lock JEEP CHEROKEE 1995 Service Repair Manual

(12) Inspect and replace any worn or damaged
planetary gear components.
ASSEMBLING REAR PLANETARY, BRAKE
PACK, CLUTCH AND SHAFT
(1) Install hub and snap ring in ring gear (Fig. 11)
(2) Identify ring gear thrust bearing and races by
following dimensions (Fig. 10):
²Outer diameter of bottom race is 44.8 mm (1.764
in.) and inner diameter is 27.6 mm (1.087 in.).
²Outer diameter of bearing is 44.7 mm (1.760 in.)
and inner diameter is 30.1 mm (1.185 in.).
²Outer diameter of upper race is 44.8 mm (1.764
in.) and inner diameter is 28.8 mm (1.134 in.).
(3) Lubricate ring gear thrust bearing and races
with petroleum jelly and install them in ring gear
(Fig. 10).
(4) Coat planetary thrust washers with petroleum
jelly and install them in gear (Fig. 9).(5) Install No. 2 one-way clutch in planetary gear.
Be sure flanged side of clutch faces upward (Fig. 12).
(6) Install clutch retaining snap ring and install
clutch inner race (Fig. 7). Turn race counterclockwise
to ease installation.
(7) Verify one-way clutch operation. Hold gear and
turn inner race in both directions. Race should turn
freely counterclockwise, but lock when turned clock-
wise.
(8) Install planetary gear in ring gear.
Fig. 8 Removing.Installing One-Way Clutch
Fig. 9 Removing/Installing Rear Planetary Thrust
Washers
Fig. 10 Removing/Installing Ring Gear Thrust
Bearing And Races
21 - 246 AW-4 TRANSMISSION OVERHAULJ

(9) Assemble clutch discs and clutch plates (Fig. 4).
Sequence is disc first, then a plate. Use seven discs
and plates in a 6-cyl. transmission.
(10) Install brake pack on planetary gear (Fig. 4).
(11) Install new seal ring on output shaft (Fig. 3).
Be sure ring ends are interlocked as shown.(12) Set assembled components aside for final as-
sembly.
FIRST-REVERSE BRAKE PISTON AND
TRANSMISSION CASE OVERHAUL
BRAKE DISASSEMBLY AND INSPECTION
(1) Remove bearing and race assembly from trans-
mission case (Fig. 2).
(2) Check first/reverse brake piston operation with
compressed air (Fig. 3). Piston should move smoothly
and not bind or stick. If piston operation is incorrect,
case or piston may require replacement.
(3) Compress piston return springs with Tool 7539
and remove piston snap ring (Fig. 4).
Fig. 12 Installing No. 2 One-Way Clutch
Fig. 1 First-Reverse Brake Pistons And Transmission Case
Fig. 11 Removing/Installing Ring Gear Hub
JAW-4 TRANSMISSION OVERHAUL 21 - 247

(7) Remove second coast modulator valve retainer
and remove valve plug, spring and valve.
(8) Remove lock-up relay valve retainer and re-
move relay valve and sleeve assembly (Fig. 8).
(9) Remove relay valve, spring and plunger from
valve sleeve (Fig. 9).
(10) Remove secondary pressure regulator valve re-
tainer and remove plug, regulator valve and spring
(Fig. 10).
(11) Remove cut-back valve retainer and remove
plug, cut-back valve and spring (Fig. 11).
(12) Remove 2-3 shift valve retainer and remove
plug, spring and 2-3 shift valve (Fig. 12).
(13) Remove low coast modulator valve retainer
and remove valve plug, spring and low coast modula-
tor valve (Fig. 13).
(14) Clean the upper body components with solvent
and dry them with compressed air only. Do not use
shop towels or rags. Lint or foreign material from
towels or rags can interfere with valve operation.
(15) Inspect condition of the upper body compo-
nents. Replace the upper body if any of the bores are
scored or corroded. Replace any valves, plugs or
sleeves if scored or worn. Replace the oil strainer if
cut, torn or damaged in any way.
Fig. 7 Removing/Installing Second Coast Modulator
Valve
Fig. 8 Removing/Installing Converter Clutch Relay
Valve
Fig. 9 Relay Valve Components
21 - 258 AW-4 TRANSMISSION OVERHAULJ

(16) Inspect the valve body springs. Replace any
spring having rusted, distorted, or collapsed coils-
.Measure length of each spring. Replace any spring if
free length is less than specified in the chart (Fig.
14).
UPPER BODY ASSEMBLY
(1) Lubricate the valves, springs, plugs, sleeves
and the valve bores in the upper body with automatic
transmission fluid.
(2) Note position of the valve retainers (A) and
stop (B) for assembly reference (Fig. 15).
(3) Install low coast modulator valve, spring and
plug in valve bore. Press valve plug inward and in-
stall retainer (Fig. 13).
(4) Install 2-3 shift valve, spring and plug in valve
bore. Press plug inward and install retainer (Fig. 12).(5) Install cut-back valve spring, valve and plug
(Fig. 11). Press plug inward and install retainer.
(6) Install secondary regulator valve spring, valve
and plug in valve bore. Press plug inward and install
retainer (Fig. 10).
(7) Assemble lock-up relay valve. Install spring
and plunger in valve sleeve (Fig. 9). Then install as-
sembled valve in sleeve.
(8) Install assembled lock-up relay valve in valve
bore and install retainer (Fig. 8).
(9) Install second coast modulator valve, spring
and plug in valve bore. Press plug inward and install
retainer (Fig. 7).
(10) Install 3-4 shift valve, spring and plug in bore.
Press plug inward and install retainer (Fig. 6).
Fig. 14 Upper Body Spring/Valve Identification
21 - 260 AW-4 TRANSMISSION OVERHAULJ

(11) Install second brake piston sleeve (Fig. 8).
Sleeve lip faces up and toward case front as shown.
(12) Install second brake drum gasket with In-
staller Tool 7544 (Fig. 9). Gasket depth is 43.7 mm
(1.720 in.).(13) Install park lock pawl, spring and pin (Fig.
10).
(14) Connect park lock rod to manual valve shift
sector (Fig. 11).
Fig. 8 Installing Second Brake piston Sleeve
Fig. 9 Installing Second Brake Drum Gasket
Fig. 10 Installing Park Lock Pin, Spring And Pawl
Fig. 11 Installing Park Lock Rod
JAW-4 TRANSMISSION OVERHAUL 21 - 267

(15) Position park lock rod bracket on case and
tighten bracket attaching bolts to 10 Nzm (7 ft. lbs.)
torque (Fig. 12).
(16) Verify park lock operation. Move shift sector
to Park position. Park pawl should be firmly engaged
(locked) in planetary ring gear (Fig. 13).(17) Install No. 1 one-way clutch (Fig. 14). Short
flanged side of clutch faces up and toward case front.
(18) Install second brake pack (Fig. 15). Install
disc then plate. Continue installation sequence until
correct number of discs-plates are installed. Use five
discs and five plates.
(19) Install second brake pack retainer with
rounded edge of retainer facing disc.
(20) Install second brake pack snap ring.
Fig. 12 Installing Park Rod Bracket
Fig. 13 Checking Park Pawl Engagement
Fig. 14 Installing No. 1 One-Way Clutch
Fig. 15 Installing Second Brake Pack
21 - 268 AW-4 TRANSMISSION OVERHAULJ

(21) Check brake pack clearance with feeler gauge
(Fig. 16). Clearance should be 0.062 - 1.98 mm (0.024
- 0.078 in.). If brake pack clearance is not correct,
brake pack components are not seated. Reassemble
brake pack if necessary.
(22) Install planetary sun gear and input drum
(Fig. 17). Be sure drum thrust washer tabs are
seated in drum. Use petroleum jelly to hold thrust
washer in position if necessary.(23) Install front planetary gear on sun gear (Fig.
18).
(24) Support output shaft with wood blocks (Fig.
19).
Fig. 16 Checking Second Brake Pack Clearance
Fig. 17 Installing Sun Gear And Input Drum
Fig. 18 Installing Front Planetary Gear
Fig. 19 Supporting Output Shaft
JAW-4 TRANSMISSION OVERHAUL 21 - 269

(69) Verify input shaft rotation. Shaft should rotate
smoothly and not bind.
(70) Lubricate and install new O-ring on transmis-
sion throttle cable adapter and install cable in case
(Fig. 55).
(71) Check clutch and brake operation. Operate
clutches and brakes with compressed air applied
through feed holes in case (Fig. 56). Listen for clutch
and brake application. If you do not hear a clutch or
brake apply, disassemble transmission and repair
fault before proceeding.It is necessary to block
the overdrive clutch accumulator feed hole No.
8 (Fig. 56) in order to check direct clutch oper-
ation.
(72) Lubricate and install new O-rings on accumu-
lator pistons (Fig. 57).
Fig. 53 Installing Oil Pump Thrust Race
Fig. 54 Installing Oil Pump
Fig. 55 Installing Transmission Throttle Cable
Fig. 56 Clutch And Brake Feed Hole Locations
21 - 278 AW-4 TRANSMISSION OVERHAULJ

SHIFT LINKAGE ADJUSTMENT
(1) Shift transfer case into 4L position.
(2) Raise vehicle.
(3) Loosen lock bolt on adjusting trunnion (Figs. 3
and 4).
4) Be sure linkage rod slides freely in trunnion.
Clean rod and apply spray lube if necessary.
(5) Verify that transfer case range lever is fully en-
gaged in 4L position.
(6) Tighten adjusting trunnion lock bolt.
(7) Lower vehicle.
SHIFT LEVER REMOVAL (XJ)
(1) Shift transfer case into 4L.
(2) Raise vehicle.
(3) Loosen adjusting trunnion locknut and slide
shift rod out of trunnion (Fig. 4). If rod lacks enough
travel to come out of trunnion, push trunnion out of
torque shaft.
(4) Lower vehicle.
(5) Remove console. Refer to park brake section in
Group 5 for procedures.
(6) Remove screws attaching lever assembly to
floorpan and remove assembly and shift rod (if left
attached).
SHIFT LEVER INSTALLATION (XJ)
(1) If shift rod was not removed from lever assem-
bly, work rod down through floorpan opening. Then
position lever assembly on floorpan and install as-
sembly attaching screws.
(2) Install console.
(3) Raise vehicle.
(4) Connect trunnion to torque shaft arm. Or, slide
shift rod into trunnion on range lever. Be sure shift
rod slides freely in trunnion.
(5) Verify that range lever is in 4L position. Then
tighten trunnion lock bolt.(6) Lower vehicle and check transfer case shift op-
eration.
SHIFT LEVER REMOVAL (YJ)
(1) Shift transfer case into neutral.
(2) Remove shift lever knob and retaining nut.
Then remove shift lever boot and bezel.
(3) Raise vehicle
(4) Loosen lock bolt in adjusting trunnion and slide
shift rod out of trunnion (Fig. 3).
(5) Remove bolts/nuts attaching bracket and brace
assembly to transmission (Fig. 5).
(6) Remove shift lever and bracket as assembly.
(7) YJ shift lever assembly is serviceable. If any
assembly part must be replaced, remove pivot bolt,
lever pin E-clip, and lever pin and spring. Then dis-
assemble and replace necessary part (Fig. 6).
SHIFT LEVER INSTALLATION (YJ)
(1) Assemble lever components, if necessary. Lube
pivot bolt and pin with Mopar multi-mileage grease
before installation.
(2) Work shift lever upward into vehicle interior.
Then position lever and bracket assembly on trans-
mission and install attaching bolts/nuts.
(3) Place transfer case range lever in 4L position.
Then slide shift rod into trunnion and tighten lock
bolt.
Fig. 3 Adjusting Trunnion And Lock Bolt (YJ)
Fig. 4 Shift Linkage (XJ)
21 - 286 NP231 TRANSFER CASEJ

TRANSFER CASE DISASSEMBLY AND OVERHAUL
Two versions of the NP231 are used in current
models. One version retains the synchronizer
components used in previous years. A newly intro-
duced version does not have synchro components.
The non-synchro version is not equipped with a
synchro gear, struts, springs, or stop ring. During
overhaul, note which version is being serviced
and order needed parts accordingly.
(1) Remove fill and drain plugs. Also remove speed-
ometer adapter and pinion if not previously removed.
(2) Remove front yoke. Discard yoke seal washer
and nut. They should not be reused.
(3) Move transfer case range lever rearward to 4L
position.
(4) Remove extension housing attaching bolts.
(5) Tap extension housing in clockwise direction to
break sealer bead and remove housing (Fig. 1).
CAUTION: To avoid damaging the sealing surfaces
of the extension housing and rear retainer, do not
pry or wedge the housing off the retainer.
(6) Remove rear bearing snap ring (Fig. 2).
(7) Remove rear retainer attaching bolts.
(8) Remove rear retainer. Position screwdriver un-
der each tab on retainer housing (Fig. 3). Then care-
fully pry retainer upward and off rear case.
CAUTION: Do not pry against the sealing surfaces
of the retainer or rear case. The surfaces could be
damaged.
(9) Remove bolts attaching rear case to front case.
Retain bolts and washers.
(10) Separate rear case from front case (Fig. 4) Insert
screwdrivers into slots cast in case ends. Then gently
pry upward to break sealer bead and loosen rear case.
CAUTION: Do not pry against the sealing surfaces of
the retainer or rear case. The surfaces could be dam-
aged.
Fig. 1 Extension Housing Removal
Fig. 2 Rear Bearing Snap Ring Removal
Fig. 3 Rear Retainer Removal
Fig. 4 Loosening Rear Case
JNP231 TRANSFER CASE 21 - 289