Jeep Cherokee (XJ): Service procedures
(1) Be sure transmission fluid is at normal operating
temperature. Normal operating temperature is
reached after approximately 15 miles (25 km) of
operation.
(2) Position vehicle on level surface. This is important
for an accurate fluid level check.
(3) Shift transmission through all gear ranges and
back to Park.
(4) Apply parking brakes.
(5) Verify that transmission is in Park.
(6) Wipe off dipstick handle to prevent dirt from
entering fill tube. Then remove dipstick and check
fluid level and condition.
(7) Correct fluid level is to FULL mark on dipstick
when fluid is at normal operating temperature
(Fig. 44).
(8) If fluid level is low, top off level with Mopar
Dexron IIE/Mercon. Mopar Dexron II can be used but
only if Mercon is not available. Do not overfill
transmission. Add only enough fluid to bring
level to Full mark.
(9) If too much fluid was added, excess amount can
be removed with suction gun and appropriate diameter plastic tubing. Tubing only
has to be long enough
to extend into oil pan.
Inspect the appearance of the fluid during the fluid
level check. Fluid color should range from dark red to
pink and be free of foreign material, or particles. If
the fluid is dark brown or black in color and smells
burnt, the fluid has been overheated and must be
changed.
Transmission operation should also be checked if
the fluid is severely discolored and contains quantities
of foreign material, metal particles, or clutch disc
friction material.
A small quantity of friction material or metal
particles in the oil pan is normal. The particles
are usually generated during the break-in
period and indicate normal seating of the various
transmission components. The best way to refill the transmission after a fluid
change or overhaul is as follows:
(1) If transmission has been overhauled, install
transmission in vehicle.
(2) Remove dipstick and insert clean funnel in
transmission fill tube.
(3) Add following initial quantity of Mopar Dexron
IIE/Mercon to transmission:
(4) If fluid/filter change was performed, add 4
pints (2 quarts) of fluid to transmission.
(a) If transmission was completely overhauled
and torque converter was replaced or drained, add
10 pints (5 quarts) of fluid to transmission.
(b) Remove funnel and install dipstick.
(5) Operate vehicle until fluid reaches normal
operating temperature.
(6) Apply parking brakes.
(7) Let engine run at normal curb idle speed, apply
service brakes. Then shift transmission through all
gear ranges and back to PARK (leave engine running).
(8) Remove dipstick and check fluid level. Add only
enough fluid to bring level to Full mark on dipstick.
Do not overfill. If too much fluid is added, excess
amount can be removed with suction gun and
plastic tubing. Tubing only has to be long
enough to extend into oil pan.
(9) When fluid level is correct, shut engine off,
release park brake, remove funnel, and reseat dipstick
in fill tube. Transmission control module (TCM)
service Use the DRB scan tool to diagnose transmission
control module function whenever a fault is suspected.
Replace the module only when the scan tool
indicates the module is actually faulty. Measuring the oil pump output volume will determine
if sufficient oil flow to the transmission oil
cooler exists, and whether or not an internal transmission
failure is present.
Verify that the transmission fluid is at the proper
level. Refer to the Fluid Level Check procedure in
this section. If necessary, fill the transmission to the
proper level with Mopart ATF+3, type 7176, Automatic
Transmission Fluid.
(1) Disconnect the To cooler line at the cooler
inlet and place a collecting container under the disconnected
line.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or internal
damage to the transmission may occur.
(2) Run the engine at curb idle speed , with the
shift selector in neutral.
(3) If one quart of transmission fluid is collected in
the container in 20 seconds or less, oil pump flow volume
is within acceptable limits. If fluid flow is intermittent,
or it takes more than 20 seconds to collect
one quart of fluid, refer to the Hydraulic Pressure
tests in this section for further diagnosis.
(4) Re-connect the To cooler line to the transmission
cooler inlet.
(5) Refill the transmission to proper level. When a transmission failure has contaminated the
fluid, the oil cooler(s) must be flushed. The torque
converter must also be replaced. This will insure that
metal particles or sludged oil are not later transferred
back into the reconditioned (or replaced) transmission.
The only recommended procedure for flushing coolers
and lines is to use Tool 6906A Cooler Flusher. CAUTION: The transmission oil cooler requires a
two stage flushing procedure due to an internally
mounted thermostat. Failure to follow the procedure
can result in severe transmission damage.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1-1968. WEAR STANDARD INDUSTRIAL RUBBER
GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTIBLE
LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CONTACT
WITH YOUR EYES OR SKIN: IF EYE CONTAMINATION
OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION. COOLER FLUSH USING TOOL 6906A (1) Remove cover plate filler plug on Tool 6906A.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions generally
used to clean automatic transmission components.
DO NOT use solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906A.
(3) Verify pump power switch is turned OFF. Connect
red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmission
cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Connect the BLUE pressure line to the OUTLET
(From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Remove the transmission oil cooler from the
vehicle. Refer to the Group 7, Cooling System, for the
proper procedures.
(8) Remove the transmission oil cooler thermostat.
Refer to the Group 7, Cooling System, for the proper
procedures.
(9) Re-install the thermostat cover onto the oil
cooler and install the snap ring.
(10) Re-connect the oil cooler to the transmission
cooler lines.
(11) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
NOTE: This flushes the bypass circuit of the cooler
only.
(12) Turn pump OFF.
(13) Remove the thermostat cover from the oil
cooler.
(14) Install Special Tool Cooler Plug 8414 into the
transmission oil cooler.
(15) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
NOTE: This flushes the main oil cooler core passages
only.
(16) Turn pump OFF.
(17) Remove the thermostat cover from the oil
cooler.
(18) Remove Special Tool Cooler Plug 8414 from
the transmission oil cooler.
(19) Install a new thermostat spring, thermostat,
cover, and snap-ring into the transmission oil cooler.
(20) Install the transmission oil cooler onto the
vehicle.
(21) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(22) Turn pump ON for 30 seconds to purge flushing
solution from cooler and lines. Turn pump OFF.
(23) Place CLEAR suction line into a one quart
container of Mopart ATF Plus 3, type 7176 automatic
transmission fluid.
(24) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the transmission
cooler and lines. Turn pump OFF.
(25) Disconnect alligator clips from battery. Reconnect
flusher lines to cover plate, and remove flushing
adapters from cooler lines. Damaged or worn threads in the aluminum transmission
case and valve body can be repaired by the
use of Heli-Coils, or equivalent. This repair consists
of drilling out the worn-out damaged threads. Then
tap the hole with a special Heli-Coil tap, or equivalent,
and installing a Heli-Coil insert, or equivalent, into the hole. This brings the
hole back to its original
thread size.
Heli-Coil, or equivalent, tools and inserts are
readily available from most automotive parts suppliers.Checking fluid level
Fig. 43 Checking Operation Of Torque Converter Stator One-Way Clutch
Fig. 44 Transmission Fluid LevelChecking fluid condition
Refilling after overhaul or fluid/
filter change
Oil pump volume check
Flushing coolers and tubes
Aluminum thread repair
Other materials:
Cleaning and inspection
BATTERY
The following information details the recommended
cleaning and inspection procedures for the battery
and related components. In addition to the maintenance
schedules found in this service manual and the
owner's manual, it is recommended that these procedures
be performed any time the b ...