engine 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

(11) Confirm proper adjustment by starting engine
in Park and Neutral. Engine should start in these
positions only.If engine starts in any position
other than Park or Neutral, adjustment is incor-
rect or neutral switch is faulty.
(12) Lower vehicle and verify that steering lock op-
erates correctly.
SHIFT CABLE ADJUSTMENT (XJ)
(1) Shift transmission into Park.
(2) Raise vehicle.
(3) Release cable adjuster clamp to unlock cable
(Figs. 2 and 3). Clamp is at transmission end of ca-
ble.
(4) Unsnap cable from transmission cable bracket
(Figs. 2 and 3).
(5) Move transmission shift lever fully rearward to
Park detent. Lever is on manual valve shaft at
driver side of case.
(6) Verify positive engagement of park lock by at-
tempting to rotate propeller shaft. Shaft will not ro-
tate when park lock is engaged.
(7) Snap cable into cable bracket.
(8) Lock shift cable by pressing cable adjuster
clamp down until it snaps into place.
(9) Check engine starting. Engine should start
only in Park and Neutral.
(10) Lower vehicle.
PARK INTERLOCK CABLE ADJUSTMENT (XJ)
(1) Shift transmission into Park.
(2) Turn ignition switch to Lock position.
(3) Remove shift lever bezel and console screws.
Raise bezel and console for access to cable.
Fig. 1 Gearshift Linkage (YJ)
Fig. 2 Shift Cable (XJ)
J30RH/32RH IN-VEHICLE SERVICE 21 - 97

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

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

30RH/32RH TRANSMISSION REMOVAL AND INSTALLATION
INDEX
page page
ConverterÐPump SealÐDrive Plate Service . . . 109
Transmission and Converter Installation....... 109Transmission and Converter Removal........ 108
TRANSMISSION AND CONVERTER REMOVAL
(1) Remove fan shroud attaching bolts.
(2) Disconnect transmission fill tube at upper
bracket.
(3) Raise vehicle.
(4) Remove inspection cover from converter hous-
ing and remove skid plate for access, if necessary.
(5) Remove transmission fill tube and fill tube
O-ring.
(6) Remove starter motor.
(7) Mark propeller shafts and axle yokes for align-
ment reference.
(8) Disconnect propeller shafts at yokes. Secure
shafts to frame rails with wire.
(9) Disconnect exhaust pipes at exhaust manifolds,
if necessary.
(10) Drain transfer case lubricant.
(11) Disconnect vehicle speed sensor wires.
(12) Disconnect transfer case shift linkage.
(13) Disconnect gearshift linkage and throttle ca-
ble at transmission levers.
(14) Disconnect park/neutral position switch wires.
(15) Disconnect and remove crankshaft position
sensor. Retain sensor bolt for reinstallation.
CAUTION: The crankshaft position sensor can be
damaged during transmission removal (or installa-
tion) if the sensor is still bolted to the engine block.
To avoid damage, remove the sensor before remov-
ing the transmission.
(16) Remove converter housing access cover and
mark drive plate and converter for alignment refer-
ence.
(17) Remove bolts attaching converter to drive
plate.
(18) Support engine with support stand.
(19) Support transmission-transfer case assembly
with transmission jack. Secure transmission to jack
with safety chain.
(20) Remove bolts/nuts attaching cushion and
torque arm bracket to skid plate (Fig. 1).
(21) Remove skid plate, or rear crossmember, if
equipped.
(22) Lower transmission slightly and disconnect
cooler lines at transmission.Refer to In-Vehicle
Service section for procedures.(23) Remove bolts attaching transmission to en-
gine.
(24) Move transmission and converter rearward
until clear of crankshaft.
(25) Hold converter in position and lower transmis-
sion until converter housing clears engine.
(26) Remove converter from transmission.
(27) Remove transfer case from transmission.
(28) If necessary, following components can now be
serviced:
²torque converter
²torque converter drive plate
²oil pump seal
²engine rear core hole plugs
²engine rear oil galley plugs
Fig. 1 Transmission Rear Mount
21 - 108 30RH/32RH TRANSMISSION REMOVAL AND INSTALLATIONJ

CONVERTERÐPUMP SEALÐDRIVE PLATE SERVICE
Drive Plate
The drive plate can be replaced or removed for service
access after the transmission is out of the vehicle (Fig. 2).
CAUTION: On YJ models with a 2.5L engine and
30RH transmission, special bolts are used to attach
the driveplate to the crankshaft. These bolts have a
smaller hex head for torque converter clearance.
DO NOT interchange these bolts with similar size
bolts for any reason.
Torque Converter
The torque converter can be replaced or removed
for service access after the transmission has been re-
moved (Fig. 2).
The torque converter is not a serviceable part. If
the converter is contaminated or damaged in any
way, it must be replaced as an assembly.Do not at-
tempt to flush a converter contaminated by
metal or clutch facing particles. Flushing will
not remove these contaminants.
A new torque converter and oil pump are used in
30RH/32RH transmissions built after the 1993
model year. The new converter has a different
style drive hub. The hub was changed to accept
the new design drive flats on the oil pump inner
gear. The drive flats replace the square lugs used
previously. If converter replacement should be-
come necessary, be sure to use the new style con-
verter. The new converter and oil pump are not
interchangeable with previous style parts.The oil pump seal is accessible and can be replaced af-
ter the transmission and torque converter are removed.
Use Remover Tool C-3981B to remove the seal
(Fig. 3). To use the tool, first start the tool into the
seal by hand. Next, thread the tool into the seal as
far as it will go. Use a wrench on the tool hex to turn
the tool. Continue tightening until all the tool
threads firmly grip the metal part of the seal. Then
tighten the tool puller screw to withdraw the seal
from the pump body.
Use Installer Tool C-4193 to install and seat the
seal (Fig. 4).
Be sure to lubricate the pump seal and converter
hub with transmission fluid before installation.
TRANSMISSION AND CONVERTER INSTALLATION
CAUTION: The transmission oil cooler and lines
must be reverse flushed if repair corrected a prob-
lem that generated sludge and/or debris. Sludge
and metal or friction particles from a gear or clutch
pack failure must be removed before reinstalling
the transmission. This is necessary to avoid re-con-
taminating the repaired transmission. Failure to re-
move sludge or debris from the cooler and lines
will result in a repeat failure and shop comeback.
Fig. 2 Typical Converter And Drive Plate
Fig. 3 Pump Seal Removal
Fig. 4 Pump Seal Installation
J30RH/32RH TRANSMISSION REMOVAL AND INSTALLATION 21 - 109

(1) Lubricate converter drive hub and pump seal
with Mopar ATF Plus, or Dexron II transmission
fluid. Then install converter. Turn converter back
and forth to align drive slots in converter hub with
pump gear lugs. Be sure converter is fully seated in
pump (Fig. 5).
(2) Temporarily secure converter with C-clamp or
metal strap attached across converter housing.
(3) Position transmission on jack and secure it
with safety chains.
(4) Raise transmission and align converter with
drive plate.
(5) Move transmission forward. Then raise, lower
or tilt transmission to align converter housing with
engine block dowels.
(6) Install two converter housing lower attaching
bolts and tighten bolts to draw housing toward en-
gine.
(7) Install and tighten converter attaching bolts.
(8) Install and tighten bolts that attach transmis-
sion to engine (Fig. 6).
(9) Install crankshaft position sensor as follows:
CAUTION: Clearance between the sensor pickup
face and driveplate ring gear must be correctly es-
tablished before engine startup. A cardboard
spacer, attached to the sensor face, is used for thispurpose. Failure to establish correct clearance will
result in sensor breakage.
(a) Remove any remaining fragments of original
cardboard spacer from sensor pickup face.
Fig. 5 Checking Torque Converter Seating
Fig. 6 Transmission Attachment
21 - 110 30RH/32RH TRANSMISSION REMOVAL AND INSTALLATIONJ

(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

AW-4 AUTOMATIC TRANSMISSION
CONTENTS
page page
AW-4 IN-VEHICLE SERVICE............. 173
AW-4 TRANSMISSION DIAGNOSIS........ 167
AW-4 TRANSMISSION OVERHAUL........ 192
AW-4 TRANSMISSION REMOVAL AND
INSTALLATION....................... 189GENERAL INFORMATION................ 156
TRANSMISSION/TRANSFER CASE
SPECIFICATIONS..................... 320
GENERAL INFORMATION
INDEX
page page
Components and Operation................ 157
Description............................ 156
FirstÐThirdÐReverse Gear Components...... 159
Fourth Gear Overdrive Components......... 158
Geartrain Operation and Application Charts.... 159Hydraulic System........................ 160
Torque Converter........................ 158
Transmission Identification................. 157
Transmission Ranges and Shift Lever Positions . 157
DESCRIPTION
The AW-4 is a 4-speed, electronically controlled au-
tomatic transmission (Fig. 1). Running gear consists
of a torque converter, oil pump, three planetary gear
sets, clutch and brake units, hydraulic accumulators,
a valve body with electrical solenoids and a transmis-sion control module (TCM). The AW-4 is used in XJ
models with a 4.0L engine.
Cables are used for shifting and transmission
throttle pressure control. A park/neutral position
switch permits engine starting in Park and Neutral
range only.
Fig. 1 AW-4 Automatic Transmission
21 - 156 TRANSMISSION AND TRANSFER CASEJ

net complete one revolution. Sensor signals are sent
to the transmission control module.
The park/neutral position switch is mounted on the
valve body manual shaft. The switch signals shift
linkage and manual valve position to the transmis-
sion control module through an interconnecting har-
ness. The switch prevents engine starting in all gears
other than Park or Neutral.
The brake switch is in circuit with the torque con-
verter clutch solenoid. The switch disengages the
converter clutch whenever the brakes are applied.
The switch is mounted on the brake pedal bracket
and signals the transmission control module when
the pedal is pressed or released.
TORQUE CONVERTER
A four element torque converter is used for all ap-
plications. The converter consists of the front cover
and pump, stator, turbine, and an electronic modu-
lated converter clutch mechanism.
The converter clutch mechanism consists of a slid-
ing clutch piston, clutch springs and the clutch disc
material (Fig. 4). The clutch provides optimum
torque transfer and economy when engaged.
The clutch disc is attached to the converter front
cover. The clutch piston and clutch springs are at-
tached to the turbine hub. The springs dampen en-
gine firing impulses and loads during the initial
phase of converter clutch engagement.
Clutch engagement is controlled by transmission
valve body solenoid number three and by the con-
verter clutch relay valve. The solenoid channels line
pressure to the clutch through the relay valve at
clutch engagement speeds.
Torque converter clutch engagement occurs in sec-
ond gear in 1-2 position; third gear in 3 position and
third and fourth gear in D position.
FOURTH GEAR OVERDRIVE COMPONENTS
The overdrive system consists of the input shaft, one-
way clutch, planetary sun gear, ring gear, planetary car-
rier, direct clutch and overdrive brake (Fig. 5). The
overdrive elements are controlled and applied through
transmission valve body solenoid number two.
In overdrive fourth gear, the brake prevents the
overdrive sun gear from turning. During operation,
the overdrive elements operate as follows:
The overdrive input shaft and planetary carrier ro-
tate as a unit. The sun gear and overdrive direct
clutch drum are in mesh and operate as a single
unit. The direct clutch splines function as the hub for
the overdrive brake. The one-way clutch outer race is
in mesh with the planetary carrier. The inner race is
fixed to the sun gear shaft.
Fig. 5 Fourth Gear Overdrive Components
Fig. 4 Torque Converter With Modulated Clutch
21 - 158 AW-4 AUTOMATIC TRANSMISSIONJ