front JEEP CHEROKEE 1994 Service Repair Manual

30RH/32RH IN-VEHICLE SERVICE
INDEX
page page
Checking Fluid Level and Condition........... 96
Front Band Adjustment.................... 99
Gearshift Linkage Adjustment (YJ)............ 96
Governor and Park Gear Service............ 101
Oil Filter Replacement.................... 100
Park Interlock Cable Adjustment (XJ)......... 97
Park Lock Component Replacement......... 102
Park/Neutral Position Switch Service......... 103
Rear Band Adjustment.................... 99
Recommended Fluid...................... 96
Servicing Transmission Cooler Lines and Fittings. 106
Shift Cable Adjustment (XJ)................ 97
Speedometer Service.................... 103
Transmission Cooler Flow Testing........... 106
Transmission Cooler Reverse Flushing....... 105
Transmission Throttle Cable Adjustment (XJ/YJ) . 98
Valve Body Installation................... 101
Valve Body Removal..................... 100
Valve Body Service...................... 100
RECOMMENDED FLUID
The recommended and preferred fluid for 30RH/
32RH transmissions is Mopar ATF Plus, Type 7176.
Mopar Dexron II is acceptable but should only be
used when ATF Plus is not available.
Transmission fluid capacity is approximately 17
pints (7.9 liters). This is the approximate amount of
fluid required to fill the transmission and torque con-
verter after overhaul.
CHECKING FLUID LEVEL AND CONDITION
(1) Position vehicle on flat, level surface. This is
important in obtaining an accurate fluid level check.
(2) To avoid false readings, which could produce
under or over fill condition, do not check level until
fluid is at normal operating temperature.
(3) Shift transmission into Neutral.
(4) Apply parking brakes.
(5) Operate engine at curb idle speed.
WARNING: WHEN PERFORMING UNDERHOOD OP-
ERATIONS WITH THE ENGINE RUNNING, KEEP
YOUR HANDS WELL AWAY FROM HOT OR ROTAT-
ING ENGINE COMPONENTS. DO NOT WEAR
LOOSE ARTICLES OF CLOTHING WHICH COULD
BECOME ENTANGLED IN ENGINE COMPONENTS
OR ACCESSORIES.
(6) Shift transmission through all gear ranges and
back to Neutral (leave engine running).
(7) Clean exterior of dipstick cap and fill tube be-
fore removing transmission dipstick.
(8) Remove dipstick and inspect fluid level.
²Correct level is to FULL mark
²Acceptable level is between ADD and FULL marks
(9) Check fluid condition. Fluid should be dark to
light red in color and free of dirt or debris.
(10) If fluid is discolored or smells burned but
transmission operation was OK, check cooler flow,
flush cooler and lines and change fluid and filter.
Then road test again to confirm proper operation.(11) If fluid is black or dark brown, burned/turned
to sludge, contains large quantities of metal or fric-
tion material particles, transmission will need over-
haul. Especially if problems were evident during
road test and preliminary diagnosis. Fluid cooler
should also be flow tested and flushed if necessary.
GEARSHIFT LINKAGE ADJUSTMENT (YJ)
(1) Check linkage adjustment by starting engine in
Park and Neutral.
(2) Adjustment is OK if engine starts only in park
and Neutral. Adjustment is incorrect if engine starts
in one but not both positions.
(3) If engine starts in any position other than Park
or Neutral, or if engine will not start at all, park/
neutral position switch may be faulty.
(4) Shift transmission into Park.
(5) Raise vehicle.
(6) Check condition of shift rods, bellcrank, bell-
crank brackets and linkage bushings/grommets (Fig.
1). Tighten, repair, replace worn, damaged parts. Do
not attempt adjustment if linkage components are
worn or damaged.
(7) Loosen shift rod trunnion lock bolt or nut. Be
sure upper shift rod slides freely in trunnion (Fig. 1).
Also be sure shift rods and bellcrank rotate freely
and do not bind at any point.
(8) Verify that manual lever is in Park detent
(Fig. 1). Move lever all the way rearward to be sure
it is in Park.
(9) Check for positive engagement of park lock by
attempting to rotate propeller shaft. Shaft will not
turn when park pawl is engaged.
(10) Adjust shift rod trunnion to a obtain free pin
fit in bellcrank arm and tighten trunnion lock bolt or
nut. Prevent shift rod from turning while tightening
bolt or nut. Gearshift linkage lash must be elimi-
nated to obtain proper adjustment. Eliminate lash by
pulling downward on shift rod and pressing upward
on bellcrank.
21 - 96 30RH/32RH IN-VEHICLE SERVICEJ

THROTTLE CABLE ADJUSTMENT
PROCEDURE
Cable adjustment is performed entirely in the
engine compartment. It is not necessary to raise
the vehicle for access to any other components.
(1) Shift transmission into Park and shut engine
off.
(2) Press cable release button (Fig. 5).
(3) Push cable conduit back into cable adjuster
body as far as possible (Fig. 6).
(4) Rotate throttle body lever to wide open throttle
position. Cable will ratchet to correct adjustment
point as lever is rotated (Fig. 6).
FRONT BAND ADJUSTMENT
The front band adjusting screw is located on the
left side of the transmission case above the manual
valve and throttle valve levers.
(1) Raise vehicle.
(2) Loosen band adjusting screw locknut. Then
back locknut off 4-5 turns.
(3) Clean adjusting screw threads with Mopar rust
penetrant if necessary. Then lubricate threads withMopar spray lube or petroleum jelly. Be sure screw
turns freely in case. This is necessary for accurate
adjustment.
(4) Tighten band adjusting screw to 8 Nzm (72 in.
lbs.) torque with inch-pound torque wrench.If
Adapter Extension C-3705 is needed in order to
reach adjusting screw, tighten screw to only 5-6
Nzm (47-50 in. lbs.) torque (Fig. 7).
(5) Back off front band adjusting screw as follows:
²On 30RH (2.5L), back adjusting screw off
2-1/2 turns
²On 32RH (4.0L), back adjusting screw off
2-1/4 turns
(6) Hold adjuster screw in position and tighten
locknut to 41 Nzm (30 ft. lbs.) torque.
(7) Lower vehicle.
REAR BAND ADJUSTMENT
The transmission oil pan must be removed for ac-
cess to the rear (low-reverse) band adjusting screw.
(1) Raise vehicle.
(2) Remove transmission oil pan and drain fluid.
(3) Loosen band adjusting screw locknut 5-6 turns.
Be sure adjusting screw turns freely in lever.
(4) Tighten adjusting screw as follows: On 32Rh
transmission, tighten screw to 8 Nzm (72 in. lbs.)
torque. On 30RH transmission, tighten adjusting
screw to 5 Nzm (41 in. lbs.) torque (Fig. 8).
(5) Back off rear band adjusting screw as follows:
²On 30RH (2.5L), back adjusting screw off 7
turns
²On 32RH (4.0L), back adjusting screw off 4
turns
(6) Hold adjusting screw in place and tighten lock-
nut to 34 Nzm (25 ft. lbs.) torque.
(7) Position new gasket on oil pan and install pan
on transmission. Tighten pan bolts to 17 Nzm (150 in.
lbs.) torque.
(8) Lower vehicle and refill transmission with rec-
ommended fluid.
Fig. 5 Throttle Valve Cable Components
Fig. 6 Throttle Valve Cable Adjustment
Fig. 7 Front Band Adjustment
J30RH/32RH IN-VEHICLE SERVICE 21 - 99

(10) Install speedometer adapter clamp and retain-
ing screw. Tighten clamp screw to 10-12 Nzm (90-110
in. lbs.) torque.
(11) Connect wires to vehicle speed sensor.
(12) Lower vehicle and top off transmission fluid
level if necessary.
SPEEDOMETER COMPONENT REMOVAL
(TWO-PIECE SENSOR)
(1) Raise vehicle.
(2) Disconnect speed sensor wires.
(3) Remove bolt attaching vehicle speed sensor to
sensor adapter. Then slide sensor out of adapter.
(4) Inspect speed sensor mounting area in sensor
adapter. If transmission fluid is found in this area,
oil seal in metal speedometer adapter is leaking and
will have to be replaced.
(5) Remove speedometer adapter clamp bolt and
remove clamp (Fig. 18).
(6) Remove speedometer adapter, sensor adapter
and speedometer pinion as assembly.
SPEEDOMETER COMPONENT INSTALLATION
AND INDEXING (TWO-PIECE SENSOR)
(1) Replace speedometer O-ring if cut, torn, or worn.
(2) If oil seal in metal speedometer adapter needs
replacement, remove old seal with pointed tool. Then
install new seal with Special Tool C-4004. Push seal
into place with tool until tool bottoms (Fig. 19).
(3) Clean speedometer adapter mounting surface of
transmission, or transfer case thoroughly.
(4) Lubricate adapter seals with transmission fluid.
(5) Count number of teeth on speedometer pinion.
Do this before installing pinion and adapter.
(6) Note range numbers on face of speedometer
adapter (Fig. 20). These numbers correspond to num-
ber of teeth on speedometer pinion.
(7) Install pinion in adapter and install assembled
pinion and adapter in transmission or transfer case.
(8) Rotate speedometer adapter until required
range numbers are at 6 o'clock position (Fig. 20).
Verify that range numbers correspond to num-
ber of teeth on pinion.
(9) Push speedometer adapter into place until seated.
(10) Install speedometer adapter clamp and bolt.
Tighten bolt to 11 Nzm (100 in. lbs.) torque.
(11) Install sensor adapter on speedometer adapter
(Fig. 18). Tighten sensor adapter coupling nut to 17
Nzm (150 in. lbs.) torque.
(12) Carefully align and insert vehicle speed sensor
into sensor adapter.
(13) Install bolt that attaches speed sensor to
adapter. Tighten bolt to 5-8 Nzm (48-72 in. lbs.)
(14) Connect wires to speed sensor.
(15) Lower vehicle.
(16) Check top off transmission fluid level if necessary.
TRANSMISSION COOLER REVERSE FLUSHING
The transmission main cooler is located in the ra-
diator lower tank. The cooler is not a serviceable
component. If the cooler is damaged in any way, the
radiator will have to be replaced.
On models with an auxiliary cooler, the cooler is
mounted in front of the radiator or air conditioningFig. 18 Speedometer Components (With Two-Piece
Sensor)
Fig. 19 Installing Speedometer Adapter Seal (With
Two-Piece Sensor And Metal Adapter)
Fig. 20 Indexing Speedometer Adapter (With Two-
Piece Sensor)
J30RH/32RH IN-VEHICLE SERVICE 21 - 105

condenser. The auxiliary cooler is a serviceable com-
ponent and can be repaired if necessary.
The main and auxiliary coolers should be thor-
oughly reverse flushed if a transmission failure
contaminates the fluid. Reverse flushing the cooler
and lines will prevent sludge and particles from
flowing back into the transmission after repair.
The same flushing procedure is used for main and
auxiliary coolers. Pressure equipment is preferred for
reverse flushing. However, reverse flushing can be
performed using hand operated equipment as de-
scribed in the following procedure.
REVERSE FLUSHING PROCEDURE
(1) Disconnect cooler lines at transmission. Refer
to Figure 21 for cooler line fitting identification.
Front fitting is outlet to cooler and rear fitting is in-
let from cooler.
(2) Position drain pan under cooler outlet line to
material flushed through cooler and lines.
(3) Reverse flush cooler using hand operated suc-
tion gun filled with mineral spirits. Insert gun nozzle
(or hose) into cooler inlet (return) line. Then force
mineral spirits through Line and cooler.
(4) Continue reverse flushing until fluid exiting in-
let (pressure) line is clear and free of debris/residue.
Replace radiator if fluid cannot be pumped
through cooler.
(5) Clear flushing materials from cooler and lines
with short pulses of compressed air. Insert air gun
nozzle into cooler inlet (return) line and continue
short pulses of air until all fluid is cleared from
cooler and lines.
(6) Pump one quart of fresh automatic transmis-
sion fluid through cooler and lines before reconnect-
ing cooler lines.
TRANSMISSION COOLER FLOW TESTING
The transmission main and auxiliary coolers
should be flow tested whenever a fluid overheat con-
dition is suspected. An overheat condition is indi-
cated when the fluid changes from the normal red, to
a dark orange, or brown color.
The same method of flow testing is used for both
coolers.Cooler flow is checked by measuring the amount of
fluid flow through the cooler in a 20 second time pe-
riod. The test is performed with the engine running
and transmission in neutral. Fluid is then pumped
through the cooler by the transmission oil pump.
(1) Disconnect cooler inlet line at transmission fitting.
(2) Securely attach hose to end of inlet line and po-
sition line in a one quart test container.
(3) Add extra quart of fluid to transmission.
(4) Use stopwatch to check flow test time.
(5) Shift transmission into neutral and set parking
brake.
(6) Start and run engine at curb idle speed and im-
mediately note cooler flow. Approximately one quart of
fluid should flow into test container in 20 second period.
(7) If cooler flow is intermittent, flows less than
one quart in 20 seconds, or does not flow at all,
cooler is faulty and must be replaced.
SERVICING TRANSMISSION COOLER LINES AND
FITTINGS
Fitting Types
The transmission cooler lines are attached with
quick disconnect fittings.
A flange on the cooler line serves as the sealing
mechanism. The wire retainer clip (Fig. 22), secures
the cooler line in the fitting by this flange. The clip
fits behind the flange to hold the line in place.
Three different fitting styles may be used. Type 1
fittings have the retainer clip exposed (Fig. 22). Type
2 fittings have the retainer clip and fitting body en-
cased in a shrink wrap material (Fig. 23). Type 3 fit-
tings have the retainer clip encased in a metal sleeve
crimped onto the fitting body (Fig. 24).
Fitting Release Tool
A release tool isrequiredto disconnect each of the
fitting types. A plastic tool is clipped directly to one
of the cooler lines on models with the type 2 and 3
fittings. This tool can also be used to disconnect type
1 fittings. The tool is needed to spread the wire re-
tainer clip in each fitting. The clip must be opened in
order to release the cooler line from the fitting.
Fig. 21 Identifying Transmission Cooler Lines
Fig. 22 Type 1 Quick Disconnect Fitting
21 - 106 30RH/32RH IN-VEHICLE SERVICEJ

(b) Align and install new spacer on sensor
pickup face. Spacer has adhesive backing so it will
adhere to sensor face.
(c) Insert sensor into housing until it just
touches ring gear teeth. Then install and tighten
sensor attaching bolt. Correct clearance is estab-
lished when spacer is peeled off by ring gear dur-
ing engine startup.
(10) Install transmission fill tube and O-ring (Fig.
6).
(11) Connect transmission cooler lines to fittings.
Refer to Figure 7 for cooler line identification.(12) Position support stand under transmission
and remove transmission jack.
(13) Install transfer case on transmission adapter.
Tighten attaching nuts to 41 Nzm (30 ft. lbs.) torque.
(14) Install rear crossmember and attach transmis-
sion rear support to crossmember.
(15) Connect vehicle speed sensor wires.
(16) Install inspection cover on converter housing.
(17) Install exhaust pipes and support brackets, if
removed.
(18) Install starter motor.
(19) Connect wires to park/neutral position switch.
(20) Connect gearshift and linkage and throttle ca-
ble.
(21) Connect transfer case shift linkage.
(22) Connect propeller shafts to transfer case
yokes.
(23) Connect front exhaust pipes and catalytic con-
verter support bracket bolts (if removed).
(24) Install skid plate, rear cushion and bracket, if
removed.
(25) Fill transfer case to bottom edge of fill plug
hole with Mopar Dexron II.
(26) Lower vehicle and fill transmission to correct
level with ATF Plus, type 7176 fluid.
(27) Install fan shroud and bolts (if removed).
(28) Check and adjust gearshift linkage if neces-
sary. Then check and adjust throttle cable if neces-
sary.
Fig. 7 Transmission Cooler Line Location And
Identification
J30RH/32RH TRANSMISSION REMOVAL AND INSTALLATION 21 - 111

30RH/32RH TRANSMISSION OVERHAUL
INDEX
page page
Adapter Housing and Park Lock Component
Overhaul............................ 120
Front Clutch Overhaul.................... 125
Front Servo and Band Overhaul............ 136
Governor and Park Gear Overhaul.......... 121
Oil Pump Overhaul...................... 122
Overhaul Service Information............... 118
Overrunning ClutchÐLow-Reverse DrumÐRear
Support Overhaul...................... 118
Planetary Gear Train Overhaul............. 131Rear Clutch Overhaul.................... 128
Rear Servo and Band Overhaul............. 136
Transmission Assembly and Adjustment
Procedures........................... 146
Transmission Assembly Tips............... 146
Transmission Case Cleaning and Inspection . . . 118
Transmission Disassembly................. 112
Valve Body Assembly and Adjustment........ 144
Valve Body Disassembly and Inspection...... 138
TRANSMISSION DISASSEMBLY
(1) Clean transmission exterior with steam gun or
with solvent. Wear eye protection during cleaning
process.
(2) Remove throttle and shift levers from valve
body manual shaft and throttle lever shaft.
(3) Mount transmission in repair stand C-3750-B
(Fig. 1).
(4) Remove nuts attaching adapter, or extension
housing to transmission case.
(5) Remove adapter/extension housing and gasket
(Fig. 2).
(6) Remove rear bearing and snap ring, if
equipped.
(7) Remove park/neutral position switch and seal
(Fig. 3).
Fig. 1 Transmission Mounted On Typical Repair
Stand
Fig. 2 Adapter Housing Removal/Installation (4 x 4
Models)
Fig. 3 Park/Neutral Position Switch Removal/
Installation
21 - 112 30RH/32RH TRANSMISSION OVERHAULJ

(8) Remove oil pan bolts and remove pan and gas-
ket (Fig. 4).
(9) Remove hex head valve body attaching bolts
(Fig. 5).
(10) Disconnect solenoid wire from case connector
(Fig. 6).
(11) Lift valve body upward, guide park rod out of
case opening and remove valve body (Fig. 7).
(12) Remove accumulator spring and piston (Fig.
8).(13) Remove front band pivot pin access plug (Fig.
9). Plug is accessible through converter housing. Use
1/4 inch drive extension to remove plug as shown.
(14) Loosen front band adjusting screw locknut 4-5
turns. Then tighten band adjusting screw until band
is tight around front clutch retainer. This prevents
front/rear clutches from coming out with pump and
possibly damaging clutch or pump components.
Fig. 4 Oil Pan Removal/Installation
Fig. 5 Valve Body Attaching Bolt Locations (Typical)
Fig. 6 Solenoid Wire Connection
Fig. 7 Valve Body Removal/Installation
Fig. 8 Removing/Installing Accumulator Piston And
Spring
Fig. 9 Removing/Installing Front Band Pivot Pin
Access Plug
J30RH/32RH TRANSMISSION OVERHAUL 21 - 113

(15) Remove oil pump bolts.
(16) Thread bolts of Slide Hammer Tools C-3752
into threaded holes in pump body flange (Fig. 10).
(17) Bump slide hammer weights outward to re-
move pump and reaction shaft support assembly from
case (Fig. 10).
(18) Loosen front band adjusting screw until band
is completely loose.
(19) Squeeze front band together and remove band
strut (Fig. 11).
(20) Remove front band reaction pin with pencil
magnet. Pin is accessible from converter housing side
of case (Fig. 12).
(21) Remove front band lever (Fig. 13)
(22) Slide front band rearward and onto driving
shell. Band will not be removed until after front/rear
clutch removal.
(23) Remove front and rear clutch units as assem-
bly. Grasp input shaft, hold clutch units together and
remove them from case (Fig. 14).(24) Lift front clutch off rear clutch (Fig. 15). Set
clutch units aside for disassembly, cleaning and over-
haul.
Fig. 10 Removing Oil Pump/Reaction Shaft Support
Fig. 11 Removing/Installing Front Band Strut
Fig. 12 Removing Front Band Reaction Pin
Fig. 13 Removing/Installing Front Band Lever
Fig. 14 Removing Front/Rear Clutch Assemblies
21 - 114 30RH/32RH TRANSMISSION OVERHAULJ

(25) Remove output shaft thrust washer from out-
put shaft (or from rear clutch hub).
(26) Remove output shaft thrust plate from output
shaft hub (Fig. 16).
(27) Slide front band off driving shell (Fig. 17) and
remove band from case.
(28) Remove E-clip from one end of governor valve
shaft and remove valve and shaft from governor body
(Fig. 19). Reinstall E-clip on shaft to avoid losing it.
(29) Remove thick snap, thrust washer and thin
snap ring that retain governor body and park gear
on shaft (Fig. 19).
(30) Loosen bolts attaching governor body to park
gear.(31) Mark position of governor body on park gear
with center punch or scriber.
Fig. 15 Separating Front/Rear Clutch Assemblies
Fig. 16 Removing/Installing Output Shaft Thrust
Plate
Fig. 17 Front Band Removal/Installation
Fig. 18 Removing Governor Valve And Shaft
Fig. 19 Governor Body/Park Gear Attachment
J30RH/32RH TRANSMISSION OVERHAUL 21 - 115

(32) Remove governor body and park gear as as-
sembly (Fig. 20). Work park gear out of rear support
and slide assembly off output shaft.
(33) Remove planetary geartrain as assembly (Fig.
21). Support geartrain with both hands during re-
moval. Do not allow machined surfaces on output
shaft to become nicked or scratched.
(34) Loosen rear band adjusting screw until band
is fully released and does not grip low reverse drum.
(35) Remove snap ring that secures low-reverse
drum to rear support (Fig. 22).
(36) Remove rear band lever pins as follows:
(a) On 30RH transmission, rear band has only
one pivot pin. Remove pin with parallel jaw snap
ring pliers (Fig. 23). Spread plier jaws in pin bore
to grip pin. Then remove pin with a twist and pull
motion.(b) On 32RH transmission, rear band has two
pins. Remove pivot pin and reaction pin with par-
allel jaw snap ring pliers (Fig. 24).
(37) Remove rear band lever, link and strut.
(38) Mark position of rear support for assembly
reference (Fig. 25). Use scriber or center punch to
mark case and support.
(39) Remove rear support bolts and remove support
from low-reverse drum and case (Fig. 26). Keep rear
support bolts together for assembly reference.
(40) Remove bolts attaching overrunning clutch
cam to case (Fig. 27).
(41) Remove low-reverse drum and overrunning
clutch as assembly. Slide drum and clutch through
rear band and out of case. Set drum and clutch as-
sembly aside for cleaning and inspection.
(42) Remove rear band and link from case.
(43) Compress front servo rod guide about 3 mm
(1/8 in.) with Valve Spring Compressor Tool
C-3422-B (Fig. 28). A C-clamp and tool C-4470 can
also be used to compress rod guide.
Fig. 20 Removing/Installing Governor Body And
Park Gear
Fig. 21 Planetary Geartrain Removal
Fig. 22 Removing Low-Reverse Drum Snap Ring
Fig. 23 Removing Rear Band Lever Pivot Pin (30RH)
21 - 116 30RH/32RH TRANSMISSION OVERHAULJ