Jeep Cherokee (XJ): Manual valve shaft seal. Accumulator pistons and springs. Second coast brake servo

Jeep Cherokee (XJ) 1984 - 2001 Service Manual > Transmission and transfer case > AW-4 automatic transmission > Removal and installation > Manual valve shaft seal. Accumulator pistons and springs. Second coast brake servo

Manual valve shaft seal

REMOVAL

Fig. 74 Manual Valve Shaft And Seals
Fig. 74 Manual Valve Shaft And Seals

1 - SHAFT SEAL
2 - PIN
3 - MANUAL VALVE SHAFT
4 - SHAFT SEAL
5 - SPACER SLEEVE
6 - SHIFT SECTOR

(1) Remove park/neutral position switch and disconnect transmission shift lever (Fig. 74).

(2) Remove oil pan and valve body.

(3) Remove bolts attaching park rod bracket to case (Fig. 75).

Fig. 75 Removing/Installing Park Rod Bracket
Fig. 75 Removing/Installing Park Rod Bracket

1 - PARK ROD
2 - PARK ROD BRACKET

Fig. 76 Removing/Installing Park Rod
Fig. 76 Removing/Installing Park Rod

1 - SHIFT SECTOR
2 - MANUAL VALVE SHAFT
3 - PARK ROD

(5) Cut spacer sleeve with chisel and remove it from manual valve shaft (Fig. 77).

(6) Remove pin from shaft and sector with pin punch.

(7) Remove shaft and sector from case.

Fig. 77 Cutting Spacer Sleeve
Fig. 77 Cutting Spacer Sleeve

1 - SPACER
2 - MANUAL VALVE SHAFT

(8) Pry shaft seals out of case (Fig. 78).

Fig. 78 Removing Manual Valve Shaft Seals
Fig. 78 Removing Manual Valve Shaft Seals

1 - MANUAL VALVE SHAFT SEAL

INSTALLATION

(1) Inspect the manual valve shaft and sector.

Replace either component if worn or damaged.

(2) Coat replacement shaft seals with petroleum jelly and seat them in the case using an appropriately sized driver/socket (Fig. 79).

Fig. 79 Installing Manual Valve Shaft Seals
Fig. 79 Installing Manual Valve Shaft Seals

1 - SHAFT SEAL INSTALLER

(3) Install new spacer sleeve on sector (Fig. 80).

Fig. 80 Installing Spacer Sleeve On Sector
Fig. 80 Installing Spacer Sleeve On Sector

1 - SHIFT SECTOR
2 - SPACER SLEEVE

(4) Lubricate manual valve shaft with petroleum jelly and install it through the left side of the transmission case.

(5) Lubricate sector and sleeve with petroleum jelly and install them on shaft.

(6) Install the manual valve shaft through the remainder of the transmission case.

(7) Align hole in spacer sleeve with notch in sector.

Then install shift sector roll pin. Tap pin into sector and shaft and securely stake sleeve to sector and shaft.

(8) Connect park rod to sector (Fig. 76).

(9) Install park rod bracket (Fig. 81). Tighten bracket bolts to 10 N·m (7 ft. lbs.) torque.

Fig. 81 Installing Park Rod Bracket
Fig. 81 Installing Park Rod Bracket

1 - PARK ROD BRACKET

(10) Install valve body, oil screen and oil pan.

(11) Install park/neutral position switch.

Accumulator pistons and springs

REMOVAL

(1) Remove valve body.

(2) Remove accumulator pistons with compressed air (Fig. 82). Apply air through small feed hole next to each piston bore. Catch each piston in a shop towel as it exits bore.

CAUTION: Use only enough air pressure to ease each piston out of the bore. In addition, remove the pistons one at a time and tag the pistons and springs for assembly reference. Do not intermix them.

(3) Remove and discard piston O-ring seals. Then clean pistons and springs with solvent.

INSTALLATION

(1) Inspect pistons, springs and piston bores.

Replace worn damaged pistons. Replace broken, collapsed or distorted springs. Replace case if piston bores are damaged.

Fig. 82 Accumulator Piston Removal
Fig. 82 Accumulator Piston Removal

1 - AIR GUN NOZZEL IN FEED HOLE
2 - PISTONS

(2) If small cushion spring in any piston must be replaced, remove spring retainer clip and remove spring from piston (Fig. 83). A small hooked tool or small thin blade screwdriver can be used to remove clip. A thin wall, deep socket, or pin punch can be used to seat clip after spring replacement.

Fig. 83 Small Cushion Spring Retention
Fig. 83 Small Cushion Spring Retention

1 - ACCUMULATOR PISTON (TYPICAL)
2 - SMALL CUSHION SPRING
3 - RETAINER CLIP

(3) Install new O-ring seals on pistons. Lubricate seals and pistons and piston bores with transmission fluid.

(4) Install pistons and springs (Fig. 84).

Fig. 84 Accumulator Pistons, Springs And Spacers
Fig. 84 Accumulator Pistons, Springs And Spacers

(5) Install valve body, oil screen and oil pan.

Second coast brake servo

REMOVAL

(1) Remove valve body.

(2) Remove servo piston cover snap ring with snap ring pliers (Fig. 85).

(3) Remove servo piston and cover with compressed air. Apply compressed air through oil hole in servo boss to ease piston out of bore (Fig. 86).

Fig. 85 Removing/Installing Servo Piston Cover Snap Ring
Fig. 85 Removing/Installing Servo Piston Cover Snap Ring

1 - SERVO PISTON COVER SNAP RING
2 - SNAP RING PLIERS

Fig. 86 Removing Servo Cover And Piston
Fig. 86 Removing Servo Cover And Piston

1 - PISTON AND COVER
2 - OIL HOLE

(4) Remove and discard seal and O-rings from cover and piston (Fig. 87). Inspect E-ring, piston, spring and retainer, piston rod and piston spring.

Replace worn or damaged parts.

Fig. 87 Second Coast Brake Servo Components

Fig. 87 Second Coast Brake Servo Components

1 - SERVO PISTON
2 - SEAL RING
3 - SPRING AND RETAINER
4 - PISTON ROD
5 - PISTON SPRING
6 - SERVO COVER O-RINGS
7 - SERVO COVER
8 - SNAP RING
9 - E-RING

INSTALLATION

(1) Install new seals on cover and piston.

(2) Lubricate servo components with transmission fluid.

(3) Assemble and install servo components in case.

Be sure servo piston rod is properly engaged in the second coast brake band.

(4) Compress cover and piston and install cover snap ring.

(5) Install valve body, oil screen and oil pan.

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