JEEP XJ 1995 Service And Repair Manual

30RH/32RH TRANSMISSION OVERHAUL
INDEX
page page
Adapter/Extension Housing Inspection and Park
Lock Component Overhaul................ 127
Front Clutch Overhaul..................... 134
Front Servo and Band Overhaul............. 146
Governor and Park Gear Overhaul........... 127
Oil Pump Overhaul....................... 131
Overhaul Service Information................ 125
Overrunning ClutchÐLow-Reverse DrumÐRear
Support Overhaul....................... 125
Planetary Gear Train Overhaul.............. 141Rear Clutch Overhaul..................... 138
Rear Servo and Band Overhaul.............. 146
Transmission Assembly and Adjustment Procedures. 155
Transmission Assembly Tips................ 155
Transmission Case Cleaning and Inspection.... 125
Transmission Disassembly.................. 119
Valve Body Assembly and Adjustment......... 153
Valve Body Disassembly and Inspection....... 147
TRANSMISSION DISASSEMBLY
(1) Clean transmission exterior with steam gun or
with solvent. Wear eye protection during cleaning
process.
(2) Remove throttle and shift levers from valve
body manual shaft and throttle lever shaft.
(3) Mount transmission in repair stand C-3750-B
(Fig. 1).
(4) Remove nuts attaching adapter, or extension
housing to transmission case.
(5) Remove adapter/extension housing and gasket
(Fig. 2).
(6) Remove rear bearing and snap ring, if
equipped.(7) Remove park/neutral position switch and seal
(Fig. 3).
Fig. 1 Transmission Mounted On Typical Repair
Stand
Fig. 2 Adapter Housing Removal/Installation (4 x 4
Models)
Fig. 3 Park/Neutral Position Switch Removal/
Installation
J30RH/32RH TRANSMISSION OVERHAUL 21 - 119

(8) Remove oil pan bolts and remove pan and gas-
ket (Fig. 4).
(9) Remove hex head valve body attaching bolts
(Fig. 5).
(10) Disconnect solenoid wire from case connector
(Fig. 6).
(11) Lift valve body upward, guide park rod out of
case opening and remove valve body (Fig. 5).
(12) Remove accumulator spring and piston (Fig.
8).(13) Remove front band pivot pin access plug (Fig.
9). Plug is accessible through converter housing. Use
1/4 inch drive extension to remove plug as shown.
(14) Loosen front band adjusting screw locknut 4-5
turns. Then tighten band adjusting screw until band
is tight around front clutch retainer. This prevents
front/rear clutches from coming out with pump and
possibly damaging clutch or pump components.
Fig. 4 Oil Pan Removal/Installation
Fig. 5 Valve Body Attaching Bolt Locations (Typical)
Fig. 6 Solenoid Wire Connection
Fig. 7 Valve Body Removal/Installation
Fig. 8 Removing/Installing Accumulator Piston And
Spring
Fig. 9 Removing/Installing Front Band Pivot Pin
Access Plug
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(15) Remove oil pump bolts.
(16) Thread bolts in Slide Hammer Tools C-3752
into threaded holes in pump body flange (Fig. 10).
(17) Bump slide hammer weights outward to re-
move pump and reaction shaft support assembly
from case (Fig. 10).
(18) Loosen front band adjusting screw until band
is completely loose.
(19) Squeeze front band together and remove band
strut (Fig. 11).
(20) Remove front band reaction pin with pencil
magnet. Pin is accessible from converter housing side
of case (Fig. 12).
(21) Remove front band lever (Fig. 13)
(22) Slide front band rearward and onto driving
shell. Band will not be removed until after front/rear
clutch removal.
(23) Remove front and rear clutch units as assem-
bly. Grasp input shaft, hold clutch units together and
remove them from case (Fig. 14).
Fig. 10 Removing Oil Pump/Reaction Shaft Support
Fig. 11 Removing/Installing Front Band Strut
Fig. 12 Removing Front Band Reaction Pin
Fig. 13 Removing/Installing Front Band Lever
Fig. 14 Removing Front/Rear Clutch Assemblies
J30RH/32RH TRANSMISSION OVERHAUL 21 - 121

(24) Lift front clutch off rear clutch (Fig. 15). Set
clutch units aside for disassembly, cleaning and over-
haul.
(25) Remove output shaft thrust washer from out-
put shaft (or from rear clutch hub).
(26) Remove output shaft thrust plate from output
shaft hub (Fig. 16).
(27) Slide front band off driving shell (Fig. 17) and
remove band from case.
(28) Remove E-clip from one end of governor valve
shaft and remove valve and shaft from governor body
(Fig. 19). Reinstall E-clip on shaft to avoid losing it.
(29) Remove thick snap, thrust washer and thin
snap ring that retain governor body and park gear on
shaft (Fig. 19).(30) Loosen bolts attaching governor body to park
gear.
Fig. 15 Separating Front/Rear Clutch Assemblies
Fig. 16 Removing/Installing Output Shaft Thrust
Plate
Fig. 17 Front Band Removal/Installation
Fig. 18 Removing Governor Valve And Shaft
Fig. 19 Governor Body/Park Gear Attachment
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(31) Mark position of governor body on park gear
with center punch or scriber.
(32) Remove governor body and park gear as as-
sembly (Fig. 20). Work park gear out of rear support
and slide assembly off output shaft.
(33) Remove planetary geartrain as assembly (Fig.
21). Support geartrain with both hands during re-
moval. Do not allow machined surfaces on output
shaft to become nicked or scratched.
(34) Loosen rear band adjusting screw until band
is fully released and does not grip low reverse drum.
(35) Remove snap ring that secures low-reverse
drum to rear support (Fig. 22).
(36) Remove rear band lever pins as follows:
(a) On 30RH transmission, rear band has only
one pivot pin. Remove pin with parallel jaw snapring pliers (Fig. 23). Spread plier jaws in pin bore
to grip pin. Then remove pin with a twist and pull
motion.
(b) On 32RH transmission, rear band has two
pins. Remove pivot pin and reaction pin with par-
allel jaw snap ring pliers (Fig. 24).
(37) Remove rear band lever, link and strut.
(38) Mark position of rear support for assembly
reference (Fig. 25). Use scriber or center punch to
mark case and support.
(39) Remove rear support bolts and remove sup-
port from low-reverse drum and case (Fig. 26). Keep
rear support bolts together for assembly reference.
(40) Remove bolts attaching overrunning clutch
cam to case (Fig. 27).
(41) Remove low-reverse drum and overrunning
clutch as assembly. Slide drum and clutch through
rear band and out of case. Set drum and clutch as-
sembly aside for cleaning and inspection.
(42) Remove rear band and link from case.
Fig. 20 Removing/Installing Governor Body And
Park Gear
Fig. 21 Planetary Geartrain Removal
Fig. 22 Removing Low-Reverse Drum Snap Ring
Fig. 23 Removing Rear Band Lever Pivot Pin (30RH)
J30RH/32RH TRANSMISSION OVERHAUL 21 - 123

(43) Compress front servo rod guide about 3 mm
(1/8 in.) with a large C-clamp and tool C-4470, or
Compressor Tool C-3422-B (Fig. 28).
(44) Remove front servo rod guide snap ring (Fig.
28).Exercise caution when removing snap ring.
Servo bore can be scratched or nicked if care is
not exercised.
(45) Remove compressor tools and remove front
servo rod guide, spring and servo piston.
(46) Compress rear servo spring retainer about 1.5
mm (1/16 in.) with C-clamp and Tool C-4470 or SP-
5560 (Fig. 29). Valve Spring Compressor C-3422-B
can also be used to compress spring retainer.
Fig. 24 Removing Rear Band Pivot And Reaction
Pins (32RH)
Fig. 25 Marking Rear Support For Assembly
Reference
Fig. 26 Removing Rear Support
Fig. 27 Overrunning Clutch Cam Bolt Locations
Fig. 28 Compressing Front Servo Rod Guide
21 - 124 30RH/32RH TRANSMISSION OVERHAULJ

(47) Remove rear servo spring retainer snap ring.
Then remove compressor tools and remove rear servo
spring and piston.
OVERHAUL SERVICE INFORMATION
Inspect the transmission bushings during overhaul.
Bushing condition is important as severely worn, or
scored bushings contribute to low pressures, clutch
slip and accelerated wear of other components.How-
ever, do not replace bushings as a matter of
course. Replace bushings only when they are
actually worn, or scored.
Use recommended tools to replace bushings. The
tools are sized and designed to remove, install and
seat bushings correctly. The bushing replacement
tools are included in Bushing Tool Set C-3887-B or
C-3887-J. The bushing tools are manufactured by
Miller Tool Co. and is available through the dealer
tool program.
Pre-sized service bushings are available for replace-
ment purposes. Only the sun gear bushings are not
serviced. Replace the gear as an assembly if the
bushings are worn, or scored.
Heli-Coil inserts are recommended for repairing
damaged, stripped or worn threads in aluminum
parts. These inserts are available from most automo-
tive jobbers. Stainless steel inserts are preferred.
The use of crocus cloth is permissible where neces-
sary. When used on valves, use care to avoid round-
ing off sharp edges. Sharp edges are vital as they
prevent foreign matter from getting between the
valve and valve bore.
Do not reuse oil seals, gaskets, seal rings, or
O-rings during overhaul. Replace these parts as a
matter of course. Also do not reuse snap rings or E-
clips that are bent or distorted. Replace these parts
as well.Lubricate transmission parts with Mopar ATF
Plus, Type 7176 transmission fluid during overhaul
and assembly.
Use petroleum jelly to hold parts like thrust wash-
ers in place during assembly. Use Mopar Door Ease,
Ru-Glyde, or similar products to lubricate piston
seals and O-rings to ease installation. Petroleum jelly
can also be used to prelubricate parts during reas-
sembly if desired.
TRANSMISSION CASE CLEANING AND
INSPECTION
Clean the case in a solvent tank. Flush the case
bores and fluid passages thoroughly with solvent.
Use compressed air to dry the case and clear the
fluid passages. Be sure all solvent is removed from
the case as well.
Do not use shop towels or rags to dry the case
(or any other transmission component) unless
they are made from lint-free materials. Lint
will readily adhere to case surfaces and trans-
mission components and will circulate through-
out the transmission after assembly. A sufficient
quantity of lint can block fluid passages and in-
terfere with valve body operation.
Inspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repaired with Helicoil thread inserts. However, the
case will have to be replaced if it exhibits any type of
damage or wear.
Lubricate the front band adjusting screw threads
with petroleum jelly and thread the screw part-way
into the case. Be sure the screw turns freely.
Remount the case in a repair stand after cleaning
and inspection.
OVERRUNNING CLUTCHÐLOW-REVERSE
DRUMÐREAR SUPPORT OVERHAUL
DISASSEMBLING OVERRUNNING CLUTCH/
LOW-REVERSE DRUM
If the clutch assembly came out with the low-re-
verse drum, thread two clutch cam bolts into the
cam. Then lift the cam out of the drum with the bolts
(Fig. 30). Rotate the cam back and forth to ease re-
moval if necessary. Remove the clutch roller and
spring assembly from the race afterward.
CLEANING AND INSPECTION
Clean the overrunning clutch assembly, clutch cam,
low-reverse drum and rear support in solvent. Dry
them with compressed air after cleaning.
Inspect condition of each clutch part after cleaning.
Replace the overrunning clutch roller and spring as-
sembly if any rollers or springs are worn or damaged,
or if the roller cage is distorted, or damaged. Replace
the cam if worn, cracked or damaged.
Fig. 29 Compressing Rear Servo Spring
J30RH/32RH TRANSMISSION OVERHAUL 21 - 125

Replace the low-reverse drum if the clutch race,
roller surface or inside diameter is scored, worn or
damaged.Do not remove the clutch race from
the low-reverse drum under any circumstances.
Replace the drum and race as an assembly if ei-
ther component is damaged.
Examine the rear support carefully for wear,
cracks, scoring or other damage. Be sure the support
hub is a snug fit in the case and drum. Replace the
support if worn or damaged.
ASSEMBLING OVERRUNNING CLUTCH/LOW-
REVERSE DRUM
(1) Assemble clutch rollers and springs in retainer
if necessary (Fig. 31).
(2) Install overrunning clutch roller, spring and re-
tainer assembly in clutch cam (Fig. 32).
(3) Temporarily assemble and check overrunning
clutch operation as follows:
(a) Assemble cam and clutch.(b) Install clutch assembly on low-reverse drum
with twisting motion (Fig. 33).
(c) Install drum-clutch assembly in case and in-
stall clutch cam bolts.
(d) Install rear support and support attaching
bolts.
(e) Check low-reverse drum rotation.Drum
should rotate freely in clockwise direction
and lock when turned in counterclockwise di-
rection (as viewed from front of case).
(4) Note component position for assembly refer-
ence. Bolt holes in clutch cam are countersunk on
one side, Be sure this side of cam will face rearward
when installed (Fig. 34).
Fig. 30 Removing Overrunning Clutch From
Low-Reverse Drum
Fig. 31 Overrunning Clutch Rollers, Springs,
Retainer
Fig. 32 Assembling Overrunning Clutch And Cam
Fig. 33 Temporary Assembly Of Clutch And Drum
To Check Operation
21 - 126 30RH/32RH TRANSMISSION OVERHAULJ

(5) Remove rear support, overrunning clutch and
low-reverse drum. Set components aside for final as-
sembly.If overrunning clutch will be installed
before final assembly, install cam only as de-
scribed in Transmission Assembly And Adjust-
ment section. Clutch cam must be properly
indexed in case to fit and operate properly.
ADAPTER/EXTENSION HOUSING INSPECTION AND
PARK LOCK COMPONENT OVERHAUL
Clean the housing and park lock components in sol-
vent and dry them with compressed air.
Inspect the output shaft bearing in the housing
(Fig. 35). Replace the bearing if worn, damaged, or
noisy.Examine the park lock components. If replacement
is necessary, remove the shaft with parallel jaw snap
ring pliers (Fig. 36) and remove the sprag and
spring. Then remove the spring clip and reaction
plug (Fig. 37).
Compress the reaction plug spring clip only
enough to remove or install it. The clip is easily
distorted if overcompressed. Replace the clip if
it becomes bent or distorted. Do not straighten
and reuse the clip if this occurs.
Be sure a replacement sprag is installed so the
sprag locking lug will face the park gear. Also be sure
the spring is correctly positioned as shown (Fig. 38).
The sprag may not retract if the spring is im-
properly installed.
GOVERNOR AND PARK GEAR OVERHAUL
GOVERNOR/PARK GEAR DISASSEMBLY
(1) Remove bolts attaching governor body to park
gear; then separate body from gear.
(2) Remove cone shaped filter from park gear (Fig.
39).
(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. 40).
(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. 41).
Fig. 34 Assembled Overrunning Clutch Components
Fig. 35 Adapter Housing Bearing (4 x 4 Models)
Fig. 36 Park Sprag, Shaft And Spring Removal
J30RH/32RH TRANSMISSION OVERHAUL 21 - 127

(b) Push inner weight downward with nut driver
and remove inner weight snap ring. Use Miller In-
ternal Snap Ring Pliers C-3915 to remove ring
(Fig. 41).
(c) Remove inner weight and spring from outer
weight.
(6) On 32RH, disassemblethree-stagegovernor
weight as follows:
(a) Position intermediate weight on suitable size
socket (Fig. 42).(b) Push inner weight downward with nut driver.
Then remove inner weight snap ring with Snap
Ring Plier Tool 6823 (Fig. 42).
(c) Remove inner weight and spring from inter-
mediate weight.
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.
Examine the governor components carefully. Dis-
card any snap rings or E-clips if distorted, or worn.
Be sure the governor weights operate freely in the
bores and do not bind. Also verify that the governor
valve slides freely on the shaft and in the bore.
The governor weight components (Fig. 43), and the
governor valve (Fig. 44), must slide freely in their
bores when clean and dry. Minor surface scratches
and burrs can be smoothed with crocus cloth
Fig. 37 Park Sprag Reaction Plug And Spring
Location
Fig. 38 Correct Position Of Sprag And Spring
Fig. 39 Governor Filter Position
Fig. 40 Governor Weight Retaining Snap Ring And
Washer Removal
21 - 128 30RH/32RH TRANSMISSION OVERHAULJ