front JEEP CHEROKEE 1994 Service Repair Manual

(5) Align and install converter in oil pump.
TRANSMISSION AND TORQUE CONVERTER
INSTALLATION
(1) Mount transmission on transmission jack. Then
secure transmission to jack with safety chains.
(2) Lubricate converter drive hub and oil pump
seal lip with Mopar Mercon transmission fluid. Then
install converter. Be sure converter is fully seated in
oil pump gears before proceeding. Hold converter in
place with C-clamp or strap attached to converter
housing.
(3) Align and position transmission and converter
on engine.
(4) Remove clamp or strap used to hold torque con-
verter in place.
(5) Move transmission forward seat and it on en-
gine. Be sure torque converter hub is fully seated.
(6)
Install converter housing-to-engine bolts (Fig.
53).
(7) Install converter-to-drive plate bolts.
(8) Install and connect starter motor.
(9) Install and connect crankshaft position sensor.
(10) Install transfer case on transmission. Tighten
transfer case attaching nuts to 41 Nzm (30 ft. lbs.)
torque
(11) Connect transfer case shift linkage and vac-
uum hoses.
(12) Connect exhaust components.
(13) Install rear crossmember and remove jack
used to support transmission assembly.
(14) Connect speed sensor wire harness to sensor.
(15) Connect wire harness to park/neutral position
switch.
(16) Align and connect front and rear propeller
shafts.
Fig. 51 Checking Operation Of Torque Converter
Stator One-Way Clutch
Fig. 52 Installing Oil Pump Seal
21 - 190 AW-4 TRANSMISSION REMOVAL AND INSTALLATIONJ

AW-4 TRANSMISSION OVERHAUL
INDEX
page page
Cleaning and Inspection................... 76
Direct Clutch Overhaul................... 219
First-Reverse Brake Piston and Transmission
Case Overhaul........................ 237
Forward Clutch Overhaul.................. 223
Front Planetary Gear Overhaul............. 228
Manual Valve Shaft Overhaul.............. 205
Oil Pump Overhaul...................... 206
Overdrive Planetary Gear and Clutch Overhaul . 209Overdrive Support Overhaul................ 216
Overhaul Service Tools................... 192
Rear Planetary, No. 2 One-Way Clutch and
Output Shaft Overhaul.................. 100
Second Brake Overhaul................... 100
Sun Gear and No. 1 One-Way Clutch Overhaul . 99
Transmission Assembly and Adjustment....... 255
Transmission Disassembly................. 192
Transmission Valve Body Overhaul.......... 101
OVERHAUL SERVICE TOOLS
The special tools needed to overhaul the AW-4
transmission are provided in Tool Kit 6294. However,
Pressure Test Port Adapter 7554 is not included in
this kit and must be ordered separately. The over-
haul tool kit and test port adapter are available
through the parts division and dealer special tool
program.
TRANSMISSION DISASSEMBLY
(1) Remove torque converter.
(2) Remove lower half of filler tube if not previ-
ously removed.
(3) Remove clamps attaching wire harness and
throttle cable (Fig. 1) to transmission.(4) Remove shift lever from manual valve shaft at
left side of transmission.
(5) Remove park/neutral position switch.
(6) Remove speed sensor (Fig. 2).
Fig. 1 Typical Harness And Cable Clamp Attachment
Fig. 2 Speed Sensor Removal
21 - 192 AW-4 TRANSMISSION OVERHAULJ

(37) Disassemble second coast brake piston (Fig.
29).
(38) Remove direct and forward clutch assembly
(Fig. 30).
(39) Remove thrust bearing and race from clutch
hub (Fig. 31).
(40) Remove second coast brake band E-ring from
band pin and remove brake band (Fig. 32).
(41) Remove front planetary ring gear front bear-
ing race and remove front planetary ring gear (Fig.
33).(42) Remove thrust bearing and rear race from
ring gear (Fig. 34).
(43) Remove planetary thrust race (Fig. 35).
(44) Relieve load on planetary snap ring as follows:
Loosen transmission holding fixture. Turn transmis-
Fig. 29 Second Coast Brake Piston Components
Fig. 30 Removing Direct And Forward Clutch
Assembly
Fig. 31 Remove Bearing And Race From Clutch Hub
Fig. 32 Removing Second Coast Brake Band
21 - 200 AW-4 TRANSMISSION OVERHAULJ

sion over and allow output shaft to support transmis-
sion weight. Place wood blocks under shaft to protect
splines (Fig. 35).
(45) Remove planetary snap ring and remove plan-
etary gear (Fig. 36).
(46) Remove sun gear, input drum and one-way
Fig. 33 Removing Front Planetary Ring Gear
Fig. 34 Removing Ring Gear Bearing And Rear Race
Fig. 35 Relieving Load On Planetary Snap Ring
Fig. 36 Removing Planetary Snap Ring And Gear
JAW-4 TRANSMISSION OVERHAUL 21 - 201

(6) Measure inside diameter of stator shaft bush-
ing (Fig. 2). Take measurements at front and rear of
bushing. Diameter should be maximum of 21.58 mm
(0.08496 in.) at front and 27.08 mm (1.0661 in.) at
rear. Replace stator shaft if bushing diameter is
greater than specified.
(7) Measure oil pump clearances (Fig. 3).
²Clearance between pump driven gear and pump
body should be maximum of 0.3 mm (0.012 in).
²Clearance between tips of pump gear teeth should
be maximum of 0.3 mm (0.012 in).
²Clearance between rear surface of pump housing
and pump gears should be maximum of 0.1 mm
(0.004 in.).
(8) Replace pump body and gears if any clearance
is greater than specified.
Fig. 2 Checking Pump/Stator Shaft Bushings
Fig. 3 Checking Pump Gear Clearances
JAW-4 TRANSMISSION OVERHAUL 21 - 207

(20) Check inside diameter of clutch drum bush-
ings with bore gauge or inside micrometer (Fig. 18).
Maximum inside diameter is 27.11 mm (1.0673 in.).
Replace drum if bushing inside diameter is greater
than specified.
(21) Check inside diameter of planetary gear bush-
ing (Fig. 19). Maximum inside diameter is 11.27 mm
(0.4437 in.). Replace planetary gear if bushing inside
diameter is greater then specified.
Assembling Gear And Clutch
(1) Install thrust washer in planetary gear (Fig.
20).Grooved side of washer faces up and to-
ward front.(2) Install one-way clutch in race (Fig. 21). Flanged
side of clutch must face upward as shown.
(3) Install assembled one-way clutch and outer
race in planetary gear. Be sure flanged side of clutch
is facing upward.
(4) Install clutch pack retaining plate and snap
ring in planetary gear.
(5) Coat planetary race with petroleum jelly and
install it on planetary gear. Outside diameter of race
is 41.8 mm (1.646 in.); inside diameter is 27.1 mm
(1.067 in.).
(6) Install hub in planetary ring gear and install
snap ring.
Fig. 18 Checking Clutch Drum Bushings
Fig. 19 Checking Planetary Bushing
Fig. 20 Install Planetary Thrust Washer
Fig. 21 Assembling One-Way Clutch And Race
21 - 214 AW-4 TRANSMISSION OVERHAULJ

should move smoothly and not bind or stick. If oper-
ation is incorrect, replace piston and support.
(3) Remove thrust bearing front race, thrust bear-
ing and rear race (Fig. 3).
(4) Turn overdrive support over and remove bear-
ing race and clutch drum thrust washer (Fig. 4).
(5) Compress piston return spring with Spring
Compressor 7537 and remove piston snap ring (Fig.
5).(6) Mount support in direct clutch and remove
brake piston with compressed air. Apply air to same
feed hole used when checking piston operation.
(7) Remove and discard support O-rings (Fig. 1).
Fig. 2 Checking Brake Piston Movement
Fig. 3 Removing Support Thrust Bearing And Races
Fig. 4 Removing Clutch Drum Thrust Washer And
Race
Fig. 5 Removing/Installing Piston Snap Ring
JAW-4 TRANSMISSION OVERHAUL 21 - 217

(8) Remove support seal rings (Fig. 6).
(9) Measure free length of piston return springs
with springs mounted in retainer (Fig. 7). Length
should be 17.23 mm (0.678 in.).
(10) Clean support components and dry them with
compressed air.
(11) Inspect overdrive support and brake piston. Re-
place support and piston if either part is worn or dam-
aged.
ASSEMBLING OVERDRIVE SUPPORT
(1) Lubricate new support seal rings. Then com-
press rings and install them on support (Fig. 8).
(2) Lubricate and install new O-rings on brake pis-
ton. Then carefully seat piston in support.(3) Install return springs on brake piston.
(4) Compress return springs with Spring Compres-
sor 7537 (Fig. 5) and install piston snap ring.
(5) Install support bearing race and clutch drum
thrust washer (Fig. 4).
(6) Install thrust bearing and front and rear bear-
ing races. Thrust bearing rollers should face upward
as shown (Fig. 9).
(7) Verify thrust bearing/race sizes (Fig. 9).
²Front race outer diameter is 47.8 mm (1.882 in.)
and inside diameter is 30.7 mm (1.209 in.).
Fig. 9 Installing Support Thrust Bearing And Races
Fig. 6 Removing Support Seal Rings
Fig. 7 Checking Piston Return Spring Length
Fig. 8 Installing Support Seal Rings
21 - 218 AW-4 TRANSMISSION OVERHAULJ

FRONT PLANETARY GEAR OVERHAUL
FRONT PLANETARY DISASSEMBLY
(1) Remove ring gear from planetary gear (Fig. 1).
(2) Remove front bearing and the two races from
ring gear (Fig. 1).
(3) Remove tabbed thrust race from planetary gear
(Fig. 1).
(4) Remove snap ring attaching planetary gear to
shaft and remove gear.
(5) Remove rear bearing and race from planetary
gear.
(6) Measure inside diameter of ring gear bushing.
Maximum allowable diameter is 24.08 mm (0.9480
in.). Replace ring gear if bushing inside diameter is
greater than specified.
FRONT PLANETARY ASSEMBLY
(1) Lubricate planetary and ring gear bearings and
races with petroleum jelly.
(2) Identify planetary bearings and races before in-
stallation. (Fig. 1). Bearings and races can be identi-
fied by following dimensions:
²Outer diameter of rear bearing is 47.7 mm (1.878
in.). Inner diameter is 35.5 mm (1.398 in.).
²Outer diameter of rear race 47.6 mm (1.874 in.).
Inner diameter is 33.7 mm (1.327 in.).
²Outer diameter of front race is 53.6 mm (2.110
in.). Inner diameter is 30.5 mm (1.201 in.).
²Outer diameter of front bearing is 47.7 mm (1.878
in.). Inner diameter is 32.6 (1.283 in.).
²Outer diameter of forward race is 47.0 mm (1.850
in.). Inner diameter is 26.5 mm 1.043 in.).
(3) Install rear race and bearing in gear (Fig. 2).
Fig. 1 Front Planetary Gear Components
Fig. 2 Installing Front Planetary Rear Bearing and
Race
21 - 228 AW-4 TRANSMISSION OVERHAULJ

(4) Turn planetary over and install race thrust
race (Fig. 3).
(5) Install front race and bearing and forward race
in ring gear (Fig. 4).
(6) Set planetary gear assembly aside for final as-
sembly.
SUN GEAR AND NO. 1 ONE-WAY CLUTCH
OVERHAUL
SUN GEAR AND CLUTCH DISASSEMBLY
(1) Hold sun gear and turn second brake hub
clockwise and counterclockwise (Fig. 2). Hub should
rotate freely clockwise but lock when turned counter-clockwise. Replace one-way clutch and hub if they do
not operate properly.
(2) Remove one-way clutch/second brake hub as-
sembly from drum (Fig. 3).
(3) Remove thrust washer from drum (Fig. 4).
(4) Remove two seal rings from sun gear (Fig. 5).
Fig. 1 Sun Gear And One-Way Clutch Components
Fig. 3 Installing Front Planetary Thrust Race
Fig. 4 Installing Front Planetary Front Bearing And
Races
JAW-4 TRANSMISSION OVERHAUL 21 - 229