JEEP XJ 1995 Service And Repair Manual

30RH/32RH IN-VEHICLE SERVICE
INDEX
page page
Converter Drainback Check Valve Service...... 113
Fluid and Filter Replacement................. 99
Fluid Level Check......................... 99
Front Band Adjustment.................... 102
Governor and Park Gear Service............. 105
Oil Filter Replacement..................... 103
Park Interlock Cable Adjustment (XJ).......... 101
Park Lock Component Replacement.......... 108
Park/Neutral Position Switch Service.......... 109
Rear Band Adjustment.................... 103
Recommended Fluid....................... 99Refilling After Overhaul or Fluid/Filter Change . . . 100
Shift Cable Adjustment (XJ)................. 100
Shift Linkage Adjustment (YJ)............... 100
Speedometer Service..................... 109
Throttle Valve Cable Adjustment (XJ/YJ)....... 101
Transmission Cooler Flow Testing............ 113
Transmission Cooler Line and Fitting Service.... 111
Transmission Cooler Reverse Flushing......... 114
Valve Body Installation.................... 104
Valve Body Removal...................... 104
Valve Body Service....................... 104
RECOMMENDED FLUID
Recommended (and preferred) fluid for 30RH/32RH
transmissions is Mopar ATF Plus, type 7176.
Dexron II is not really recommended and should
only be used when ATF Plus is not available.
FLUID LEVEL CHECK
Transmission fluid level should be checked monthly
under normal operation. If the vehicle is used for
trailer towing or similar heavy load hauling, check
fluid level and condition weekly.
Fluid level is checked with the engine running at
curb idle speed, the transmission in Neutral and the
transmission fluid at normal operating temperature.
FLUID LEVEL CHECK PROCEDURE
(1) Transmission fluid must be at normal operating
temperature for accurate fluid level check. Drive ve-
hicle if necessary to bring fluid temperature up to
normal hot operating temperature of 82ÉC (180ÉF).
(2) Position vehicle on level surface. This is ex-
tremely important for accurate fluid level check.
(3) Start and run engine at curb idle speed.
(4) Apply parking brakes.
(5) Shift transmission momentarily into all gear
ranges. Then shift transmission back to Neutral.
(6) Clean top of filler tube and dipstick to keep dirt
from entering tube.
(7) Remove dipstick and check fluid level as fol-
lows:
(a) Dipstick has three fluid level indicator levels
(Fig. 1) which are a MIN dot, an OK crosshatch
area, and a MAX fill arrow.
(b) Correct maximum level is to MAX arrow
mark. Correct acceptable level is to OK mark in
crosshatch area.
(c) Incorrect level is at or below MIN dot.
(d) If fluid is low, add only enough Mopar ATF
Plus restore correct level. Do not overfill.CAUTION: Do not overfill the transmission. Overfill-
ing may cause leakage out the pump vent which
can be mistaken for a pump seal leak. Overfilling
will also cause fluid aeration and foaming as the ex-
cess fluid is picked up and churned by the gear
train. This will reduce fluid life significantly.
FLUID AND FILTER REPLACEMENT
NORMAL CHANGE INTERVAL
The fluid and filter should be changed (and the
bands adjusted) at recommended maintenance inter-
vals, or whenever the transmission has been disas-
sembled for any reason.
Refer to the Driveline section in Group O, Lubrica-
tion and Maintenance for recommended change inter-
vals. Refer to the fluid/filter replacement and band
adjustment procedures in this section.
SEVERE USAGE CHANGE INTERVAL
Under severe usage, the fluid and filter should be
changed and the bands adjusted at 12,000 mile (19
000 Km) intervals.
Severe usage is defined as:
(a) More than half of vehicle operation occurs in
heavy city traffic during hot weather (above 90É F).
(b) Vehicle is used for taxi, police, limousine, or
similar commercial operation.
Fig. 1 Fluid Level Marks On Transmission Dipstick
J30RH/32RH IN-VEHICLE SERVICE 21 - 99

(c) Vehicle is used for trailer towing or heavy
load hauling.
FLUID/FILTER REPLACEMENT PROCEDURE
(1) Raise vehicle.
(2) Remove oil pan and drain fluid.
(3) Clean oil pan and pan magnet. Then clean re-
maining gasket material from gasket surface of
transmission case.
(4) Remove fluid filter screws and remove filter.
(5) Position new filter on valve body and install fil-
ter screws. Tighten screws to 4 Nzm (35 in. lbs.)
torque.
(6) Adjust rear band at this time if required.
(7) Position new gasket on oil pan and install pan
on transmission. Tighten pan bolts to 150 in. lbs. (17
Nzm) torque.
(8) Adjust front band at this time if required.
(9) Lower vehicle and refill transmission with Mo-
par ATF Plus, type 7176 fluid.
REFILLING AFTER OVERHAUL OR FLUID/FILTER
CHANGE
The most effective way to avoid overfilling after a
fluid change or overhaul is as follows:
(1) Remove dipstick and insert clean funnel in
transmission fill tube.
(2) Add following initial quantity of Mopar ATF
Plus to transmission:
(a) If only fluid and filter were changed, add3
pints (1-1/2 quarts)of ATF Plus to transmission.
(b) If transmission was completely overhauled
and torque converter was replaced or drained, add
10 pints (5 quarts)of ATF Plus to transmission.
(3) Apply parking brakes.
(4) Start and run engine at normal curb idle speed.
(5) Apply service brakes, shift transmission
through all gear ranges then back to Neutral, and
leave engine running at curb idle speed.
(6) Remove funnel, insert dipstick and check fluid
level. Add only enough fluid to bring level toMIN
dot mark on dipstick.
(7) Drive vehicle until transmission fluid is at nor-
mal operating temperature. Then recheck fluid level
as described in next step.
(8) Leave engine running at curb idle speed, shift
into Neutral, and check fluid level again. This time,
add just enough fluid to bring level up toMAX ar-
row mark but do not overfill.
(9) When fluid level is correct, shut engine off, re-
lease park brake, remove funnel, and reseat dipstick
in fill tube.
SHIFT 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,
bellcrank brackets and linkage bushings/grommets
(Fig. 2). Tighten, repair, replace worn, damaged
parts. Do not attempt adjustment if linkage compo-
nents are worn or damaged.
(7) Loosen shift rod trunnion lock bolt or nut. Be
sure upper shift rod slides freely in trunnion (Fig. 2).
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.
2). 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.
(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 in-
correct 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. 3 and 4). Clamp is at transmission end of ca-
ble.
(4) Unsnap cable from transmission cable bracket.
(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.
21 - 100 30RH/32RH IN-VEHICLE SERVICEJ

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.(4) Pull cable lock button up to release cable (Fig.
4).
(5) Pull cable forward. Then release cable and
press cable lock button down until it snaps in place.
(6) Check adjustment as follows:
(a) Check movement of release shift handle but-
ton (floor shift) or release lever (column shift). You
should not be able to press button inward or move
column lever.
(b) Turn ignition switch to On position.
(c) Press floor shift lever release button or move
column lever. Then shift into Neutral. If cable ad-
justment is correct, ignition switch can not be
turned to Lock position. Perform same check with
transmission in D range.
(7) Move shift lever back to Park and check igni-
tion switch operation. You should be able to turn
switch to Lock position and shift lever release button/
lever should not move.
THROTTLE VALVE CABLE ADJUSTMENT (XJ/YJ)
The throttle valve cable controls throttle pressure
and kickdown on 30RH/32RH transmissions (Fig. 5).
Correct cable adjustment is important to proper
shifting. The cable positions the throttle valve which
controls shift speed, shift quality and part throttle
downshift sensitivity. If the setting is incorrect, shift
quality and shift speeds will be unsatisfactory.
Fig. 2 Gearshift Linkage (YJ)
Fig. 3 Shift Cable (XJ)
J30RH/32RH IN-VEHICLE SERVICE 21 - 101

THROTTLE VALVE 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 compo-
nents.
(1) Shift transmission into Park and shut engine
off.
(2) Press cable release button (Fig. 6).
(3) Push cable conduit back into cable adjuster
body as far as possible (Fig. 7).(4) Rotate throttle body lever to wide open throttle
position. Cable will ratchet to correct adjustment
point as lever is rotated (Fig. 7).
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.
Fig. 5 Transmission Throttle Valve Cable
Fig. 4 Park Lock Cable Attachment (XJ)
Fig. 6 Throttle Valve Cable Components
21 - 102 30RH/32RH IN-VEHICLE SERVICEJ

(3) Clean adjusting screw threads with Mopar rust
penetrant if necessary. Then lubricate threads with
Mopar 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. 8).
(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. 9).
(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.
OIL FILTER REPLACEMENT
(1) Raise vehicle.
(2) Remove oil pan and drain fluid.
(3) Remove filter screws and remove oil filter (Fig.
10).
(4) Position new filter on valve body and install fil-
ter screws finger tight.
(5) Tighten filter screws to 4 Nzm (35 in. lbs.) with
inch-pound torque wrench.
(6) Position new gasket on oil pan and install pan
Fig. 7 Throttle Valve Cable Adjustment
Fig. 8 Front Band Adjustment
Fig. 9 Rear Band Lever And Adjusting Screw
Location
J30RH/32RH IN-VEHICLE SERVICE 21 - 103

on transmission. Tighten pan bolts to 17 Nzm (150 in.
lbs.) torque.
(7) Lower vehicle.
(8) Refill transmission with Mopar ATF Plus.
VALVE BODY REMOVAL
(1) Raise vehicle.
(2) Remove oil pan and drain fluid.
(3) Disconnect gearshift and throttle linkage at
transmission levers.
(4) Loosen clamp bolts and remove throttle and
manual valve levers from manual valve shaft.
(5) Disconnect park/neutral position switch wires
and remove switch and switch seal.
(6) Remove valve body oil filter.
(7) Remove valve body attaching screws. Lower
valve body slightly and remove accumulator piston
and spring (Fig. 11). Rotate valve body down and
away from case. Pull it forward to disengage park
rod and remove valve body.
(8) Position valve body on bench or on repair stand
for disassembly, cleaning and inspection (Fig. 12).
VALVE BODY SERVICE
The valve body can be disassembled for cleaning
and inspection of the individual components. Valve
body service procedures are detailed in the overhaul
section.
The only serviceable valve body components are:
²park lock rod and E-clip
²switch valve and spring
²pressure adjusting screw bracket
²throttle valve lever
²manual lever
²manual lever shaft seal, washer, E-clip and detent
ball
²fluid filter
²converter clutch solenoid
The remaining valve body components are serviced
only as part of a complete valve body assembly.
VALVE BODY INSTALLATION
(1) Place valve body manual lever in low (1 posi-
tion) so park lock rod can be installed in sprag.
(2) Position park sprag with screwdriver to ease
lock rod installation and engagement.
(3) Install new seals on accumulator piston if nec-
essary and install piston in case. A small amount of
petroleum jelly can be used to hold piston in place.
(4) Lubricate shaft of manual lever and lip of shaft
seal with petroleum jelly.
(5) Raise valve body and align park rod with case
opening and park sprag. Then push rod end through
opening and past sprag. Rotate propeller shaft if nec-
essary.
(6) Position accumulator spring on transfer plate.
Fig. 10 Oil Filter Screw Locations
Fig. 11 Accumulator Piston And Spring
Fig. 12 Valve Body Assembly
21 - 104 30RH/32RH IN-VEHICLE SERVICEJ

(7) Align valve body and seat it on case. Be sure
manual lever shaft and accumulator spring are prop-
erly seated.
(8) Hold valve body in position and install one or
two attaching bolts to hold valve body in place.
(9) Install remaining valve body bolts. Tighten all
bolts evenly in a diagonal pattern to 12 Nzm (105 in-
lbs) torque.
(10) Install new oil filter and tighten filter screws
to4Nzm (35 in. lbs.) torque.
(11) Connect converter solenoid wire to case con-
nector.
(12) Install manual and throttle levers on throttle
lever shaft. Tighten lever clamp screws and check for
free operation. Shaft and levers must operate freely
without any bind.
(13) Install oil pan and new gasket. Tighten pan
bolts to 17 Nzm (13 ft. lbs.) torque.
(14) Install seal on neutral switch, install switch in
case, and connect switch wires.
(15) Lower vehicle.
(16) Fill transmission with Mopar ATF Plus, Type
7176 fluid.
(17) Adjust gearshift linkage and throttle valve
(kickdown) cable if necessary.
GOVERNOR AND PARK GEAR SERVICE
GOVERNOR/PARK GEAR REMOVAL
(1) Raise vehicle.
(2) Mark both propeller shaft yokes for assembly
reference and disconnect propeller shafts at transfer
case.
(3) Disconnect speed sensor wires and remove
speedometer adapter and sensor.
(4) Position support stand under transmission con-
verter housing.
(5) Remove rear crossmember.
(6) Disconnect parking brake cable at equalizer
and disconnect exhaust components as necessary.
(7) Support transfer case with jack.
(8) Remove bolts attaching transfer case to trans-
mission adapter housing and remove transfer case.
(9) Remove bolts attaching adapter, or extension
housing to transmission and remove adapter/housing.
(10) Loosen but do not remove bolts that attach
governor body to park gear.
(11) Rotate transmission output shaft until gover-
nor weight assembly is accessible. Then remove
E-clip at this end of governor shaft.
(12) Remove governor valve and shaft from gover-
nor body (Fig. 13).
(13) Remove snap rings and washers that retain
governor body and park gear assembly on output
shaft (Fig. 14).
(14) Remove governor body-park gear assembly
from output shaft (Fig. 15).
GOVERNOR BODY/PARK GEAR DISASSEMBLY
(1) Remove bolts attaching governor body to park
gear; then separate body from gear.
Fig. 13 Governor Valve And Shaft Removal
Fig. 14 Governor Body/Park Gear Retaining Snap
Rings And Thrust Washer Position
Fig. 15 Governor Body And Park Gear Removal/
Installation
J30RH/32RH IN-VEHICLE SERVICE 21 - 105

(2) Remove cone shaped filter from park gear (Fig.
16).
(3) Remove snap ring and retainer washer that se-
cure governor weight assembly in body. Use Miller
C-3915 Internal Pliers to remove snap ring (Fig. 17).
(4) Remove governor weight assembly from gover-
nor body bore.
(5) On 30RH, disassembletwo-stagegovernor
weight as follows:
(a) Position weight assembly on suitable size
socket (Fig. 18).
(b) Push inner weight downward with nut driver.
Then remove inner weight snap ring with Snap
Ring Plier Tool C-3915 (Fig. 18).
(c) Remove inner weight and spring from outer
weight.
(6) On 32RH, disassemblethree-stagegovernor
weight as follows:
(a) Slide inner and intermediate assembly out of
outer weight.(b) Position intermediate weight on suitable size
socket (Fig. 19).
(c) Push inner weight downward with nut driver.
Then remove inner weight snap ring with Snap
Ring Plier Tool 6823 (Fig. 19).
(d) Remove inner weight and spring from inter-
mediate weight.
Fig. 16 Governor Filter Position
Fig. 17 Governor Weight Retaining Snap Ring And
Washer Removal
Fig. 18 Two-Stage Inner Weight Snap Ring
Removal/Installation
Fig. 19 Three-Stage Inner Weight Snap Ring
Removal/Installation
21 - 106 30RH/32RH IN-VEHICLE SERVICEJ

Governor/Park Gear Cleaning and Inspection
Thoroughly clean all the governor parts in a suit-
able cleaning solution but do not use any type of
caustic cleaning agents.
The governor weight components (Fig. 20) and the
governor valve (Fig. 21), must slide freely in their
bores when clean and dry. Minor surface scratches
and burrs can be smoothed with crocus cloth
The aluminum governor valve and outer weight
have a hard coating on them. Check condition of this
coating carefully. Do not reuse either part if the coat-
ing is damaged.
Inspect the governor weight spring for distortion.
Replace the spring, if distorted, collapsed, or broken.
Clean the filter in solvent and dry it with low pres-
sure compressed air. Replace the filter, if damaged.
Inspect the park gear for chipped or worn gear teeth
or damaged ring grooves. Replace the gear, if dam-
aged.
Check the teeth on the park gear for wear or dam-
age. Replace the gear if necessary. Inspect the metal
seal rings on the park gear hub. Replace the rings
only if severely worn, or broken.
GOVERNOR/PARK GEAR ASSEMBLY AND
INSTALLATION
(1) Lubricate governor components with transmis-
sion fluid during assembly.(2) Install new seal rings on park gear hub. Install
ring with interlock ends first and ring with plain
ends last. Slip each ring on hub and seat them in
grooves. Verify that rear ring ends are securely inter-
locked before proceeding.
CAUTION: Exercise care when installing the rings.
They are easily broken if overspread or twisted dur-
ing installation.
(3) Insert filter screen in park gear. Note that gear
has one filter bore that is concentric and one that
has a notch in it. Filter goes in bore that is concen-
tric as shown (Fig. 16).
(4) Position governor body on park gear. Be sure
filter is properly aligned in body recess.
(5) Install governor body bolts. Do not fully tighten
bolts at this time.
(6) Assemble governor weight components (Fig.
20). Then install weight assembly in governor body.
Be sure inner weight snap ring is fully seated
before proceeding.
(7) Install retainer washer and snap ring that se-
cure governor weight assembly in governor body.
(8) Align and install park gear/governor assembly
on output shaft.Be sure hole in output shaft for
governor valve shaft is aligned with governor
valve bore in governor body. Valve shaft will
Fig. 20 Governor Weight Components (2 and 3-Stage)
J30RH/32RH IN-VEHICLE SERVICE 21 - 107

bind if misalignment occurs. Remove and repo-
sition governor body if necessary.
(9) Verify that shaft bore in governor body and out-
put shaft are aligned.
(10) Verify that governor valve will be indexed
with spotface in output shaft. Reposition valve, shaft
and body if necessary.
(11) Install an E-clip on one end of governor valve
shaft. Be sure rounded side of E-clip is facing out
(away from weight).
(12) Insert governor valve shaft through governor
weight. Be sure shaft slides freely in bore.
(13) Install governor valve on shaft and in gover-
nor body bore.
(14) Install remaining E-clip on governor valve
shaft. Be sure rounded side of E-clip is facing out
(away from valve).
(15) Install governor body-park gear snap rings
and washer on output shaft as follows:
(a) On models with single snap ring, install snap
ring. Be sure ring is seated in shaft.
(b) On models with thrust washer and two snap
rings, install thin snap ring first. Then install
thrust washer second, and thick snap ring last
(Fig. 14).
16(c) Verify correct position of snap rings.Be
sure flat side of each snap ring is toward gov-
ernor body.(16) Tighten governor body-to-park gear bolts to 11
Nzm (95 in. lbs.).
(17) Install extension housing/adapter and gasket
on transmission. Tighten housing/adapter bolts to 32
Nzm (24 ft. lbs.).
(18) Install transfer case and rear crossmember.
(19) Install speed sensor and speedometer compo-
nents and connect speed sensor wires.
(20) Connect exhaust components and brake cable,
if removed.
(21) Align and connect propeller shafts. Tighten
clamp bolts to 19 Nzm (14 ft. lbs.) torque.
(22) Remove supports and lower vehicle.
(23) Check and adjust transmission fluid level.
PARK LOCK COMPONENT REPLACEMENT
COMPONENT REMOVAL
(1) Raise vehicle and remove transfer case and
adapter housing from transmission.
(2) Slide sprag shaft out of adapter housing and re-
move park sprag and spring (Fig. 22).
(3) Remove snap ring and slide plug and pin as-
sembly out of housing (Fig. 22).
(4) If park rod must be serviced, remove valve
body and remove rod.
Fig. 21 Governor Components (30RH/32RH)
21 - 108 30RH/32RH IN-VEHICLE SERVICEJ