JEEP XJ 1995 Service And Repair Manual

(2) Lubricate and install new O-ring on No. 2
brake piston.
(3) Install assembled No. 1 piston and reaction
sleeve on No. 2 piston (Fig. 8).
(4) Lubricate and install piston assembly in case
(Fig. 9). Align piston and case slots and press piston
assembly into case with hand pressure.
(5) Position piston return springs on No. 2 piston.
(6) Compress piston return springs with Tool 7539
and install piston snap ring (Fig. 4). Be sure snap
ring end gap is not aligned with any tangs on return
spring retainer.
(7) Verify piston operation with compressed air as
outlined in disassembly procedure.(8) Coat bearing and race assembly with petroleum
jelly and install it in piston assembly (Fig. 2). Bear-
ing and race assembly outer diameter is 57.7 mm
(2.272 in.) and inner diameter is 39.2 mm (1.543 in.).
Fig. 6 Removing/Installing First-Reverse Brake No.1
Piston
Fig. 7 Assembling No. 1 Piston And Sleeve
Fig. 8 Assembling First-Reverse Brake Pistons
Fig. 9 Installing First-Reverse Brake Piston
Assembly
JAW-4 TRANSMISSION OVERHAUL 21 - 249

TRANSMISSION VALVE BODY OVERHAUL
The valve body assembly consists of two sections
which are the upper body and lower body (Figures 1and 2). Disassembly, inspection and overhaul proce-
dures for each section are outlined separately. Refer
to the appropriate procedure as needed.
Fig. 1 Lower Body Components
21 - 250 AW-4 TRANSMISSION OVERHAULJ

Fig. 2 Upper Body Components
JAW-4 TRANSMISSION OVERHAUL 21 - 251

REMOVING UPPER BODY FROM LOWER BODY
(1) Remove two-piece detent spring (Fig. 3). Note
position of spring sections for assembly reference.
(2) Remove manual valve from lower body (Fig. 4).
(3) Remove bolts attaching upper body to lower
body (Fig. 5).
(4) Carefully lift and remove upper body, plate and
gaskets from lower body (Fig. 6).
(5) Disassemble and overhaul upper and lower
body sections as outlined in following procedures.
LOWER BODY DISASSEMBLY
(1) Remove check valve and spring, pressure relief
valve and spring and ball check and seat from lower
body. Note location of each valve for assembly refer-
ence (Fig. 1).
Fig. 3 Removing/Installing Detent Spring
Fig. 4 Removing/Installing Manual Valve
Fig. 5 Valve Body Bolt Locations
Fig. 6 Upper Body, Plate And Gaskets
Fig. 1 Lower Body Check Valve And Strainer
Location
21 - 252 AW-4 TRANSMISSION OVERHAULJ

(2) Remove oil strainers (Fig. 2).
(3) Note or mark position of valve retainers and
pressure reducing plug clip for assembly reference
(Fig. 2). Do not remove the retainers at this time.
(4) Remove solenoid No. 1, 2 and 3. Discard sole-
noid O-rings.
(5) Remove 1-2 shift valve retainer (Fig. 3).
(6) Remove 1-2 shift valve plug, valve spring and
valve (Fig. 4).
(7) Remove primary regulator valve as follows:
WARNING: THE PRIMARY REGULATOR VALVE
SLEEVE AND PLUNGER ARE UNDER TENSION
FROM THE VALVE SPRING. EXERT COUNTER-
PRESSURE ON THE SPRING WHILE REMOVING
THE VALVE RETAINER TO PREVENT COMPONENTS
FROM FLYING OUT.(a) Note position of valve retainer for assembly
reference (Fig. 5). Then press valve sleeve inward
with your thumb and remove retainer with magnet.
(b) Slowly release thumb pressure on sleeve and
remove sleeve, spring and washer and valve (Fig.
6). Use magnet to remove valve if necessary.
(8) Remove regulator valve plunger from sleeve
(Fig. 7).
(9) Remove retaining clip and remove pressure re-
ducing plug (Fig. 8). Cover screwdriver blade with
tape to avoid scratching valve body surface.
(10) Remove accumulator control valve retainer
and remove control valve assembly (Fig. 9).
(11) Remove spring and control valve from valve
sleeve (Fig. 10).
(12) Clean lower body valve components with sol-
vent and dry them with compressed air only. Do not
Fig. 2 Valve Retainer And Clip Location
Fig. 3 Removing 1-2 Shift Valve Retainer
Fig. 4 Removing/Installing 1-2 Shift Valve
Fig. 5 Regulator Valve Retainer Position
JAW-4 TRANSMISSION OVERHAUL 21 - 253

use shop towels or rags. Lint or foreign material from
towels or rags can interfere with valve operation.
(13) Inspect condition of lower body components.
Replace lower body if any bores are scored or cor-
roded. Replace valves, plugs or sleeves that are
scored or worn. Replace oil strainers if cut, torn or
damaged in any way.
(14) Inspect valve body springs. Replace any spring
having rusted, distorted, or collapsed coils. Measure
length of each valve body spring. Replace any spring
if free length is less than length specified in following
chart (Fig. 11).
LOWER BODY ASSEMBLY
(1) Lubricate lower body components with auto-
matic transmission fluid.
(2) Install spring and accumulator control valve in
sleeve (Fig. 11). Then install assembled components
in lower body (Fig. 9).(3) Press accumulator control valve assembly into
valve bore and install retainer (Fig. 9).
(4) Install pressure reducing plug in plug bore.
Then secure plug with retaining clip (Fig. 8).
(5) Install washer on primary regulator valve
plunger (Fig. 12).
(6) Install primary regulator valve plunger in valve
sleeve (Fig. 7).
(7) Install valve spring and regulator valve sleeve
and plunger.
(8) Press regulator valve sleeve into bore and in-
stall retainer (Fig. 5 and 6). Be sure retainer is posi-
tioned in sleeve lugs as shown.
(9) Install 1-2 shift valve, spring and plug (Fig. 4).
Then press valve assembly into bore and install re-
tainer.
(10) Install replacement O-rings on solenoids and
install solenoids on valve body. Tighten solenoid at-
taching bolts to 10 Nzm (7 ft-lbs) torque.
(11) Install oil strainers (Fig. 13).Identify strain-
ers before installation. The three strainers are
all the same diameter but are different lengths.
Two strainers are 11.0 mm (0.443 in.) long while
one strainer is 19.5 mm (0.76 in.) long (Fig. 14).
(12) Install check valve and spring (Fig. 13).
(13) Install check ball and seat (Fig. 13).
(14) Install pressure relief valve and spring (Fig.
13).
Fig. 6 Removing/Installing Primary Pressure
Regulator Valve
Fig. 7 Removing/Installing Regulator Valve Plunger
Fig. 8 Removing/Installing Pressure Reducing Plug
21 - 254 AW-4 TRANSMISSION OVERHAULJ

Fig. 10 Accumulator Control Valve Components
Fig. 11 Lower Body Valve Spring Dimensions
Fig. 9 Removing/Installing Accumulator Control
Valve Assembly
JAW-4 TRANSMISSION OVERHAUL 21 - 255

UPPER BODY DISASSEMBLY AND
INSPECTION
(1) Remove valve body plate and gaskets (Fig. 1).
Discard gaskets.
(2) Remove strainer and eight check balls (Fig. 2).
Note check ball and strainer position for assembly
reference.
Fig. 12 Installing Washer On Regulator Valve
Plunger
Fig. 13 Oil Strainer And Check Valve Installation
Fig. 1 Removing/Installing Upper Body Plate And
Gaskets
Fig. 2 Check Ball And Strainer Location/
Identification
21 - 256 AW-4 TRANSMISSION OVERHAULJ

(3) Remove valve stop and throttle cam (Fig. 3).(4) Remove throttle valve pin with magnet and remove
downshift plug, valve spring and throttle valve (Fig. 4).
(5) Turn upper body over and remove throttle
valve adjusting rings and spring (Fig. 5). Note num-
ber of adjusting rings if valve is equipped with them.
(6) Remove 3-4 shift valve retainer with magnet and
remove valve plug, spring and 3-4 shift valve (Fig. 6).
Fig. 3 Removing/Installing Valve Stop And Throttle Cam
Fig. 4 Removing/Installing Throttle ValveFig. 6 Removing/Installing 3-4 Shift Valve
Fig. 5 Throttle Valve Adjusting Ring Location (If Equipped)
JAW-4 TRANSMISSION OVERHAUL 21 - 257

(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