm (0.18-in) diameter rod to align the
shoes and the pin during installation.
(11) Install the tilt-release lever, the lever spring
and the lever pin in the key/lock cylinder housing.
Insert a wedge between the housing and the lever to
relieve the spring tension. This will allow easier re-
lease lever pin installation.
(12) Install the lock bolt in the key/lock cylinder
housing and engage it in the lock sector cam surface.
(13) Install the lock rack, the rack preload spring
and a replacement shim in the key/lock cylinder
housing. The square block tooth on the lock rack and
lock sector must mate.
(14) Install the lock spring and the spring retain-
ing screw. Tighten the screw to 4 Nzm (35 in. lbs.)
torque.
(15) Align and install the assembled key/lock cylin-
der housing on the support. Retain the lock shoes in
the disengaged position for easier housing installa-
tion.
(16) Align the pivot pin holes in the key/lock cylin-
der housing with those in the support and insert the
pivot pins.Press the housing firmly downward
when inserting the pivot pins to prevent dam-
aging the holes in the support.When the pivot
pins are within both the housing and the support
holes, seat them fully with a punch and a hammer.(17) Insert the tilt-release lever in the key/lock cyl-
inder housing and place the housing in the full-up-
ward tilt position.
(18) Lubricate tilt spring guide and tilt spring lib-
erally with chassis lubricant. Then position spring on
guide.
(19) Insert the tilt spring guide and the spring into
the key/lock cylinder housing. Install the guide re-
tainer over the spring. Engage the retainer lock tabs
with the housing lugs by pressing the retainer down-
ward and turning clockwise with a screwdriver.
(20) Place the cover on the key/lock cylinder hous-
ing. Align and install the cover retaining screws.
Tighten the screws to 7 Nzm (60 in. lbs.) torque.
(21) Route the dimmer switch wire harness down
through the steering column.
(22) To install ignition switch lock, turn the key to
the LOCK position and remove the key. This will
cause the buzzer operating lever to retract in the
key/lock cylinder. Now insert the key/lock cylinder
into the housing far enough to contact the drive
shaft. Force it inward and move the ignition switch
actuator rod up and down to align the components.
When the components align, the key/lock cylinder
will move inward and the spring-loaded retainer will
snap and lock it in place (Fig. 26).
(23) Insert the ignition key in the cylinder and
turn it to the ON position. Install the key warning
buzzer switch.
(24) Install the turn signal switch. Fold the wires
against the connector. Route the wire harness and
connector down through the steering column. Posi-
tion the switch in the key/lock cylinder housing.Do
notinstall the switch retaining screws at this time.
Fig. 26 Key/Lock Cylinder
Fig. 25 Steering Column Support Installation
JSTEERING 19 - 67

able. It will be necessary to replace the retainer
if either bushing is scored, or worn.
Inspect the piston and retainer seal surfaces for
nicks or scratches. Minor scratches can be removed
with crocus cloth. However, replace the piston and/or
retainer if the seal surfaces are seriously scored.
FRONT CLUTCH ASSEMBLY
(1) Soak clutch discs in transmission fluid while
assembling other clutch parts.
(2) Install new seals on piston and in hub of re-
tainer. Be sure lip of each seal faces interior of clutch
retainer.
(3) Lubricate lips of piston and retainer seals with
liberal quantity of Door Eze, or petroleum jelly. Then
lubricate retainer hub, bore and piston with trans-
mission fluid.
(4) Install clutch piston in retainer (Fig. 61). Use
twisting motion to seat piston in bottom of retainer.
Do not attempt to push the piston straight in.
This could fold the seals over causing leakage
and clutch slip.
(5) Position spring in clutch piston (Fig. 62).(6) Position spring retainer on top of piston spring
(Fig. 63).Make sure retainer is properly in-
stalled. Small raised tabs should be facing up-
ward. Semicircular lugs on underside of retainer
are for positioning retainer in spring.
(7) Compress piston spring and retainer with Com-
pressor Tool C-3575-A (Fig. 64). Then install new
snap ring to secure spring retainer and spring.
(8) Install clutch plates and discs (Fig. 57). Install steel
plate then disc until all plates and discs are installed.
(9) Install pressure plate and waved snap ring
(Fig. 57).
(10) Check clutch plate clearance (Fig. 64). Clear-
ance should be 1.70 to 3.40 mm (0.067 to 0.134 in.).
If clearance is incorrect, clutch discs, plates pressure
plates and snap ring may have to be changed.
Fig. 59 Front Clutch Piston Retainer Check Ball Location
Fig. 60 Retainer Bushing Locations
Fig. 61 Front Clutch Piston Installation
Fig. 62 Clutch Piston Spring Installation
Fig. 63 Correct Spring Retainer Installed Position
J30RH/32RH TRANSMISSION OVERHAUL 21 - 127

(7) Remove front planetary rear thrust washer
from driving shell.
(8) Separate and remove driving shell, rear plane-
tary and rear annulus from output shaft (Fig. 78).
(9) Remove tabbed thrust washers from rear plan-
etary gear.(10) Remove snap ring that retains sun gear in
driving shell. Then remove sun gear, spacer and
thrust plates.
PLANETARY GEARTRAIN INSPECTION
Clean the planetary components in solvent and dry
them with compressed air.
Check sun gear and driving shell condition (Fig.
79). Replace the gear if damaged or if the bushings
are scored or worn. The bushings are not serviceable.
Replace the driving shell if worn, cracked or dam-
aged.
Replace planetary gear sets if gears, pinion pins, or
carrier are damaged in any way. Replace the annu-
lus gears and supports if either component is worn or
damaged.
Inspect the geartrain spacers, thrust plates, snap
rings, and thrust washers (Fig. 79). Replace any of
these parts that are worn, distorted or damaged. Do
not attempt to reuse these parts.
The planetary gear thrust washers are different
sizes. The large diameter washers go on the front
planetary and the smaller washers go on the rear
planetary. All the washers have four locating tabs on
them. These tabs fit in the holes or slots provided in
each planetary gear.
Inspect the output shaft carefully. Pay particular
attention to the machined bushing/bearing surfaces
on the shaft and the governor valve shaft bore at the
shaft rear.
Replace the output shaft if the machined surfaces
are scored, pitted, or damaged in any way. Also re-
place the shaft if the splines are damaged, or exhib-
its cracks at any location (especially at the governor
valve shaft bore).
The annulus gears can be removed from their sup-
ports if necessary. Just remove the snap rings and
separate the two parts when replacement is neces-
sary. In addition, the annulus gear bushings can be
replaced if severely worn, or scored. However it is
not necessary to replace the bushings if they only ex-
hibit normal wear. Check bushing fit on the output
shaft to be sure.
ASSEMBLING PLANETARY GEARTRAIN
(1) Lubricate output shaft and planetary compo-
nents with transmission fluid. Use petroleum jelly to
lubricate and hold thrust washers and plates in posi-
tion.
(2) Assemble rear annulus gear and support if dis-
assembled. Be sure support snap ring is seated and
that shoulder-side of support faces rearward (Fig.
80).
(3) Install rear thrust washer on rear planetary
gear (Fig. 79). Use enough petroleum jelly to hold
washer in place. Also be sure all four washer tabs
are properly engaged in gear slots.
Fig. 76 Front Planetary Snap Ring Removal
Fig. 77 Front Planetary And Annulus Gear
Disassembly
Fig. 78 Removing Driving Shell, Rear Planetary And
Rear Annulus
21 - 132 30RH/32RH TRANSMISSION OVERHAULJ

(4) Install rear annulus over and onto rear plane-
tary gear (Fig. 80).
(5) Install assembled rear planetary and annulus
gear on output shaft (Fig. 81). Verify that assembly
is fully seated on shaft.
(6) Install front thrust washer on rear planetary
gear (Fig. 82). Use enough petroleum jelly to hold
washer on gear. Be sure all four washer tabs are
seated in slots.(7) Install spacer on sun gear (Fig. 83).
(8) Install thrust plate on sun gear (Fig. 84). Note
that driving shell thrust plates are interchangeable.
Use either plate on sun gear and at front/rear of
shell.
(9) Hold sun gear in place and install thrust plate
over sun gear at rear of driving shell (Fig. 85).
(10) Position wood block on bench and support sun
gear on block (Fig. 86). This makes it easier to align
Fig. 79 Planetary Geartrain Components (30RH/32RH)
Fig. 80 Assembling Rear Annulus And Planetary
Gear
Fig. 81 Installing Rear Annulus And Planetary On
Output Shaft
J30RH/32RH TRANSMISSION OVERHAUL 21 - 133

(12) Install assembled driving shell and sun gear
on output shaft (Fig. 88).
(13) Install rear thrust washer on front planetary
gear (Fig. 89). Use enough petroleum jelly to hold
washer in place and be sure all four washer tabs are
seated.
(14) Install front planetary gear on output shaft
and in driving shell (Fig. 90).
(15) Install front thrust washer on front planetary
gear. Use enough petroleum jelly to hold washer in
place and be sure all four washer tabs are seated.
(16) Assemble front annulus gear and support, if
necessary. Be sure support snap ring is seated.
(17) Install front annulus on front planetary (Fig.
90).
(18) Position thrust plate on front annulus gear
support (Fig. 91).Note that plate has two tabs on
it. These tabs fit in notches of annulus hub.(19) Install thrust washer in front annulus (Fig.
92).Align flat on washer with flat on planetary
hub. Also be sure washer tab is facing up.
(20) Install front annulus snap ring (Fig. 93). Use
snap ring pliers to avoid distorting ring during in-
stallation. Also be sure ring is fully seated.
Fig. 88 Installing Assembled Sun Gear And Driving
Shell On Output Shaft
Fig. 89 Installing Rear Thrust Washer On Front
Planetary Gear
Fig. 90 Installing Front Planetary And Annulus
Gears
Fig. 91 Positioning Thrust Plate On Annulus
Support
Fig. 92 Installing Front Annulus Thrust Washer
J30RH/32RH TRANSMISSION OVERHAUL 21 - 135

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.
(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.
Fig. 2 Transmission Control Module Location And
Mounting (Left Hand Drive)
Fig. 3 Transmission Control Module Location And
Mounting (Right Hand Drive)
Fig. 4 Park/Neutral Position Switch Terminals And
Testing
Fig. 5 Park/Neutral Position Switch Removal/
Installation
21 - 174 AW-4 IN-VEHICLE SERVICEJ

(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.
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).
Fig. 8 Solenoid Wire Connectors
Fig. 9 Transmission Valve Body Solenoids
Fig. 6 Park/Neutral Position Switch Adjustment
Fig. 7 Oil Screen Removal/Installation
JAW-4 IN-VEHICLE SERVICE 21 - 175

AW-4 TRANSMISSION REMOVAL AND INSTALLATION
INDEX
page page
Oil Pump Seal Replacement............... 189
Torque Converter Stator Clutch Inspection..... 189Transmission and Torque Converter Installation . 190
Transmission and Torque Converter Removal . . 189
TRANSMISSION AND TORQUE CONVERTER
REMOVAL
(1) Raise vehicle.
(2) Drain transmission fluid and reinstall oil pan
drain plug.
(3) Remove upper half of transmission fill tube
(Fig. 50).
(4) Disconnect cooler lines at transmission. Cooler
lines have quick-disconnect fittings. Press fitting re-
lease tabs and pull cooler lines and fittings out of
case or use Special Tool 7555 to disconnect them.
(5) Support engine with safety stand and support
transmission with jack.
(6) Disconnect transmission and transfer case shift
linkage.
(7) Remove necessary exhaust components.
(8) Disconnect vehicle speed sensor wires
(9) Mark position of front and rear propeller shafts
for alignment reference. Then remove shafts from ve-
hicle.
(10) Remove rear crossmember.
(11) Disconnect transmission shift cable at trans-
mission. Then disconnect transmission throttle valve
cable at engine.(12) Disconnect necessary vacuum and fluid hoses.
(13) Remove transfer case from transmission.
(14) Disconnect and remove crankshaft position
sensor.
CAUTION: The crankshaft position sensor can be
damaged if the sensor is still in place when the
transmission is removed. To avoid damage, remove
the sensor before transmission removal.
(15) Remove starter motor.
(16) Remove bolts attaching converter to drive
plate.
(17) Remove bolts attaching converter housing to
engine.
(18) Secure transmission to jack with safety
chains.
(19) Pull transmission rearward for access to con-
verter. Then secure converter in pump with C-clamp
or strap bolted to converter housing.
(20) Remove transmission from under vehicle.
(21) Remove torque converter if converter or oil
pump seal are to be serviced.
TORQUE CONVERTER STATOR CLUTCH
INSPECTION
(1) Insert Rotating Tool 7547 into converter hub
and seat tool in one-way clutch (Fig. 51).
(2) Insert Stopper Tool 7548 in one converter hub
notch and into outer race of rotating tool.
(3) Turn rotating tool clockwise. Converter clutch
should rotate freely and smoothly. Less than 2.5 Nzm
(22 in. lbs.) of torque should be required to rotate
clutch in clockwise direction.
(4) Turn rotating tool in counterclockwise direction.
Converter clutch should lock.
(5)
Replace converter if clutch binds or will not lock.
OIL PUMP SEAL REPLACEMENT
(1) Remove converter.
(2) Remove old seal. Use blunt punch to collapse
seal and pry seal out of pump housing. Do not
scratch or damage seal bore.
(3) Lubricate lip of new seal with Mopar Mercon
transmission fluid and install seal in pump with tool
7549 (Fig. 52).
(4) Lubricate converter drive hub with Mopar Mer-
con transmission fluid.
Fig. 50 Two-Piece Transmission Fill Tube
JAW-4 TRANSMISSION REMOVAL AND INSTALLATION 21 - 189