check engine JEEP CHEROKEE 1995 Service Repair Manual

CONNECTING COOLER LINES AND FITTINGS
(ALL TYPES)
(1) Wipe cooler line and fitting clean with shop
towel.
(2) Insert cooler line into fitting. Then push line
inward until retainer or insert secures line. A snap or
click sound will be heard when the insert tabs or re-
tainer clip seats behind the cooler line flange.
(3)Pull outward on cooler lines/fittings to
verify they are properly secured.
CAUTION: The wire retainer clips or insert release
tabs secure the cooler lines. If the clips or tabs are
deformed, distorted, or not fully seated, normal
fluid pressure could unseat the lines resulting in
fluid loss and transmission damage. Be very sure
the cooler lines are firmly secured as described in
step (3).
CONVERTER DRAINBACK CHECK VALVE SERVICE
The converter drainback check valve is located in
the cooler outlet (pressure) line near the radiator
lower tank. The valve prevents fluid drainback when
the vehicle is parked for lengthy periods. The valve
check ball is spring loaded and has an opening pres-
sure of approximately 2 psi. Refer to the cooler flow
test procedure for valve testing.
The valve is serviced as an assembly; it is not re-
pairable. Do not clean the valve if restricted, or con-
taminated by sludge, or debris. If the valve fails, or if
a transmission malfunction occurs that generates
sludge and/or clutch particles and metal shavings,
the valve must be replaced.
The valve must be removed whenever the cooler
and lines are reverse flushed. The valve can be flow
tested when necessary. The procedure is exactly the
same as for flow testing a cooler.
If the valve is restricted, installed backwards, or in
the wrong line, it will cause an overheat condition
and possible transmission failure.
CAUTION: The drainback valve is a one-way valve.
As such, it must be properly oriented in terms of
flow direction. In addition, the valve must only beinstalled in the pressure line. Otherwise flow will be
blocked causing overheat and eventual transmis-
sion failure.
TRANSMISSION COOLER FLOW TESTING
The transmission main and auxiliary coolers, plus
the drainback valve, should be flow tested whenever
fluid overheating is noted.
Restricted flow caused by contamination, or a
cooler malfunction, reduces lubrication fluid flow
throughout the transmission. This can result in fluid
overheating, fluid breakdown, bushing wear, shift
problems and component failure.
Normal color of transmission fluid varies from
bright red, to light pink. Fluid overheating is indi-
cated when fluid color ranges from orange-brown to
black, and the fluid smells burned, or contains
sludge.
CAUTION: If a transmission malfunction contami-
nates the fluid with clutch disc and metal particles,
the cooler and lines must be reverse flushed thor-
oughly. Flushing will prevent sludge and particles
from flowing back into the transmission and con-
verter after repair.
Cooler flow is tested by measuring the amount of
fluid pumped through the cooler in a specified time
by the transmission oil pump.The same flow test
procedure is used for the drainback valve, main
cooler, and auxiliary cooler.
Cooler And Drainback Valve Flow Test Procedure
(1) Test flow throughdrainback valveas follows:
(a) Add extra quart of ATF Plus to transmission.
(b) Disconnect pressure line at radiator fitting, or
at drainback valve and position hose or valve end
in one quart test container.
(c) Shift transmission into neutral, run engine at
idle speed for 20 seconds, and note flow from valve.
Use stopwatch to check test time.
(d) Replace drainback valve if flow is less than
one quart in 20 seconds, is intermittent, or does
not flow at all.
(e) Connect pressure hose to radiator fitting and
proceed to cooler flow test.
(2) Test flow throughmain cooleras follows:
(a) Disconnect cooler return (rear) line at trans-
mission and place it in one quart test container.
(b) Add extra quart of fluid to transmission.
(c) Shift transmission into neutral, run engine at
idle speed for 20 seconds, and note flow from valve.
Use stopwatch to check test time.
(d) Replace cooler if fluid flow is less than one
quart in 20 seconds, is intermittent, or does not
flow at all.
Fig. 33 New Style Fitting Insert (On Cooler Line)
J30RH/32RH IN-VEHICLE SERVICE 21 - 113

grip the metal part of the seal. Then tighten the tool
puller screw to withdraw the seal from the pump
body.
Use Special Tool C-4193-A to install the seal (Fig.
6). Be sure to lubricate the pump seal and converter
hub with transmission fluid before installation.
TRANSMISSION AND CONVERTER INSTALLATION
CAUTION: If the transmission was repaired to cor-
rect a problem that generated sludge and debris,
the fluid cooler and lines must be reverse flushed
and the torque converter and drainback valve re-
placed. Sludge and metal or friction particles must
be removed from the cooler system before reinstall-
ing the transmission. This avoids re-contaminating
the repaired transmission. Failure to flush the sys-
tem will result in repeat failure and a shop come-
back.
(1) Lubricate converter drive hub and pump seal
with Mopar ATF Plus transmission fluid. Then in-
stall converter. Turn converter back and forth toalign drive slots in converter hub with pump gear
lugs. Be sure converter is fully seated in pump (Fig.
7).
(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 transmission attaching bolts.
Tighten bolts just enough to hold transmission con-
verter housing in place on block.
(7) Install torque converter attaching bolts.
Tighten bolts to following torque.
²54 Nzm (40 ft. lbs.) with 9.5 in. 3-lug converter
²74 Nzm (55 ft. lbs.) with 9.5 in. 4-lug converter
²74 Nzm (55 ft. lbs.) with 10.0 in. 4-lug converter
²31 Nzm (270 in. lbs.) with 10.75 in. 4-lug converter
(8) Install and tighten remaining bolts that attach
transmission converter housing to engine block (Fig.
8).
CAUTION: Be sure the converter housing is fully
seated on the engine block dowels before tighten-
ing any bolts.
(9) Install crankshaft position sensor.
(10) Install transmission fill tube and O-ring (Fig.
5).
(11) Connect transmission cooler lines to fittings.
Refer to Figure 9 for cooler line identification.
Fig. 5 Pump Seal Removal
Fig. 6 Pump Seal Installation
Fig. 7 Checking Torque Converter Seating
J30RH/32RH TRANSMISSION REMOVAL AND INSTALLATION 21 - 117

The manual valve, 1-2 shift valve, primary regula-
tor valve, accumulator control valve, check balls, so-
lenoids and oil strainers are located in the lower
body section (Fig. 10). The remaining control and
shift valves plus check balls and one additional oil
strainer are located in the upper body section (Fig.
11).
Manual Valve
The manual valve is operated by the gearshift link-
age. The valve diverts fluid to the apply circuits ac-
cording to shift lever position.Primary Regulator Valve
The primary regulator valve (Fig. 13) modulates
line pressure to the clutches and brakes according to
engine load. The valve is actuated by throttle valve
pressure.
During high load operation, the valve increases line
pressure to maintain positive clutch and brake en-
gagement. At light load, the valve decreases line
pressure just enough to maintain smooth engage-
ment.
Fig. 10 Upper Body Components
Fig. 11 Lower Body Components
21 - 170 AW-4 AUTOMATIC TRANSMISSIONJ

(2) Verify transmission throttle cable operation.
Repair or replace cable if necessary.
(3) Check engine throttle operation. Operate accel-
erator pedal and observe injector throttle plate move-
ment. Adjust linkage if throttle plate does not reach
wide open position.
(4) Check transmission fluid level when fluid is at
normal operating temperature. Start engine. Shift
transmission through all gear ranges then back to
Neutral. Correct level is to Full or Add mark on dip-
stick with engine at curb idle speed.
(5) Check and adjust park/neutral position switch
if necessary.
(6) Check throttle position sensor adjustment and
operation. Adjust the sensor if necessary.
MANUAL SHIFTING TEST
(1) This test determines if problem is related to
mechanical or electrical component.
(2) Stop engine and disconnect transmission con-
trol module or module fuse.
(3) Road test vehicle. Shift transmission into each
gear range. Transmission should operate as follows:
²lock in Park
²back up in Reverse
²not move in Neutral
²provide first gear only with shift lever in 1-2 posi-
tion
²operate in third gear only with shift lever in 3 po-
sition
²operate in overdrive fourth gear in D position
(4) If transmission operates as described, proceed
to next step. However, if forward gear ranges were
difficult to distinguish (all feel the same), or vehicle
would not back up, refer to diagnosis charts. Do not
perform stall or time lag tests.
CAUTION: Do not overspeed the engine during the
next test step. Ease off the throttle and allow the
vehicle to slow before downshifting.
(5) Continue road test. Manually downshift trans-
mission from D to 3, and from 3 to 1-2 position. Then
manually upshift transmission through forward
ranges again.
(6) If transmission operation is OK, perform stall,
time lag and pressure tests. If transmission shifting
problem is encountered, refer to diagnosis charts.
(7) If a problem still exists, continue testing with
DRB scan tool.
HYDRAULIC PRESSURE TEST
PRESSURE TEST PROCEDURE
(1) Connect pressure test gauge to test port on pas-
senger side of transmission. Use Adapter 7554 to con-
nect gauge. Be sure test gauge has minimum
capacity of 300 psi (2100 kPa).(2) Be sure transmission fluid is at normal operat-
ing temperature.
(3) Apply parking brakes and block wheels.
WARNING: DO NOT ALLOW ANYONE TO STAND
AT THE FRONT OR REAR OF THE VEHICLE WHILE
PERFORMING THE FOLLOWING STEPS IN THE
PRESSURE TEST.
(4) Check and adjust engine curb idle speed.
(5) Apply (and hold) service brakes.
(6) Shift transmission into D range and note line
pressure with engine at curb idle speed. Pressure
should be 61-to-70 psi (421-to-481 kPa).
(7) Press accelerator pedal to wide open throttle
position and note line pressure. Pressure should be
173-to-209 psi (1196-to-1442 kPa).
CAUTION: Do not hold wide open throttle for more
than 3-4 seconds at a time.
(8) Shift transmission into Reverse and note line
pressure with engine at curb idle speed. Pressure
should be 75-to-90 psi (519-to-618 kPa).
(9) Press accelerator to wide open throttle position
and note line pressure in Reverse. Pressure should
be 213-to-263 psi (1471-to-1814 kPa).
CAUTION: Do not hold wide open throttle for more
than 4 seconds.
(10) If line pressure is not within specifications,
adjust transmission throttle cable and repeat pres-
sure test.
Fig. 27 Pressure Test Gauge Connection
JAW-4 TRANSMISSION DIAGNOSIS 21 - 177

PRESSURE TEST ANALYSIS
If pressures in D and Reverse are higher than
specified in test, check for the following:
²throttle cable loose, worn, binding or out of adjust-
ment
²throttle valve, downshift plug, throttle cam, or pri-
mary regulator valve are sticking, worn or damaged
If pressures in D and Reverse are lower than spec-
ified in test, check for following:
²throttle cable loose, worn, binding or out of adjust-
ment
²throttle valve, downshift plug, or throttle cam
sticking, worn or damaged
²primary regulator valve sticking, worn, or dam-
aged
²oil pump gears or housing worn, or damaged
²overdrive clutch worn, or damaged
If pressures are low in D range only, check for fol-
lowing:
²forward clutch worn or damaged
²fluid leakage in D range circuit (component seal
and O-rings)
If pressures are low in Reverse only, check for fol-
lowing:
²shift cable and manual valve out of adjustment
²fluid leakage in reverse circuit (component seal
and O-rings)
²direct clutch worn or damaged
²first/reverse brake worn or damaged
TORQUE CONVERTER STALL TEST
Stall testing checks the holding ability of the trans-
mission clutches and brakes and of the torque con-
verter stator overrunning clutch.Stall speeds are
checked in both Drive and Reverse ranges with
the AW-4 transmission.
(1) Before starting test, be sure fluid level is cor-
rect and fluid is at normal operating temperature.
(2) Connect tachometer to engine. Position tachom-
eter so it can be viewed from drivers seat.
(3) Apply parking brakes and block wheels.
(4) Apply and hold service brakes.
(5) Shift transfer case into 2H position.
(6) Start engine.
WARNING: DO NOT ALLOW ANYONE TO STAND AT
THE FRONT OR REAR OF THE VEHICLE DURING
THE TEST.
(7) Shift transmission into D range.
(8) Open throttle completely and record maximum
engine rpm registered on tachometer. It takes any-
where from 4 to 10 seconds to reach maximum rpm.
However, once maximum rpm has been achieved,do
not hold wide open throttle for more than 3-4
seconds.CAUTION: Stalling the converter causes a rapid in-
crease in fluid temperature. To avoid fluid overheat-
ing, hold wide open throttle for no more than 4
seconds after reaching peak rpm. In addition, if
more than one stall test is required, run the engine
at 1000 rpm with the transmission in Neutral for at
least 20 seconds to cool the fluid.
(9) Stall speed should be in 2100-2400 rpm range
in Drive.
(10) Release throttle, shift transmission into Neu-
tral, and run engine for 20-30 seconds to cool fluid.
(11) Shift transmission into Reverse.
(12) Repeat stall test described in step (8).
(13) Stall speed in Reverse should also be in 2100-
2400 rpm range.
(14) Release accelerator pedal, shift transmission
into Neutral, and run engine for 20-30 seconds to
cool fluid.
STALL SPEED TEST ANALYSIS
If engine rpm is lower than specified in D and Re-
verse, check for the following:
²engine output/performance insufficient
²stator overrunning clutch in torque converter not
holding if engine speed was 1500 rpm or less.
If stall speed in D range is higher than specified,
check for the following:
²line pressure low
²forward clutch slipping
²No. 2 one-way clutch not holding
²overdrive one-way clutch not holding
If stall speed in Reverse was higher than specified,
check for the following:
²line pressure low
²direct clutch slipping
²first/ reverse brake slipping
²overdrive one-way clutch not holding
If stall speeds were higher than specified in both D
and Reverse, check for the following:
²low fluid level
²line pressure low
²overdrive one-way clutch not holding
TIME LAG TEST
This test checks general condition of the overdrive
clutch, forward clutch, rear clutch and first/reverse
brake. Condition is indicated by the amount of time
required for clutch/brake engagement with the en-
gine at curb idle speed. Engagement time is mea-
sured for D and Reverse positions. A stop watch is
recommended for test accuracy.
TEST PROCEDURE
(1) Check and adjust transmission fluid level if
necessary.
(2) Bring transmission to normal operating tem-
perature.
21 - 178 AW-4 TRANSMISSION DIAGNOSISJ

(3) Apply parking brakes and turn off air condi-
tioning unit.
(4) Shift transfer case into 2H range.
(5) Start engine and check curb idle speed. Adjust
speed if necessary. Curb idle must be correct to en-
sure accurate test results.
(6) Shift transmission into Neutral and set stop
watch.
(7) During following test steps, start stop watch as
soon as shift lever reaches D and Reverse ranges.
(8) Shift transmission into D range and record
time it takes for engagement. Repeat test two more
times.
(9) Reset stop watch and shift transmission back to
Neutral.
(10) Shift transmission into Reverse and record
time it takes for engagement. Repeat test two more
times.(11) Engagement time in D range should be a max-
imum of 1.2 seconds. Engagement time for Reverse
should be a maximum of 1.5 seconds.
TIME LAG TEST ANALYSIS
If engagement time is longer than specified for D
range, check for the following:
²shift cable misadjusted
²line pressure low
²forward clutch worn
²overdrive clutch worn or damaged
If engagement time is longer than specified for Re-
verse, check for the following:
²shift cable misadjusted
²line pressure low
²direct clutch worn
²first/reverse brake worn
²overdrive clutch worn or damaged
JAW-4 TRANSMISSION DIAGNOSIS 21 - 179

(6) Let engine run at normal curb idle speed, apply
service brakes. Then shift transmission through all
gear ranges and back to PARK (leave engine run-
ning).
(7) Remove dipstick and check fluid level. Add only
enough fluid to bring level to Full mark on dipstick.
Do not overfill.If too much fluid is added, excess
amount can be removed with suction gun and
plastic tubing. Tubing only has to be long
enough to extend into oil pan.
(8) When fluid level is correct, shut engine off, re-
lease park brake, remove funnel, and reseat dipstick
in fill tube.
TRANSMISSION CONTROL MODULE (TCM)
SERVICE
Use the DRB scan tool to diagnose transmission
control module function whenever a fault is sus-
pected. Replace the module only when the scan tool
indicates the module is actually faulty.
TRANSMISSION CONTROL MODULE
REPLACEMENT
The transmission control module is mounted under
the instrument panel. On left hand drive models, it is
at the driver side of the lower finish panel (Fig. 2).
On right hand drive models, it is at the passenger
side of the lower finish panel (Fig. 3).
To remove the module, disconnect the wire harness,
remove the mounting screws and remove the module
from the finish panel. Tighten the module mounting
screws securely after installation. Also be sure the
wire harness is not twisted, kinked or touching any
body panels.
PARK/NEUTRAL POSITION SWITCH
SWITCH TESTING
Test switch continuity with an ohmmeter. Discon-
nect the switch and check continuity at the connector
terminal positions and in the gear ranges indicated
in Figure 3. Switch continuity should be as follows:
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.
Fig. 2 TCM Location (Left Hand Drive)
Fig. 3 TCM Location (Right Hand Drive)
Fig. 4 Park/Neutral Position Switch Terminals And
Testing
JAW-4 IN-VEHICLE SERVICE 21 - 183

(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.
(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.
Fig. 5 Park/Neutral Position Switch Removal/
Installation
Fig. 6 Park/Neutral Position Switch Adjustment
Fig. 7 Oil Screen Removal/Installation
21 - 184 AW-4 IN-VEHICLE SERVICEJ

SHIFT CABLE ADJUSTMENT
(1) Shift transmission into Park.
(2) Raise vehicle.
(3) Release cable adjuster clamp to unlock cable
(Figs. 46 and 47). Clamp is at transmission end of ca-
ble.
(4) Unsnap cable from transmission cable bracket
(Figs. 46 and 47).
(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
(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.
(4) Pull cable lock button up to release cable (Fig.
47).
(5) Pull cable forward. Then release cable and
press cable lock button down until it snaps in place.
(6) Check adjustment as follows:
Fig. 45 Throttle Cable Adjustment
Fig. 46 Shift and Interlock Cables
Fig. 44 Throttle Cable Components
JAW-4 IN-VEHICLE SERVICE 21 - 195

the front bumper and radiator support be removed
for access to the cooler lines and attaching bracket.
REVERSE FLUSHING MAIN AND AUXILIARY
COOLERS AND COOLER LINES
Reverse flushing the cooler and lines will prevent
sludge and particles from flowing back into the
transmission after repair. The flushing procedure ap-
plies to standard (in-radiator) coolers and auxiliary
coolers equally.
Pressure equipment is preferred for reverse flush-
ing. However, reverse flushing can be performed us-
ing hand operated equipment as described in the
following procedure.
(1) Disconnect cooler lines at transmission and at
auxiliary cooler (Figs. 48 and 49).
(2) Position drain pan under cooler line to catch
material flushed through coolers and lines.
(3) Reverse flush each cooler using hand operated
suction gun filled with mineral spirits. Insert gun
nozzle (or hose) into cooler inlet (return) line. Then
force mineral spirits through into line and through
cooler.
(4) Continue reverse flushing until fluid exiting in-
let (pressure) line is clear and free of debris/residue.
(5) Replace radiator if fluid cannot be pumped
through main cooler. Replace auxiliary cooler if leaks
are evident, or if fluid cannot be pumped through it.
(6) Clear flushing materials from coolers 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.(7) Pump one quart of fresh automatic transmis-
sion fluid through cooler and lines before reconnect-
ing cooler lines.
FLOW TESTING TRANSMISSION MAIN
COOLER
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 fit-
ting.
(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.
TRANSMISSION COOLER LINE FITTINGS
Quick connect fittings are used at the transmission
cooler line connections. The fitting seals and guides
are serviceable.
Replace the seals and guides whenever the fittings
exhibit leakage, or will not properly snap into place.
Fig. 49 Auxiliary Cooler Mounting (Right Hand Drive)
JAW-4 IN-VEHICLE SERVICE 21 - 197