JEEP XJ 1995 Service And Repair Manual

TORQUE CONVERTER STATOR CLUTCH
INSPECTION
(1) Insert Rotating Tool 7547 into converter hub
and seat tool in one-way clutch (Fig. 3).
(2) Insert Stopper Tool 7548 in one converter hub
notch and into outer race of rotating tool.
(3) Turn rotating tool clockwise. Converter clutch
should rotate freely and smoothly. Less than 2.5 Nzm
(22 in. lbs.) of torque should be required to rotate
clutch in clockwise direction.
(4) Turn rotating tool in counterclockwise direction.
Converter clutch should lock.
(5) Replace converter if clutch binds or will not
lock.
OIL PUMP SEAL REPLACEMENT
(1) Remove converter.
(2) Remove old seal. Use blunt punch to collapse
seal and pry seal out of pump housing. Do not
scratch or damage seal bore.
(3) Lubricate lip of new seal with transmission
fluid and install seal in pump with tool 7549 (Fig. 4).
(4) Lubricate converter drive hub with transmis-
sion fluid.
(5) Align and install converter in oil pump.
TRANSMISSION AND TORQUE CONVERTER
INSTALLATION
(1) Mount transmission on transmission jack. Then
secure transmission to jack with safety chains.
(2) Lubricate converter drive hub and oil pump
seal lip with transmission fluid. Then install con-
verter. Be sure converter is fully seated in oil pump
gears before proceeding. Hold converter in place with
C-clamp or strap attached to converter housing.
(3) Align and position transmission and converter
on engine.
(4) Remove clamp or strap used to hold torque con-
verter in place.
(5) Move transmission forward seat and it on en-
gine. Be sure torque converter hub is fully seated.
(6) Install converter housing-to-engine bolts (Fig.
5).
(7) Install converter-to-drive plate bolts.
(8) Install and connect starter motor.
(9) Install and connect crankshaft position sensor.
(10) Install transfer case on transmission. Tighten
transfer case attaching nuts to 41 Nzm (30 ft. lbs.)
torque
(11) Connect transfer case shift linkage and vac-
uum hoses.
(12) Connect exhaust components.
(13) Install rear crossmember and remove jack
used to support transmission assembly.
(14) Connect speed sensor wire harness to sensor.
(15) Connect wire harness to park/neutral position
switch.(16) Align and connect front and rear propeller
shafts.
Fig. 3 Checking Operation Of Torque Converter
Stator One-Way Clutch
JAW-4 TRANSMISSION REMOVAL AND INSTALLATION 21 - 199

(17) Connect transmission wire harnesses and
transfer case vacuum and wire harnesses.(18) Connect transmission cooler lines.
(19) Connect transmission throttle cable at engine.
(20) Install new O-ring seal on upper half of trans-
mission fill tube. Then connect upper and lower tube
halves.
(21) Lower vehicle.
(22) Fill transmission with Mopar Dexron IIE/Mer-
con automatic transmission fluid.
Fig. 5 Transmission Mounting
Fig. 4 Installing Oil Pump Seal
21 - 200 AW-4 TRANSMISSION REMOVAL AND INSTALLATIONJ

AW-4 TRANSMISSION OVERHAUL
INDEX
page page
Cleaning and Inspection................... 214
Direct Clutch Overhaul.................... 228
First-Reverse Brake Piston and Transmission Case
Overhaul............................. 247
Forward Clutch Overhaul................... 232
Front Planetary Gear Overhaul.............. 237
Manual Valve Shaft Overhaul............... 215
Oil Pump Overhaul....................... 216
Overdrive Planetary Gear and Clutch Overhaul . . 218Overdrive Support Overhaul................ 226
Overhaul Service Tools.................... 201
Rear Planetary, No. 2 One-Way Clutch and Output
Shaft Overhaul......................... 244
Second Brake Overhaul................... 241
Sun Gear and No. 1 One-Way Clutch Overhaul . . 238
Transmission Assembly and Adjustment........ 265
Transmission Disassembly................. 201
Transmission Valve Body Overhaul........... 250
OVERHAUL SERVICE TOOLS
The special tools needed to overhaul the AW-4
transmission are provided in Tool Kit 6294. However,
Pressure Test Port Adapter 7554 is not included in
this kit and must be ordered separately. The over-
haul tool kit and test port adapter are available
through the parts division and dealer special tool
program.
TRANSMISSION DISASSEMBLY
(1) Remove torque converter.
(2) Remove lower half of filler tube if not previ-
ously removed.
(3) Remove clamps attaching wire harness and
throttle cable (Fig. 1) to transmission.(4) Remove shift lever from manual valve shaft at
left side of transmission.
(5) Remove park/neutral position switch.
(6) Remove speed sensor (Fig. 2).
Fig. 1 Typical Harness And Cable Clamp Attachment
Fig. 2 Speed Sensor Removal
JAW-4 TRANSMISSION OVERHAUL 21 - 201

(7) Remove converter housing bolts and remove
housing (Fig. 3) from case.
(8) Remove adapter housing.
(9) Remove speedometer drive gear snap ring and
remove gear and gear spacer if equipped (Fig. 4).(10) Remove speed sensor rotor and key. Use wood
dowel or hammer handle to loosen and remove rotor
(Fig. 5).
(11) Remove transmission oil pan, oil screen and
screen gaskets (Fig. 6). Then mount transmission in
holding fixture.
Fig. 3 Converter Housing Removal
Fig. 4 Removing Speed Sensor And Speedometer
Drive Gear
Fig. 5 Removing Transmission Speed Sensor Rotor
Fig. 6 Removing Oil Screen
21 - 202 AW-4 TRANSMISSION OVERHAULJ

(12) Remove valve body oil feed tubes (Fig. 7).
(13) Disconnect valve body solenoid wires (Fig. 8).
(14) Remove harness bracket bolt and remove har-
ness and bracket Fig. 9).
(15) Remove valve body bolts (Fig. 10).
(16) Disconnect throttle cable from throttle cam
(Fig. 11).
Fig. 9 Removing Bracket And Harness
Fig. 10 Valve Body Bolt Locations
Fig. 11 Disconnecting Throttle Cable
Fig. 7 Valve Body Oil Tube Removal
Fig. 8 Solenoid Wire Location
JAW-4 TRANSMISSION OVERHAUL 21 - 203

(17) Remove valve body from case. Then remove ac-
cumulator springs, spacers and check ball and spring
(Fig. 12).
(18) Remove second brake and clutch accumulator
pistons with compressed air (Fig. 13). Apply air pres-
sure through feed port and ease the pistons out of
the bore.
(19) Remove overdrive brake accumulator piston
with compressed air (Fig. 13).
(20) Remove overdrive clutch accumulator piston
with compressed air (Fig. 13).
(21) Remove throttle cable.
Fig. 12 Removing Accumulator Springs, Spacers
And Check Ball
Fig. 13 Accumulator Piston Removal
21 - 204 AW-4 TRANSMISSION OVERHAULJ

(22) Remove oil pump bolts and remove pump with
bridge-type Puller 7536 (Fig. 14).
(23) Remove race from oil pump (Fig. 15).(24) Remove overdrive planetary gear and clutch
assembly (Fig. 16).
(25) Remove race from overdrive planetary (Fig.
17).
Fig. 14 Oil Pump Removal
Fig. 15 Oil Pump Race Removal
Fig. 16 Removing Overdrive Planetary
And Clutch Assembly
Fig. 17 Overdrive Planetary Race Removal
JAW-4 TRANSMISSION OVERHAUL 21 - 205

(26) Remove thrust bearing, race and overdrive
planetary ring gear (Fig. 18).
(27) Measure stroke length of overdrive brake pis-
ton as follows:
(a) Mount dial indicator on case (Fig. 19).
(b) Mount Gauge Tool 7546 so it contacts piston
(Fig. 19).(c) Apply 57-114 psi air pressure through piston ap-
ply port and note piston stroke on dial indicator. Stroke
length should be: 1.40 - 1.70 mm (0.055 - 0.0699 in.).
(d) If stroke is not within limits, replace piston
and retainer.
(28) Remove overdrive brake snap ring (Fig. 20).
Fig. 18 Removing Bearing, Race And
Planetary Ring Gear
Fig. 19 Measuring Overdrive Brake Piston Stroke
Fig. 20 Removing Overdrive Brake Snap Ring
21 - 206 AW-4 TRANSMISSION OVERHAULJ

(29) Remove overdrive brake clutch pack (Fig. 21).
Then measure disc thickness with a micrometer.
Minimum disc thickness is 1.84 mm (0.0724 in.). Re-
place clutch pack if necessary.
(30) Remove overdrive support lower race and up-
per bearing and race assembly (Fig. 22).(31) Remove overdrive support bolts (Fig. 23).
(32) Remove overdrive support snap ring with
Snap Ring Plier Tool 7540 (Fig. 24).
Fig. 21 Removing/Measuring Overdrive Brake Disc
Thickness
Fig. 22 Overdrive Support Bearing/Race Removal
Fig. 23 Overdrive Support Bolt Removal
Fig. 24 Removing/Installing Overdrive Support Snap
Ring
JAW-4 TRANSMISSION OVERHAUL 21 - 207

(33) Remove overdrive support (Fig. 25) with
bridge-type Puller 7536.
(34) Remove race from hub of overdrive support
(Fig. 26).(35) Measure stroke length of second coast brake
piston rod as follows:
(a) Make reference mark on piston rod (Fig. 27)
as shown.
(b) Apply 57-114 psi air pressure through piston
feed hole and check stroke length with Gauge Tool
7552 (Fig. 27).
(c) Stroke length should be 1.5 - 3.0 mm (0.059 -
0.118 in.).
(d) If stroke length is incorrect, install new pis-
ton rod and recheck stroke. If stroke is still incor-
rect, replace second coast brake band.
(e) Replacement piston rods are available in two
different lengths which are: 71.4 mm (2.811 in.)
and 72.9 mm (2.870 in.).
Fig. 25 Removing Overdrive Support
Fig. 26 Remove Overdrive Support Race
Fig. 27 Measuring Second Coast Brake Piston Rod
Stroke
21 - 208 AW-4 TRANSMISSION OVERHAULJ