Jeep Cherokee (XJ): Cleaning and inspection. Adjustments. Specifications

Cleaning and inspection

TRANSMISSION PARTS CLEANING AND INSPECTION

Clean the transmission components with solvent and dry them with compressed air only. Do not use shop towels or rags.

Blow compressed air through all oil feed passages and channels to be sure they are clear. Inspect the transmission components for wear and damage.

Replace components that are damaged or worn beyond the limits specified in the individual overhaul procedures.

Replace all O-rings, gaskets and seals. These components are not reusable. Also replace any snap ring that is distorted or damaged.

During overhaul assembly operations, lubricate the transmission components with Mopar Mercony automatic transmission fluid or petroleum jelly as indicated.

Petroleum jelly should be used to prelubricate thrust bearings, washers and races. It can also be used to hold parts in position during assembly.

Soak replacement clutch and brake pack components in transmission fluid for at least 30 minutes before installation.

Adjustments

Gearshift cable

Check adjustment by starting the engine in Park and Neutral. Adjustment is OK if the engine starts only in these positions. Adjustment is incorrect if the engine starts in one but not both positions. If the engine starts in any position other than Park or Neutral, or if the engine will not start at all, the park/ neutral position switch may be faulty.

Gearshift Adjustment Procedure

(1) Shift transmission into Park.

(2) Raise vehicle.

(3) Release cable adjuster clamp (at transmission end of cable) to unlock cable.

(4) Unsnap cable from cable mounting bracket on transmission (Fig. 300).

(5) Slide cable eyelet off transmission shift lever.

(6) Verify transmission shift lever is in Park detent by moving lever fully rearward. Last rearward detent is Park position.

(7) Verify positive engagement of transmission park lock by attempting to rotate propeller shaft.

Shaft will not rotate when park lock is engaged.

(8) Slide cable eyelt onto transmission shift lever.

(9) Snap shift cable adjuster into mounting bracket on transmission.

(10) Lock shift cable by pressing cable adjuster clamp down until it snaps into place.

(11) Lower vehicle and check engine starting.

Engine should start only in Park and Neutral.

Fig. 300 Shift Cable Attachment At Transmission-Typical
Fig. 300 Shift Cable Attachment At Transmission-Typical

1 - THROTTLE VALVE CABLE
2 - TRANSMISSION SHIFT LEVER
3 - SHIFT CABLE
4 - SHIFT CABLE BRA

Brake transmission shift interlock cable adjustment

(1) Shift transmission into PARK.

(2) Remove shift lever bezel and console screws.

Raise bezel and console for access to cable.

(3) Pull cable lock button up to release cable (Fig.

301).

(4) Turn ignition switch to LOCK position.

(5) Use a spacer to create a one millimeter gap between the shifter pawl and top of the shift gate.

(6) Pull cable forward. Then release cable and press cable lock button down until it snaps in place.

(7) Check adjustment as follows: (a) Check movement of release shift handle button (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 RUN position.

(c) Shifting out of park should not be possible.

(d) Apply the brake and attempt to shift out of PARK. Shifting should be possible.

(e) While the transmission is shifted out of PARK, release the brake and attempt to shift through all gears. Release the shift button at least once during this procedure. The ignition key should not go to the LOCK position.

Fig. 301 Park Lock Cable Attac
Fig. 301 Park Lock Cable Attac

1 - PARK LOCK CABLE
2 - CABLE LOCK BUTTON
3 - SHIFT LEVER ASSEMBLY
4 - SHIFT CABLE

(f) Return transmission to the PARK position without applying the brake.

(8) Move shift lever back to PARK and check ignition switch operation. You should be able to turn switch to LOCK position and shift lever release button/ lever should not move.

Transmission throttle valve cable adjustment

(1) Shift transmission into Park, shut engine off and raise hood.

(2) Press cable release button (Fig. 302).

(3) Push cable conduit back into cable sheath as far as possible (Fig. 303).

(4) Rotate lever on throttle body to wide open throttle position. Cable will ratchet to correct adjustment point as lever is rotated (Fig. 303).

Fig. 302 Throttle Cable Components
Fig. 302 Throttle Cable Components

1 - CONDUIT
2 - RELEASE BUTTON
3 - CABLE CONNECTOR
4 - CABLE

Fig. 303 Throttle Cable Adjustment
Fig. 303 Throttle Cable Adjustment

1 - RELEASE BUTTON
2 - ROTATE THROTTLE BODY LEVER TO W. O. T. POSITION
3 - CABLE
4 - CABLE BRACKET

Specifications

AW-4 AUTOMATIC TRANSMISSION

AW-4 GENERAL SPECIFICATIONS

Gear Ratios:

First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.804:1
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.531:1
Third . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.000:1
Fourth (Overdrive) . . . . . . . . . . . . . . . . . . 0.753:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . 2.393:1

Transmission Fluid . . Jeep automatic transmission fluid or DEXRONt II
Fluid Level . To "Full" mark with fluid hot (normal operating temperature)
Fluid Capacity (all models) . . . 8.0 Liters (8.45 qts.)

Test Specifications

Stall Speed:

In D Range and Reverse . . . . . . . 2100-2400 rpm
Line Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
In D at Curb Idle . . . . . 61-70 psi (421-481 kPa)
In D at WOT . . . . . . 173-209 psi (1196-1442 kPa)
In Reverse at Curb Idle . 75-90 psi (519-618 kPa)
In Reverse at WOT . 213-263 psi (1471-1814 kPa)

Time Lag Test:

Engagement in D Range . . . . . . . . . . 1.2 seconds
Engagement in Reverse . . . . . . . . . . . 1.5 seconds
Valve Body Solenoid Resistance . . . . . . 11-15 ohms

Transmission Fluid Normal Operating

Temperature . . . . . . . . . . . . 50-80C (122-176F)
TPS Input Voltage (AU) . . . . . . . 5.0 Volts (approx.)
TPS Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . .
4-Cylinder . . . . . . . . . . . . . . . 0.2 Volts (approx.)
6-Cylinder . . . . . . . . . . . . . . . 4.2 Volts (approx.)

AW-4 CLUTCH DISC AND PLATE THICKNESS

AW-4 CLUTCH DISC AND PLATE THICKNESS

AW-4 OIL PUMP WEAR LIMITS

Drive Gear

Tip Clearance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard . . . 0.11-0.14 mm (0.0043 -0.0055 in.)
Maximum Allowance . . . . . . . . 0.3 mm (0.012 in.)

Gear-to-Pump Body

End Clearance:

Standard . . . . . 0.02-0.05 mm (0.0008-0.0020 in.)
Maximum Allowance . . . . . . . . 0.1 mm (0.004 in.)

Driven Gear-to-Pump

Body Clearance:

Standard . . . . . 0.07-0.15 mm (0.0028-0.0059 in.)
Maximum Allowance . . . . . . . . 0.3 mm (0.012 in.)

AW-4 BUSHING AND PISTON CLEARANCE

AW-4 BUSHING AND PISTON CLEARANCE

AW-4 RETAINER AND PISTON SPECIFICATIONS

AW-4 RETAINER AND PISTON SPECIFICATIONS

AW-4 VALVE BODY BALL DIMENSIONS

AW-4 VALVE BODY BALL DIMENSIONS

AW-4 CLUTCH AND BRAKE PACK REQUIREMENTS

AW-4 CLUTCH AND BRAKE PACK REQUIREMENTS

AW-4 VALVE AND SPRING IDENTIFICATION

AW-4 VALVE AND SPRING IDENTIFICATION

AW-4 ACCUMULATOR COMPONENT IDENTIFICATION

AW-4 ACCUMULATOR COMPONENT IDENTIFICATION

AW-4 TORQUE SPECIFICATIONS

Description Torque

Converter Housing Bolts . . . . . . . . . . . . . . . . . . . . .
10 mm . . . . . . . . . . . . 32-36 N·m (23-27 ft. lbs.)
12 mm . . . . . . . . . . . . 55-59 N·m (40-43 ft. lbs.)
Cooler Line Retaining Clip Nuts . . . . . . . . 2-4 N·m (18-35 in. lbs.)
Cooler Line Bracket Nuts . . . . . . . . . . . . 5-11 N·m (48-96 in. lbs.)
Cooler Line Fitting Nuts (at auto. trans.

fittings) . . . . . . . . . 18-23 N·m (160-200 in. lbs.)
Detent Spring Bolt . . . . . 9-11 N·m (80-96 in. lbs.)
Dust Cover Nuts/Bolts . . . . . . . . . . . . . . 18-23 N·m (159-203 in. lbs.)
Extension Housing Bolts . . . . . . . . . . . . 32-36 N·m (23-27 ft. lbs.)
Fill Tube Bracket Bolt . . 50-64 N·m (37-47 ft. lbs.)
Neutral Switch Bolt . . . . . 12-14 N·m (8-10 ft. lbs.)
Nut . . . . . . . . . . . . . . . . . 6-8 N·m (53-70 ft. lbs.)
OD Support Bolt (to case) . . . . . . . . . . . 23-27 N·m (18-20 ft. lbs.)

Description Torque

Oil Pan Bolts . . . . . . . . . . . 6-8 N·m (53-70 in. lbs.)
Oil Pan Drain Plug . . . . 19-21 N·m (14-16 ft. lbs.)
Oil Pump Bolt (to case) . 21-23 N·m (16-18 ft. lbs.)
Oil Pump Bolt (to stator shaft) . . . . . . . . . 9-11N·m (80-96 in. lbs.)
Oil Screen Bolt . . . . . . . . 9-11 N·m (80-96 in. lbs.)
Park Pawl Bracket . . . . . 9-11 N·m (80-96 in. lbs.)
Propeller Shaft Clamp Screws . . . . . . . . 16-23N·m (140-200 in. lbs.)
Rear Mount-To-Transmission Bolts . . . . . 60-81N·m (44 ft. lbs.)
Rear Mount-To-Clevis Bracket
Bolt/Nut . . . . . . . . . . . 54-75 N·m (40-55 ft. lbs.)
Rear Mount Clevis Bracket-To-Crossmember
Nuts . . . . . . . . . . . . . . 33-49 N·m (24-36 ft. lbs.) Shift Cable Bracket Screws At
Transmission . . . . . 25-39 N·m (221-345 in. lbs.)
Shift Lever Mounting Cover Screws . . . . . 1-2 N·m (9-20 in. lbs.)
Shift Lever Housing Nuts . . . . . . . . . . . 16-26 N·m (141-230 in. lbs.)

Description Torque

Solenoid Harness Bolt . . . . 6-8 N·m (57-75 in. lbs.)
Speedometer Adapter Clamp Screw . . . . 10-12 N·m (90-110 in. lbs.)
Speed Sensor Coupling Nut . . . . . . . . . . 14-20 N·m (125-175 in. lbs.)
Throttle Cable Engine Bracket Screws . . 7-11 N·m (63-94 in. lbs.)
Throttle Cable Retaining Screw
(at transmission) . . . . . 8-10 N·m (70-98 in. lbs.)
Transfer Case Mounting Nuts . . . . . . . . 30-41 N·m (22-30 ft. lbs.)
Transmission Shift Lever Nut . . . . . . . . 15-17 N·m (134-154 in. lbs.)
Transmission-To-Engine Block Bolts . . . 50-64 N·m (37-47 ft. lbs.)
Valve Body Bolts (to case) . . . . . . . . . . . . 9-11 N·m (80-96 in. lbs.)
Valve Body Bolts (to valve body) . . . . . . . . 6-7 N·m (54-58 in. lbs.)

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    The valve body assembly consists of two sections which are the upper body and lower body (Fig. 298) and (Fig. 299). Disassembly, inspection and overhaul procedures for each section are outlined sep ...

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