sensor JEEP YJ 1995 Service And Repair Manual

(21) Remove clutch release bearing, release fork
and retainer clip.
(22) Remove clutch housing from transmission.
TRANSMISSION INSTALLATION
(1) Install clutch housing on transmission. Tighten
housing bolts to 37 Nzm (27 ft. lbs.) torque.
(2) Lubricate contact surfaces of release fork pivot
ball stud and release fork with high temp grease.
Then install release bearing, fork and retainer clip.
(3) Mount transmission on transmission jack.
(4) Lightly lubricate pilot bearing and transmis-
sion input shaft splines with Mopar high temp
grease.
(5) Align transmission input shaft, release bearing,
and clutch disc splines. Then slide transmission into
place.
(6) Install and tighten clutch housing-to-engine
bolts to 38 Nzm (28 ft. lbs.) torque.Be sure the
housing is properly seated on engine block be-
fore tightening bolts.
(7) Lower transmission approximately 7-8 cm (3
in.) for access to shift tower. Be sure transmission is
in first or third gear.
(8) Reach up and around transmission and insert
shift lever in shift tower. Press lever retainer down-
ward and turn it clockwise to lock it in place. Then
install lever dust boot on shift tower.
(9) Install slave cylinder in clutch housing.
(10) Align and install transfer case on and trans-
mission. Tighten transfer case-to-transmission nuts
to 35 Nzm (26 ft. lbs.) torque.
(11) Connect transfer case vent hose and shift link-
age. Check and adjust linkage if necessary.
(12) Connect transfer case vent hose.
(13) Secure wire harnesses in clips/tie straps on
transmission and transfer case.
(14) Connect backup light switch wires.
(15) Connect vehicle speed sensor wires.
(16) Install and connect crankshaft position sensor.
(17) Install rear crossmember (Fig. 5). On XJ,
tighten crossmember-to-frame bolts to 41 Nzm (31 ft.
lbs.) torque. Then tighten transmission-to-rear sup-
port bolts/nuts to 45 Nzm (33 ft. lbs.) torque. On YJ,
tighten bolts/nuts to indicated torque (Fig. 5).
(18) Remove jack stand.
(19) Align and install front/rear propeller shafts.
Tighten shaft U-joint clamp bolts to 19 Nzm (170 in.
lbs.) torque.
(20) Install skid plate, if equipped. Tighten bolts to
42 Nzm (31 ft. lbs.) torque. Tighten stud nuts to 17
Nzm (150 in. lbs.) torque.
(21) Top off transmission and transfer case lubri-
cant levels.
(22) Lower vehicle.
TRANSMISSION DISASSEMBLY AND OVERHAUL
ADAPTER HOUSING AND FRONT BEARING
RETAINER REMOVAL
(1) Drain transmission lubricant.
(2) Remove release bearing and lever.
(3) Remove clutch housing bolts and remove hous-
ing.
(4) On 2-wheel drive models, remove vehicle speed
sensor, speedometer adapter and speedometer driven
gear. Then remove extension housing seal (Fig. 1).
(5) Remove detent spring and ball. Remove detent
plug (Fig. 2) and remove detent spring and ball with
pencil magnet.
Fig. 1 Removing 2-Wheel Drive Extension Housing
Seal
Fig. 2 Detent Ball Plug Location
JAX 4/5 MANUAL TRANSMISSION 21 - 5

(10) Install lock ball and spring in housing. Then
apply sealer to ball plug and install plug (Fig. 91).
Tighten plug to 19 Nzm (14 ft. lbs.) torque.
(11) Install reverse pins in housing (Fig. 92).
Tighten pins to 27 Nzm (20 ft. lbs.) torque.(12) Install shift tower and new gasket on housing
(Fig. 93). Tighten tower bolts to 18 Nzm (13 ft. lbs.)
torque.
(13) Install backup lamp switch (Fig. 93). Tighten
switch to 37 Nzm (27 ft. lbs.) torque.
(14) On 2-wheel drive models, install new seal in
extension housing (Fig. 94).
(15) Install vehicle speed sensor. Refer to proce-
dure in In-Vehicle Service section.
(16) Install clutch housing, release bearing, release
fork and retainer clip.
Fig. 91 Installing Ball Plug
Fig. 92 Install Reverse Pins
Fig. 93 Installing Shift Tower And Backup Lamp
Switch
Fig. 94 Extension Housing Seal InstallationÐ2WD
Models
21 - 32 AX 4/5 MANUAL TRANSMISSIONJ

(6) On XJ, remove rear crossmember. On YJ, re-
move skid plate (Fig. 1).
(7) Disconnect transmission shift linkage, speed-
ometer cable, transfer case vacuum lines and clutch
hydraulic lines.
(8) Lower transmission-transfer case assembly no
more than 7.6 cm (3 in.) for access to shift lever.
(9) Reach up and around transmission case and
unseat shift lever dust boot from transmission shift
tower (Fig. 2). Move boot upward on shift lever for
access to lever retainer.
(10) Disengage shift lever as follows:
(a) Reach up and around transmission case and
press shift lever retainer downward with your fin-
gers.
(b) Turn retainer counterclockwise to release it.
(c) Lift lever and retainer out of shift tower (Fig.
2).It is not necessary to remove shift lever
from floorpan boot. Simply leave lever in
place for later installation.(11) Mark front and rear propeller shafts for in-
stallation alignment (Fig. 2). Then remove both
shafts.
(12) Remove crankshaft position sensor (Fig. 4).
(13) Disconnect transmission and transfer case
vent hoses.
(14) Remove slave cylinder from clutch housing.
(15) Remove wire harnesses from clips/tie straps
on transmission and transfer case.
(16) Support transmission-transfer case assembly
with transmission jack. Secure assembly to jack with
safety chains.
(17) Reposition adjustable jack stand under engine.
Be sure to place wood block between jack and oil
pan.
(18) Remove clutch housing brace rod.
(19) Remove clutch housing-to-engine bolts and re-
move transmission-transfer case assembly.
(20) Remove bolts attaching transmission to trans-
fer case and separate components.
(21) Remove release bearing, fork and retainer
clip.
(22) Remove clutch housing from transmission.
TRANSMISSION INSTALLATION
(1) Install clutch housing on transmission. Tighten
housing bolts to 37 Nzm (27 ft-lbs) torque.
(2) Lubricate contact surfaces of release fork, lever
and pivot ball stud. Then install bearing, fork and
clip in clutch housing.
(3) Mount transmission on transmission jack. Se-
cure transmission with safety chains.
(4) Lightly lubricate pilot bearing and transmis-
sion input shaft splines with Mopar high tempera-
ture grease.
(5) Align transmission input shaft and clutch disc
splines and install transmission.
Fig. 2 Removing/Installing Shift Lever
Fig. 3 Marking Propeller Shaft And Axle Yoke
Fig. 4 Crankshaft Position Sensor Location
21 - 36 AX 15 MANUAL TRANSMISSIONJ

(6) Install and tighten clutch housing-to-engine
bolts to 38 Nzm (28 ft. lbs.) torque.Be sure housing
is properly seated on engine before tightening
bolts.
(7) Lower transmission no more than 7.6 cm (3 in.)
for access to the shift tower.
(8) Reach up and around the transmission and in-
sert shift lever in shift tower. Press lever retainer
downward and turn it clockwise to lock it in place.
Then install lever dust boot on shift tower.
(9) Install and connect crankshaft position sensor.
(10) Align and install transfer case on transmis-
sion. Tighten transfer case attaching nuts to 35 Nzm
(26 ft. lbs.) torque.
(11) Connect transfer case vacuum and vent hoses.
(12) Install and connect transfer case shift linkage.
Check and adjust linkage if necessary.
(13) Secure wire harnesses to clips/tie straps on
transmission and transfer case.
(14) Connect backup light switch wires.
(15) Install clutch slave cylinder.
(16) Connect vehicle speed sensor wires.
(17) On XJ, install rear crossmember and attach
cushion and bracket. Tighten crossmember-to-frame
bolts to 41 Nzm (30 ft. lbs.) torque. Tighten transmis-
sion-to-rear cushion and bracket bolts/nuts to 45 Nzm
(33 ft. lbs.) torque.
(18) On YJ, install rear cushion and bracket and
skid plate. Tighten attaching bolts/nuts to indicated
torque (Fig. 1).
(19) Align and install front/rear propeller shafts.
Tighten shaft U-joint clamp bolts to 19 Nzm (170 in.
lbs.) torque.
(20) On XJ, install skid plate if removed. Tighten
bolts to 42 Nzm (31 ft. lbs.) torque. Tighten stud nuts
to 17 Nzm (150 in. lbs.) torque.
(21) Top off transmission and transfer lubricant
levels.
(22) Remove supports and lower vehicle.
TRANSMISSION DISASSEMBLY AND OVERHAUL
ADAPTER HOUSING REMOVAL
(1) Remove release bearing, release lever and re-
lease fork from clutch housing. Then remove clutch
housing from transmission.
(2) Remove backup light switch. Then remove
drain plug (Fig. 1) and drain transmission lubricant
into pan.
(3) Remove shift tower bolts and remove tower
from adapter or extension housing (Fig. 2).
(4) Remove gasket from shift tower (Fig. 3).
Fig. 1 Drain Plug And Backup Light Switch Location
Fig. 2 Shift Tower Removal/Installation
Fig. 3 Shift Tower Gasket Removal/Installation
JAX 15 MANUAL TRANSMISSION 21 - 37

(28) Position new shift tower gasket on adapter
housing (Fig 127).
(29) Install shift tower (Fig. 128). Tighten tower
attaching bolts to 18 Nzm (13 ft. lbs.) torque.(30) Install new gasket on backup light switch and
install switch. Tighten switch to 37 Nzm (27 ft. lbs.)
torque.
(31) Install new washer on drain plug. Then install
and tighten plug to 37 Nzm (27 ft. lbs.) torque.
(32) If transmission will be filled with gear lubri-
cant before installation, place transmission in a level
position. Then fill with Mopar 75W-90, grade GL-5
gear lubricant.
(33) Install new washer on fill plug. Then install
and tighten plug to 37 Nzm (27 ft. lbs.) torque.
(34) Install clutch housing and hydraulic concen-
tric bearing.
(35) On models with extension housing, install new
seal in housing with suitable size installer tool (Fig.
129). Lubricate seal lips with petroleum jelly before
installation.
(36) On models with extension housing, install
speedometer driven gear, speedometer adapter and
speed sensor.
Fig. 127 Shift Tower Gasket Installation
Fig. 128 Shift Tower Installation
Fig. 129 Installing Extension Housing Seal
21 - 66 AX 15 MANUAL TRANSMISSIONJ

(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

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

Inspection
Check the sprag shaft for scores and for free move-
ment in the housing and sprag.
Check the sprag and control rod springs for loss of
tension or distortion. Check the square lug on the
sprag for broken edges. Check the lugs on the gover-
nor support (park gear) for broken edges. Replace
any park lock components that are worn or damaged.
Check the knob on the end of the control rod for
nicks, burrs and free turning. Replace the rod if the
knob is grooved, or worn, or if the rod is bent. The
park lock rods used in Chrysler 3-speed transmis-
sions are different lengths. If the rod must be re-
placed, be sure to install the correct length and
shape rod.
COMPONENT INSTALLATION
(1) Install park lock rod on valve body.
(2) Install reaction plug and pin assembly in the
housing and install the snap ring.
(3) Position sprag and spring in housing and in-
stall sprag shaft. Be sure square lug on sprag is fac-
ing park gear and that spring is positioned so it
moves sprag away from park gear.
(4) Install valve body.
(5) Install adapter housing and transfer case.
PARK/NEUTRAL POSITION SWITCH SERVICE
The starter feed circuit of the switch is through the
switch center terminal (Fig. 23). It provides a ground
for the starter solenoid circuit through the gearshift
lever in park and neutral only.
The two outer terminals of the park/neutral posi-
tion switch are for the backup lamp switch circuit.
SWITCH TEST PROCEDURE
(1) Remove wiring connector from switch.
(2) Test continuity between switch center terminal
and transmission case. Continuity should exist onlywhen transmission is in Park or Neutral. Replace
switch if continuity occurs in any gear other than
Park or Neutral.
(3) Shift into reverse and test continuity between
two outside terminals on switch. Continuity should
exist only when transmission is in reverse.
(4) Leave transmission in reverse and test continu-
ity between each switch outer terminal and transmis-
sion case. Continuity should not exist between either
pin and case in reverse.
(5) If switch tests OK, check gearshift linkage ad-
justment or backup light circuit. Replace switch if it
fails continuity tests.
SWITCH REPLACEMENT
(1) Position drain pan under neutral switch.
(2) Disconnect switch wires.
(3) Remove switch from transmission.
(4) Move shift lever to Park and Neutral positions.
Inspect manual lever fingers, lever and shaft for
proper alignment with switch opening in case. Re-
place lever if worn or bent. Do not attempt to
straighten the lever.
(5) Install new switch and seal in case. Tighten
switch to 33 Nzm (24 ft. lbs.) torque.
(6) Adjust transmission fluid level as required.
(7) Verify switch operation.
SPEEDOMETER SERVICE
Rear axle gear ratio and tire size determine speed-
ometer pinion requirements. If the pinion must be re-
placed, refer to the parts catalogue information for
the correct part. It is important for speedometer ac-
curacy that the pinion have the correct number of
teeth.
The speedometer assembly used in XJ models is
the new unit type (one-piece) speed sensor (Fig. 24).
However, YJ models may be equipped with either the
new unit style, or the older style that has a two-piece
Fig. 22 Park Lock ComponentsFig. 23 Park/Neutral Position Switch And Manual
Lever
J30RH/32RH IN-VEHICLE SERVICE 21 - 109

speed sensor and metal adapter (Fig. 25). Service
procedures for both styles are described in the follow-
ing procedures.
SPEEDOMETER ASSEMBLY REMOVAL (WITH
UNIT STYLE SENSOR)
(1) Raise vehicle.
(2) Disconnect wires from vehicle speed sensor.
(3) Remove adapter clamp and screw (Fig. 24).
(4) Remove speed sensor and speedometer adapter
as assembly.
(5) Remove speed sensor retaining screw and re-
move sensor from adapter.
(6) Remove speedometer pinion from adapter.
(7) Inspect sensor and adapter O-rings (Fig. 24).
Remove and discard O-rings if worn or damaged.
(8) Inspect terminal pins in vehicle speed sensor.
Clean pins with Mopar electrical spray cleaner if
dirty or oxidized. Replace sensor if faulty, or pins are
loose, severely corroded, or damaged.
SPEEDOMETER INSTALLATION AND
INDEXING (UNIT STYLE)
(1) Thoroughly clean adapter flange and adapter
mounting surface in housing. Surfaces must be clean
for proper adapter alignment and speedometer oper-
ation.
(2) Install new O-rings on speed sensor and speed-
ometer adapter if necessary (Fig. 25).
(3) Lubricate sensor and adapter O-rings with
transmission fluid.
(4) Install vehicle speed sensor in speedometer
adapter. Tighten sensor attaching screw to 2-3 Nzm
(15-27 in. lbs.) torque.(5) Install speedometer pinion in adapter.
(6) Count number of teeth on speedometer pinion.
Do this before installing assembly in housing. Then
lubricate pinion teeth with transmission fluid.
(7) Note index numbers on adapter body (Fig. 25).
These numbers will correspond to number of teeth on
pinion.
(8) Install speedometer assembly in housing.
(9) Rotate adapter until requiredrange numbers
are at 6 o-clock position. Be sure range index
numbers correspond to number of teeth on pin-
ion gear.
(10) Install speedometer adapter clamp and retain-
ing screw. Tighten clamp screw to 10-12 Nzm (90-110
in. lbs.) torque.
(11) Connect wires to vehicle speed sensor.
(12) Lower vehicle and top off transmission fluid
level if necessary.
SPEEDOMETER COMPONENT REMOVAL
(TWO-PIECE SENSOR)
(1) Raise vehicle.
(2) Disconnect speed sensor wires.
(3) Remove bolt attaching vehicle speed sensor to
sensor adapter. Then slide sensor out of adapter.
(4) Inspect speed sensor mounting area in sensor
adapter. If transmission fluid is found in this area,
oil seal in metal speedometer adapter is leaking and
will have to be replaced.
(5) Remove speedometer adapter clamp bolt and
remove clamp (Fig. 26).
(6) Remove speedometer adapter, sensor adapter
and speedometer pinion as assembly.
Fig. 24 Speedometer Components (With Unit Style Sensor)
21 - 110 30RH/32RH IN-VEHICLE SERVICEJ

SPEEDOMETER COMPONENT INSTALLATION
AND INDEXING (TWO-PIECE SENSOR)
(1) Replace speedometer O-ring if cut, torn, or
worn.
(2) If oil seal in metal speedometer adapter needs
replacement, remove old seal with pointed tool. Then
install new seal with Special Tool C-4004. Push seal
into place with tool until tool bottoms (Fig. 27).
(3) Clean speedometer adapter mounting surface of
transmission, or transfer case thoroughly.
(4) Lubricate adapter seals with transmission
fluid.
(5) Count number of teeth on speedometer pinion.
Do this before installing pinion and adapter.(6) Note range numbers on face of speedometer
adapter (Fig. 27). These numbers correspond to num-
ber of teeth on speedometer pinion.
(7) Install pinion in adapter and install assembled
pinion and adapter in transmission or transfer case.
(8) Rotate speedometer adapter until required
range numbers are at 6 o'clock position (Fig. 28).
Verify that range numbers correspond to num-
ber of teeth on pinion.
(9) Push speedometer adapter into place until
seated.
(10) Install speedometer adapter clamp and bolt.
Tighten bolt to 11 Nzm (100 in. lbs.) torque.
(11) Install sensor adapter on speedometer
adapter. Tighten sensor adapter coupling nut to 17
Nzm (150 in. lbs.) torque.
(12) Carefully align and insert vehicle speed sensor
into sensor adapter.
(13) Install bolt that attaches speed sensor to
adapter. Tighten bolt to 5-8 Nzm (48-72 in. lbs.)
(14) Connect wires to speed sensor.
(15) Lower vehicle.
(16) Check top off transmission fluid level if neces-
sary.
TRANSMISSION COOLER LINE AND FITTING
SERVICE
The transmission cooler lines are attached with
quick connect fittings. Two types of fitting will be
used.
Fig. 25 Location Of Index Numbers On Speedometer
Adapter (Unit Style Sensor)
Fig. 26 Speedometer Components (With Two-Piece
Sensor)
Fig. 27 Installing Speedometer Adapter Seal (With
Two-Piece Sensor And Metal Adapter)
Fig. 28 Indexing Speedometer Adapter (With
Two-Piece Sensor)
J30RH/32RH IN-VEHICLE SERVICE 21 - 111