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21a - gianecri

1. 21 4 TRANSMISSION AND TRANSFER CASE DESCRIPTION AND OPERATION Continued 1 CONVERTER CLUTCH 2 TORQUE CONVERTER 3 OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY 4 FRONT BAND 5 FRONT CLUTCH 6 DRIVING SHELL 7 REAR BAND 8 TRANSMISSION OVERRUNNING CLUTCH 9 OVERDRIVE UNIT 10 PISTON RETAINER 11 OVERDRIVE CLUTCH 12 DIRECT CLUTCH 13 INTERMEDIATE SHAFT 14 FRONT BEARING 15 HOUSING 16 REAR BEARING 17 OUTPUT SHAFT 18 SEAL 19 OVERDRIVE OVERRUNNING CLUTCH 20 OVERDRIVE PLANETARY GEAR 21 DIRECT CLUTCH SPRING 22 OVERDRIVE CLUTCH PISTON 23 VALVE BODY ASSEMBLY 24 FILTER 25 FRONT PLANETARY GEAR 26 REAR CLUTCH 27 TRANSMISSION 28 REAR PLANETARY GEAR TRANSMISSION IDENTIFICATION Transmission identification numbers are stamped on the left side of the case just above the oil pan gas ket surface Fig 2 Refer to this information when ordering replacement parts 80b11960 Fig 2 Transmission Part And Serial Number Location 1 PART NUMBER 2 BUILD DATE 3 SERIAL NUMBER RECOMMENDED FLUID NOTE Refer to the Service Procedures section of this Group for fluid level checking procedures FLUID TYPE Mopar ATF Plus 3 Type 7176 automatic trans mission fluid is the recommended fluid for Chrysler automatic transmissions Dexron 11 fluid IS NOT recommended Clutch
2. 97 OVERRUNNING CLUTCH CAM OVERDRIVE PISTON 81 PLANETARY GEARTRAIN OUTPUT SHAFT 92 REAR CLUTCH 22222522222 88 REAR SERVO PISTON 21 2 TRANSMISSION AND TRANSFER CASE TRANSMISSION 69 VALVE BODY ex eres Rte RR REG 49 CLEANING AND INSPECTION 114 FRONT CLUTCH 115 FRONT SERVO eh ets 114 OIL PUMP AND REACTION SHAFT SUPPORT 115 OVERDRIVE 116 OVERRUNNING CLUTCH LOW REVERSE DRUM OVERDRIVE PISTON RETAINER 114 PLANETARY GEARTRAIN 116 REAR CLUTCH 116 see ea cie es 114 5 113 DESCRIPTION AND OPERATION 44 RE TRANSMISSION Vehides equipped with the 3 1L turbo diesel engine use the 44RE automatic transmission The 44 is a four speed fully automatic transmis sion Fig 1 with an electronic governor First through third gear ranges are provided by the dutches bands overrunning clutch and planetary gear sets in the transmission Fourth gear range is provided by the overdrive unit that contains an over drive dutch direct dutch planetary gear set and overrunning dutch The overdrive dutch is applied in fourth gear only The direct clutch is applied in all WJ VALVE BODY ER awmi aaa 112 ADJ
3. 4 5 J 1 5 14 5 2 1 3ATVA L3IHS 2 1 1 ond 3ATVA TII AJNO 1 m H 9 1 S ALII S ond 3 1LLOHH L 1 3NTVA 1 141 5 c 1 Q OAH3S YOLYINAINDOV OAH3S 1 HOL TIO HV3H GION310S HONH3JAOS Ofrid HONH3AOD 21 133 TRANSMISSION AND TRANSFER CASE WJ SCHEMATICS AND DIAGRAMS Continued 68 4808 189 8 0 atunssatd dud NOILLONS 84 29 9 3unssaud 380 783183ANOO isd 75 9 3Hnssaud HONH3AOD DAMNA isd 86 40 71OH1NOO 5 2 1 isd 29 68 3unssaud 245 NI Or TnVHGAH ATLLOYHL 4848019 HV35 5 TWANVIA NI 43437 0193135 110 NOILVOIHSfIT HOLNTS LNOYS MVA HOLIMS 011 201 E dION310S df14201 NOILVOIHB TI OL H3lH3JANOO ano
4. 3AT1VA i 17 E 3ATVA 1OHLNOO LIIHS 2 1 dH TH Ell d SRF em u IHS 6 2 31 LOHHL f isd 69 29 3Hnss3Hd ond HONH3AOD isd 69 29 3unssaud INIT 1 F E o o 1 O 9 9 1 21 12 T i 3AIHQHHAO HOLY TINAINDOV OAH3S LNOHH 21 125 TRANSMISSION AND TRANSFER CASE WJ SCHEMATICS AND DIAGRAMS Continued o8pyaeon NOLLOnS isd 01 66 aynssaud 38nualg3ANOO 001 09 FATWA 31LLOHHL OL 3unss3ud SANIT isd 02 82 1 5 2 1 isd v6 0 3unssaud TILLOHHL isd 022 091 5 5 INIT lt H3A31 901997135 3SH3A3H NI o
5. 16 GEARSHIFT CABLE 10 HYDRAULIC PRESSURE TEST 12 OVERDRIVE ELECTRICAL CONTROLS 10 PARK NEUTRAL POSITION SWITCH 10 PRELIMINARY DIAGNOSIS 9 page NV247 TRANSFER 140 page ROAD TESTING 11 THROTTLE VALVE CABLE 11 SERVICE PROCEDURES ALUMINUM THREAD REPAIR 29 CONVERTER DRAINBACK CHECK VALVE SERVICE Re 28 FLUID AND FILTER REPLACEMENT 26 FLUID LEVEL CHECK 26 FLUSHING COOLERS AND TUBES 28 OIL PUMP VOLUME CHECK 28 TRANSMISSION FILL PROCEDURE 27 REMOVAL AND INSTALLATION BRAKE TRANSMISSION SHIFT INTERLOCK CABLE uuu eee ug 40 FLOOR SHIFTER is RR 38 GEARSHIFT CABLE 36 GOVERNOR SOLENOID AND PRESSURE SENSOR 42 OUTPUT SHAFT FRONT BEARING 48 OUTPUT SHAFT REAR BEARING 48 OVERDRIVE HOUSING BUSHING 47 OVERDRIVE UNIT 46 PARK NEUTRAL POSITION SWITCH 36 TORQUE CONVERTER 35 TRANSMISSION 29 VALVE BODY ER bane IEEE 44 YOKE SEAL REPLACEMENT 36 DISASSEMBLY AND ASSEMBLY FRONT CLUTCH 87 FRONT SERVO PISTON 83 OIL PUMP AND REACTION SHAFT SUPPORT 83 OVERDRIVE UNIT
6. 3ATVA 0 S AYCHIAO 3ATVA 141 7 8 JAVA NANOGMODI 3ATVA 2111081 JAVA 7 6 3NTVA 0 LAIHS 2 1 3ATVA 146 2 1 e 3ATVA Td JAVA 3 1LLOHS 3NTVA LIIHS 6 2 3TLLOHHL 41 3 1LLOtHHL HONH3AOD YOLVINANDOV 6 H LNTO OAHu3S 3AIHQU3AO GION31OS HONH3AOS YOLVINANISV OAH3S LNOHS TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS Continued 21 124 TVYLNAN NI MO TH 31034808 ATLLOYHL 0380719 TWHLONAN H3A31 YOLDSTSS 11101 1 4 SATVA SNINIL dfi 4201 H LT 1 3ATVA 001 E F i GION310S 105 1 F 14IHS 1 8 NOILVOIUS T1 H LNT LNOYS OL H31HdJANOO anogor Naayos mr
7. 5 55 AND TRANSFER CASE 21 139 SPECIAL TOOLS Continued Remover Bushing SP 5324 Installer Bushing SP 5325 Remover 6957 CO Installer 6951 Adapter C 3705 Retainer 6583 21 140 TRANSMISSION AND TRANSFER CASE NV247 TRANSFER CASE TABLE OF CONTENTS page DESCRIPTION AND OPERATION NV247 TRANSFER CASE 140 DESCRIPTION AND OPERATION NV247 TRANSFER CASE The NV247 transfer case is used with the 3 1L turbo diesel engine Refer to Group 21 Transmission Transfer Case of the gasoline engine manual for additional information 80ba7a31 Fig 1 NV247 Transfer Case REMOVAL AND INSTALLATION TRANSFER CASE REM OVAL 1 Open the hood and disconnect the negative bat tery cable 2 Remove the 2 upper fan shroud retaining bolts 3 Raise the vehicle on a hoist 4 Remove the 2 lower fan shroud retaining bolts CAUTION Mark the position of the driveshaft in relation to its companion flange prior to disassem bly Driveshaft must be reinstalled in the same posi tion it was in prior to disassembly 5 Remove the front driveshaft retaining bolts Fig 2 and remove the driveshaft from the transfer REMOVAL AND INSTALLATION TRANSFER CASE 140 Fig 2 Front Driveshaft Retaining Bolts 1 TRANSFER CASE 2 FRONT DRIVESHAFT RETAINING BOLTS 3 REFERENCE MARK case companion flange Support t
8. 35 in 106 torque 3 Install 1 2 and 2 3 shift valves and springs 4 Install 1 2 shift control valve and spring 5 Install retainer spring limit valve and 2 3 throttle plug from limit valve housing 6 Install limit valve housing and cover plate Tighten screws to 4 N m 35 in Ibs 7 Install shuttle valve as follows a Insert plastic guides in shuttle valve second ary spring and install spring on end of valve b Install shuttle valve into housing c Hold shuttle valve in place d Compress secondary spring and install E dip in groove at end of shuttle valve e Verify that spring and E dip are properly seated before proceeding 8 Install shuttle valve cover plate Tighten cover plate screws to 4 35 in 106 torque 9 Install 1 2 and 2 3 valve governor plugs in valve body 10 Install throttle plug 11 Align and install governor plug cover Tighten cover screws to 4 35 in Ibs torque shuttle valve primary spring and 3RANSMISSION AND TRANSFER CASE 21 63 DISASSEMBLY AND ASSEMBLY Continued J9421 217 Fig 102 Shuttle And Boost Valve Components 1 SPRING 8 SHUTTLE VALVE COVER 2 RETAINER 9 SHUTTLE VALVE 3 BOOST VALVE 10 SHUTTLE VALVE PRIMARY SPRING 4 BOOST VALVE PLUG 11 GOVERNOR PLUG COVER 5 SPRING GUIDES 12 THROTTLE PLUG 6 E CLIP 13 UPPER HOUSING 7 SHUTTLE VALVE SECONDARY SPRI
9. 18008 5 5 3ATVA 3ATVA 3 1LLOMHL ES x 5 3AT1VA TOH INOO 141 8 2 1 JAVA 31LLnHS JILLOHHL OL IMYA O O o 19 LNOYS 5 LNOH4 8 HV3H YALYAANOD anouor 3ATVA L3IHS 2 1 9nd HONH3AO9 55216 3A1VA 1 5 6 2 HO91019 HV3H GION3108 HONH3JAOS Ofrld HONU3AO9 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS Continued 21 132 88034808 isd 6 0 3unssaud ao NOLLONS 84 25 6 aunssatudq 38N71 43LH3AN09 084 06 0 dunssaud HONH3AOD isd se sz TOULNOD LAIHS 2 1 isd 29 89 3unssatid L MOT NI 29r TOVHGAH 845012 9 15015 H3A31 HOLOGT3S darin 10 NOI1V2IHS TI 19 4 NOILVDIHSfTI OL SATVA SNIWI1 MAL 3ATVA dn 3201 YALYAANOD 3nouorl GION310S df1201 lol 15008 NI IMIYA 141 5 t p Ll LE 1 NA003913 JAYA TILLOBHL 3ATVA
10. LIMIT VALVE COVER 13 THROTTLE PRESSURE SPRING AND PLUG 7 LIMIT VALVE AND SPRING 5 551 AND TRANSFER CASE 21 59 DISASSEMBLY AND ASSEMBLY Continued VALVE BODY LOWER HOUSING 1 Remove timing valve cover 2 Remove 3 4 timing valve and spring 3 Remove 3 4 quick fill valve spring and plug 4 Remove 3 4 shift valve and spring 5 Remove converter dutch valve spring and plug Fig 93 6 Remove converter dutch timing valve retainer and valve spring 80468495 Fig 93 Lower Housing Shift Valves And Springs 1 LOWER HOUSING 11 OVERDRIVE SEPARATOR PLATE 2 E CLIP 12 3 4 QUICK FILL SPRING AND VALVE 3 ACCUMULATOR END PLATE 13 HARNESS 4 3 4 ACCUMULATOR PISTON AND SPRING 14 CASE CONNECTOR 5 3 4 ACCUMULATOR HOUSING 15 SOLENOID GASKET 6 3 4 SHIFT VALVE AND SPRING 16 CONVERTER CLUTCH SOLENOID 7 PLUG 17 OVERDRIVE SOLENOID 8 SPRING RETAINER 18 TIMING VALVE COVER 9 CONVERTER CLUTCH VALVE AND SPRING 19 PLUG 10 CONVERTER CLUTCH TIMING VALVE AND SPRING 20 3 4 TIMING VALVE AND SPRING 21 60 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 3 4 ACCUMULATOR HOUSING 1 Remove end plate from housing 2 Remove piston spring 3 Remove piston Remove and discard piston seals Fig 94 D 804d8eb9 Fig 94 Accumulator Housing Components 1 ACCUMULATOR PISTON 2
11. SS BLE j ay Ne S DN 824 AVES 1 80ba79cd Fig 39 Transfer Case Shift Cable 1 CLIP 2 SHIFTER 3 TRANSFER CASE SHIFT LEVER PIN 4 TRANSFER CASE SHIFT CABLE 6 Remove the clip retaining the transfer case shift cable to the shifter bracket assembly 7 Remove the transfer case shift cable from the shifter assembly 8 Disconnect all shifter assembly 9 Remove the shifter assembly retaining nuts from the floor pan Fig 40 wiring connectors from the 80be44bc Fig 40 Shifter Assembly 1 FLOOR PAN 2 SHIFTER ASSEMBLY TRANSMISSION AND TRANSFER CASE 21 39 10 the shifter from the vehicle INSTALLATION 1 Install the shifter in the vehicle 2 Install the shifter assembly retaining nuts on the floor pan mounted studs Fig 41 Torque to 28 N m 250 in Ibs 80be44bc Fig 41 Shifter Assembly 1 FLOOR PAN 2 SHIFTER ASSEMBLY 3 Connect all wiring on the shifter assembly 4 Install the transfer case shift cable on the shifter bracket assembly and secure with clip Fig 42 Rs LNA 3 lt s my 80ba79cd Fig 42 Transfer Case Shift Cable 1 CLIP 2 SHIFTER 3 TRANSFER CASE SHIFT LEVER PIN 4 TRANSFER CASE SHIFT CABLE 21 40 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued 5 Snap the transfer case shift cable onto the shift lever
12. 150 165 torque 6 Lower vehide and fill transmission with Mopar ATF Plus 3 type 7176 fluid TRANSMISSION FILL PROCEDURE To avoid overfilling transmission after a fluid change or overhaul perform the following procedure 1 Remove dipstick and insert dean funnel in transmission fill tube 2 Add following initial quantity of Plus 3 to transmission a If only fluid and filter were changed add 6 pints 3 quarts of ATF Plus 3 to transmission b If transmission was completely overhauled torque converter was replaced or drained and cooler was flushed add 16 pints 8 quarts of ATF Plus 3 to transmission 3 Apply parking brakes 4 Start and run engine at normal curb idle speed 5 Apply service brakes shift transmission through all gear ranges then back to NEUTRAL set parking brake and leave engine running at curb idle speed 6 Remove funnel insert dipstick and check fluid level If level is low add fluid to bring level to MIN mark on dipstick Check to see if the oil level is equal on both sides of the dipstick If one side is noticeable higher than the other the dipstick has picked up some oil from the dipstick tube Allow the oil to drain down the dipstick tube and re check 7 Drive vehicle until transmission fluid is at nor mal operating temperature 8 With the engine running at curb idle speed the gear selector in NEUTRAL and the parking brake applied check the t
13. 19 Position the transmission support crossmem ber mount assembly and install the 4 transmission mount retaining bolts Fig 25 Torque the bolts to 75 N m 55 ft Ibs 20 Install a jack under the transmission support crossmember and raise slightly eB e lt gt s LET 800 4667 Fig 25 Transmission Support Crossmember Position amp Orientation 1 TRANSFER CASE 2 TRANSMISSION MOUNT RETAINING BOLTS 2 OF 4 3 EXHAUST SYSTEM SUPPORT BRACKET RETAINING BOLTS 4 CROSSMEMBER RETAINING BOLTS 5 TRANSMISSION 6 CROSSMEMBER RETAINING BOLTS 21 Install the transfer case on the transmission Torque the transfer case retaining nuts to 75 N m 55 ft Ibs 22 Using the jack raise the transmission assem bly into position and install the 8 transmission sup port crossmember retaining bolts Fig 25 Torque the bolts to 41 N m 30 ft Ibs WJ 23 Unclip the wire harness from the transmis sion support crossmember 24 Position the exhaust system support brackets and install the retaining bolts Torque the bolts to 41 N m 30 ft Ibs Fig 25 25 Install the vent tube on the transfer case 26 Connect the transfer case shift cable on the shifter arm 27 Install the rear driveshaft Torque the bolts to 32 24 ft Ibs Be certain to install the drive shaft in the same position
14. 4 Using a suitable driver inserted through the rear end of housing drive bearing from housing INSTALLATION 1 Place replacement bearing in position in hous ing 2 Using a suitable driver drive bearing into housing until the snap ring groove is visible 3 Install snap ring to hold bearing into housing Fig 63 4 Install overdrive geartrain into housing 5 Install overdrive unit in vehide OUTPUT SHAFT FRONT BEARING REM OVAL 1 Remove overdrive unit from the vehide 2 Remove overdrive geartrain from housing 3 Remove snap ring holding output shaft front bearing to overdrive geartrain Fig 64 4 Pull bearing from output shaft 80315860 Fig 63 Output Shaft Rear Bearing 1 OUTPUT SHAFT REAR BEARING 2 OVERDRIVE HOUSING 3 SNAP RING INSTALLATION 1 Place replacement bearing in position on geartrain with locating retainer groove toward the rear 2 Push bearing onto shaft until the snap ring groove is visible 3 Install snap ring to hold bearing onto output shaft Fig 64 4 Install overdrive geartrain into housing 5 Install overdrive unit in vehicle 80315861 Fig 64 Output Shaft Front Bearing 1 OUTPUT SHAFT FRONT BEARING 2 SNAP RING 3 OUTPUT SHAFT 4 GROOVE TO REAR 5 OVERDRIVE GEARTRAIN W DISASSEMBLY AND ASSEMBLY VALVE BODY Remove the valve body from the transmission refer to Removal and Installation procedures section
15. PRELIMINARY DIAGNOSIS Two basic procedures are required One procedure for vehicles that are drivable and an alternate proce dure for disabled vehicles will not back up or move forward VEHICLE IS DRIVEABLE 1 Check for transmission fault codes using DRB scan tool 2 Check fluid level and condition 80ba79c2 Fig 6 Ignition Interlock Cable 4 STEERING COLUMN ASSEMBLY 5 INTERLOCK CABLE 3 ADJUSTMENT CLIP 1 SHIFT MECHANISM 2 SHIFTER BTSI LEVER 21 10 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING Continued 3 Adjust throttle and gearshift linkage if com plaint was based on delayed erratic or harsh shifts 4 Road test and note how transmission upshifts downshifts and engages 5 Perform stall test if complaint is based on slug gish acceleration Or if abnormal throttle opening is needed to maintain normal speeds with a properly tuned engine 6 Perform hydraulic pressure test if shift prob lems were noted during road test 7 Perform air pressure test to check dutch band operation VEHICLE IS DISABLED 1 Check fluid level and condition 2 Check for broken or disconnected gearshift or throttle linkage 3 Check for cracked leaking cooler lines or loose or missing pressure port plugs 4 Raise and support vehicle on safety stands start engine shift transmission into gear and note following If propeller shaft turns but wheels do not problem is with
16. 13 Engage wire connectors into pressure sensor and solenoid Fig 48 14 Install transmission fluid pan and new filter 15 Lower vehicle and road test to verify repair 80b6b3a0 Fig 47 B T S 1 Solenoid Connector Location 1 LEFT MULTIFUNCTION SWITCH CONNECTOR 2 LOWER CLOCKSPRING CONNECTORS 3 RIGHT MULTIFUNCTION SWITCH CONNECTOR 4 SHIFTER INTERLOCK CABLE CONNECTOR 80315865 5 SHIFTER INTERLOCK SOLENOID CONNECTOR Fig 48 Governor Solenoid And Pressure Sensor 6 IGNITION SWITCH CONNECTOR RECEPTACLES 1 PRESSURE SENSOR 7 SKIM CONNECTOR 2 PRESSURE SOLENOID 3 GOVERNOR INSTALLATION Before installing the pressure sensor and solenoid in the governor body replace O ring seals clean the gasket surfaces and replace gasket 1 Lubricate O ring on pressure sensor with CN transmission fluid 2 Align pressure sensor to bore in governor body Fig 52 3 Push pressure sensor into governor body 4 Install retainer to hold pressure sensor to gov ernor body 5 Place gasket in position on back of governor body Fig 51 6 Place governor body in position on valve body 7 Install bolts to hold governor body to valve body ir 2 oM pressure solenoid with Fig 49 Pressure Solenoid Retainer 1 PRESSURE SOLENOID RETAINER 2 GOVERNOR 80915866 21 44 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued A 80315867 Fig 50 Pressure
17. 13 Install top pressure plate 14 Install selective snap ring Be sure snap ring is fully seated in retainer groove 15 Using a suitable gauge bar and dial indicator measure clutch pack clearance Fig 186 a Position gauge bar across the clutch drum with the dial indicator pointer on the pressure plate Fig 186 Using two small screw drivers lift the pres sure plate and release it c Zero the dial indicator d Lift the pressure plate until it contacts the snap ring and record the dial indicator reading Clearance should be 0 64 1 14 mm 0 025 0 045 in If dearance is incorrect steel plates discs selec tive snap ring and pressure plates may have to be changed The selective snap ring thicknesses are 107 109 in 098 100 in 095 097 in 083 085 in 076 078 in 071 073 in 060 062 in 16 Coat rear dutch thrust washer with petro leum jelly and install washer over input shaft and into dutch retainer Fig 187 Use enough petroleum jelly to hold washer in place 17 Set rear dutch aside for installation during final assembly 21 92 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 80 483 Fig 186 Checking Rear Clutch Pack Clearance 1 DIAL INDICATOR 2 PRESSURE PLATE 3 SNAP RING 4 STAND 5 REAR CLUTCH 6 GAUGE BAR 1 W c j 2 3 q k 2229 e A Le SN lt nj 80444514
18. 3 4 ACCUMULATOR HOUSING 3 TEFLON SEALS 4 PISTON SPRING 5 COVER PLATE AND SCREWS ASSEMBLY CAUTION Do not force valves or plugs into place during reassembly If the valve body bores valves and plugs are free of distortion or burrs the valve body components should all slide into place easily In addition do not overtighten the transfer plate and valve body screws during reassembly Over tightening can distort the housings resulting in valve sticking cross leakage and unsatisfactory operation Tighten valve body screws to recom mended torque only LOWER HOUSING 1 Lubricate valves springs and the housing valve and plug bores with clean transmission fluid Fig 93 2 Install 3 4 timing valve spring and valve in lower housing 3 Install 3 4 quick fill valve in lower housing 4 Install 3 4 quick fill valve spring and plug in housing 5 Install timing valve end plate Tighten end plate screws to 4 N m 35 in Ibs torque 3 4 ACCUMULATOR 1 Lubricate accumulator piston seals and hous ing piston bore with dean transmission fluid Fig 94 2 Install new seal rings on accumulator piston 3 Install piston and spring in housing 4 Install end plate on housing TRANSFER PLATE 1 Install rear dutch and rear servo check balls in transfer plate Fig 95 2 Install filter screen in upper housing separator plate Fig 96 3 Align and position upper housing separator plate on trans
19. oS a3 o C 4 J9321 151 Fig 87 Upper Housing Separator Plate 1 TRANSFER PLATE 2 UPPER HOUSING SEPARATOR PLATE 3 FILTER SCREEN 4 BRACE 80917125 Fig 85 Check Ball 1 ECE CHECK BALL 3 16 J9321 437 Fig 88 Rear Clutch And Rear Servo Check Ball Locations 1 REAR CLUTCH CHECK BALL Fig 86 Transfer Plate Esa E EE 1 UPPER HOUSING 2 TRANSFER PLATE 80b170f9 21 56 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued VALVE BODY UPPER HOUSING 1 Note location of check balls in valve body upper housing Fig 89 Then remove the one large diame ter and the six smaller diameter check balls 2 Remove governor plug and shuttle valve covers Fig 91 3 Remove E dip that secures shuttle valve sec ondary spring on valve stem Fig 90 4 Remove throttle plug primary spring shuttle valve secondary spring and spring guides Fig 91 5 Remove boost valve retainer spring and valve if not previously removed 6 Remove throttle plug and 1 2 and 2 3 governor plugs Fig 78 7 Turn upper housing around and remove limit valve and shift valve covers Fig 92 8 Remove limit valve housing Then remove retainer spring limit valve and 2 3 throttle plug from limit valve housing Fig 92 9 Remove 1 2 shift control valve and spring Fig 92
20. that front dutch thrust washer is properly positioned Fig 147 Use petroleum jelly to hold thrust washer in place if necessary 24 Lubricate oil pump body seal with petroleum jelly Lubricate pump shaft seal lip with petroleum jelly 25 Thread two Pilot Stud Tools C 3288 B into bolt holes in oil pump bore flange Fig 148 26 Align and install oil pump gasket Fig 148 J9121 194 Fig 147 Reaction Shaft Support Seal Rings And Front Clutch Thrust Washer 1 REACTION SHAFT SUPPORT HUB 2 FRONT CLUTCH THRUST WASHER 3 SEAL RINGS 27 Install oil pump Fig 149 Align and position pump on pilot studs Slide pump down studs and work it into front clutch hub and case by hand Then install 2 or 3 pump bolts to hold pump in place WJ DISASSEMBLY AND ASSEMBLY Continued J9121 195 Fig 148 Installing Pilot Studs And Oil Pump Gasket 1 OIL PUMP GASKET 2 PILOT STUD TOOLS C 3288 B 28 Remove pilot stud tools and install remaining oil pump bolts Tighten bolts alternately in diagonal pattern to 20 N m 15 ft Ibs 99121 196 Fig 149 Installing Oil Pump Assembly In Case 1 OIL PUMP 2 PILOT STUD TOOL 3 PILOT STUD TOOL TRANSMISSION AND TRANSFER CASE 21 79 29 Measure input shaft end play Fig 150 NOTE If end play is incorrect transmission is incorrectly assembled or output shaft thrust washer and or thrust plate are worn and need to be ch
21. tr 1 5 595 o 2 251 1 19 LNOYS H21f19 uvau HILM YOLVINANDOV OAH3S QION310S HONH3AOD OAH3S LNOHH 127 21 TRANSMISSION AND TRANSFER CASE WJ SCHEMATICS AND DIAGRAMS Continued 7803808 isd 8 0 3unssatd 1114 dud NOILLONS 84 25 6 3unssdud 38n 83183ANOO 84 02 80 3HhsS3Hd 2 1 isd 6 0 aunssaud ATLLOYHL 84 25 0 aunssauyd HONH3AOD isd 6 29 3unssaud dV39 aNOOHS 3AlHG NI Ol TOVHGAH ATLLOYHL LHVd GNOOAS 3AIHG NI H3A31 HOLOd3 13S 110 NOILVOIHS TI HOL YTIO H31H3ANOO NOLLVOIHSITI OL 831009 3ATVA 4010 3201 VT 3A1VA GION310S df11201 mom cs IMYA 14IHS P 3ATVA 3N1VA 1OULNOO 14IHS 2 1 141 5 2 1 ond t t 3ATVA Til AJNO AM 3ATVA 3 1LLOHS 5 ond ATLLOYHL Q SLE FATWA uolvinNnoov 2 6 o o 95 HOLN1D 1 HOLNTD HY3H OAH3S GION310S HONH3AOD H21f 119 J3AIHQH3AO YOLVINAINIDSY OAH3S 1
22. 3ATVA 141 5 1 6 5 eee gt 3 3ATVA NMOGWODI IMIYA FILLOWHL AXA 3AT1VA AINO t m E HOLVINANDOV 6 PARE SADNESS 1 12 3ATVA lt 3ATVA LdIHS 2 1 Q 9nd WUONH3AOS 3AT1VA 3 T1LLOHS 3TLLOHHL JAVA ond 31LLOHHL HONHJAOD LNOYS HO1fr10 uoivinnoov OAH3S GION3710S HONH3AOD OAH3S 1 TRANSMISSION AND TRANSFER CASE 21 135 SPECIFICATIONS GEAR RATIOS 1ST GEAR 2 74 TRANSMISSION 2ND GEAR 1 54 e GEAR 1 00 GENERAL 4TH GEAR 0 69 e REV GEAR 2 21 oen mm in DESCRIPTION TORQUE Fitting cooler line at trans 18 13 ft Ibs Bolt torque convertor 31 N m 23 ft Ibs Bolt nut crossmember 68 N m 50 ft Ibs FLORE SECUN us Bolt driveplate to crankshaft 75 N m 55 ft Ibs Clutch pack clearance Plug front band reaction 17 N m 13 ft Ibs mm i Locknut front band adj 34 N m 25 ft Ibs Switch park neutral 34 N m 25 ft Ibs Bolt fluid 17 N m 13 ft Ibs Screws fluid filter 4 N m 35 in Ibs Bolt oil 20 N m 15 ft Ibs I I Bolt overrunning clutch cam 17 N m 13 ft Ibs Bolt O D totrans 34 N m 25 ft Ibs usage Bolt
23. 9 d 16 Remove E dip and washer that retains throt 1 CASE CONNECTOR 2 GOVERNOR SOLENOID WIRES tle lever shaft in manual lever Fig 73 3 CONVERTER CLUTCH SOLENOID 17 Remove manual lever and throttle lever Fig 4 SOLENOID SCREWS 74 Rotate and lift manual lever off valve body and 5 OVERDRIVE SOLENOID throttle lever shaft Then slide throttle lever out of 6 GOVERNOR SENSOR WIRES valve body 7 HARNESS 18 Position pencil magnet next to detent housing to catch detent ball and spring Then carefully remove Retainer Tool 6583 and remove detent ball and spring Fig 75 WJ DISASSEMBLY AND ASSEMBLY Continued 19 Remove screws attaching pressure adjusting screw bracket to valve body and transfer plate Fig 76 Hold bracket firmly against spring tension while removing last screw J9521 178 Fig 71 Detent Ball And Spring 1 SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING TRANSMISSION AND TRANSFER CASE 21 51 J9321 424 Fig 73 Throttle Lever E Clip And Washer 1 THROTTLE LEVER SHAFT 2 E CLIP AND WASHER 3 MANUAL SHAFT 8 J9121 81 Fig 72 Park Rod 1 MANUAL LEVER 2 E CLIP 3 PARK ROD J9321 425 Fig 74 Manual And Throttle Lever 1 PARK ROD 2 MANUAL LEVER ASSEMBLY 3 THROTTLE LEVER 21 52 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued J9321 426 Fig 75 Detent Ball And Spring 1 DETEN
24. ADJ USTMENTS Continued 80bce9fb Fig 273 Throttle Valve Cable at Throttle Linkage 1 THROTTLE LINKAGE 2 THROTTLE VALVE CABLE LOCKING CLIP 3 THROTTLE VALVE CABLE 80bce9fb Fig 274 Throttle Valve Cable at Throttle Linkage 1 THROTTLE LINKAGE 2 THROTTLE VALVE CABLE LOCKING CLIP 3 THROTTLE VALVE CABLE 7 Verify positive engagement of transmission park lock by attempting to rotate propeller shaft Shaft will not rotate when park lock is engaged 8 Snap the shift cable eyelet onto the transmis sion shift lever Fig 276 9 Lower the vehicle on the hoist 10 Tighten the shift cable adjustment screw to 7 N m 65 in Ibs 11 Verify correct cable operation Engine should start only in the Park and Neutral positions 12 Install the shifter bezel and floor console com ponents removed for access BAND ADJUSTMENTS FRONT BAND ADJUSTMENT The front kickdown band adjusting screw is located on the left side of the transmission case above the manual valve and throttle valve levers 1 Raise vehicle 2 Loosen band adjusting screw locknut 3 5 turns Fig 277 Be certain the center adjusting screw turns freely in case Apply lubricant to screw threads if necessary 80ba79cb Fig 275 Shift Cable at Shifter SHIFT LEVER PIN ADJUSTMENT SCREW SHIFT CABLE SHIFTER ASSEMBLY BRACKET WJ ADJ USTMENTS Continued 80bc4e93 Fig 276 Tr
25. ASSEM BLY Clean and inspect front servo components 1 Lubricate new O ring and seal rings with petroleum jelly and install them on piston guide and rod 2 Install rod in piston Install spring and washer on rod Compress spring and install snap ring Fig 161 3 Set servo components aside for installation dur ing transmission reassembly REAR SERVO PISTON DISASSEMBLY 1 Remove small snap ring and remove plug and spring from servo piston Fig 162 2 Remove and discard servo piston seal ring ASSEM BLY 1 Lubricate piston and guide seals with petro leum jelly Lubricate other servo parts with Mopar ATF Plus 3 Type 7176 transmission fluid 2 Install new seal ring on servo piston 3 Assemble piston plug spring and new snap ring 4 Lubricate piston seal lip with petroleum jelly TRANSMISSION AND TRANSFER CASE 21 83 D 7 ES 22 7 Fig 161 Front Servo 8031f588f 1 PISTON RINGS 2 SERVO PISTON 3 O RING 4 SNAP RING 5 PISTON ROD GUIDE 6 SEAL RING 7 SNAP RING 8 SERVO SPRING 9 WASHER 10 SPRING 11 PISTON ROD J9121 64 Fig 162 Rear Servo Components 1 SNAP RING 2 PISTON SEAL 3 PISTON PLUG 4 SPRING RETAINER 5 SNAP RING 6 PISTON SPRING 7 CUSHION SPRING 8 PISTON OIL PUMP AND REACTION SHAFT SUPPORT DISASSEMBLY 1 Remove seal ring from housing and reaction shaft support Fig
26. Fault required 3 Valve Body Malfunction 3 Remove clean and inspect Look for Sticking 1 2 shift valve 2 3 shift valve governor plug or broken springs 4 Front Servo Piston Cocked in 4 Inspect servo and repair as required Bore 5 Front Band Linkage Malfunction 5 Inspect linkage and look for bind in linkage 21 20 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION NO KICKDOWN OR 1 Throttle 1 Throttle Linkage Misadjusted Misadjusted 1 1 Adjust linkage linkage NORMAL DOWNSHIFT 2 E Pedal Travel 2 OU s floor mat is not under pedal repair Restricted worn accelerator cable or bent brackets 3 Valve Body Hydraulic Pressures 3 Perform hydraulic pressure tests to Too High or Too Low Due to Valve determine cause and repair as required Body Malfunction or Incorrect Correct valve body pressure adjustments as Hydraulic Control Pressure required Adjustments 4 Governor Circuit Electrical 4 Test with DRB scan tool and repair as Fault required 5 Valve Body Malfunction 5 Perform hydraulic pressure tests to determine cause and repair as required Correct valve body pressure adjustments as required 6 TPS Malfunction 6 Replace sensor check with DRB scan tool 7 PCM Malfunction 7 Check with DRB scan tool and replace if required 8 Valve Body Malfunction 8 Repair sticking 1 2 2 3 shift valves
27. J9321 356 m j i PUSH OUTPUT Fig 216 Overdrive Clutch Reaction Snap Ring SHAFT FORWARD 2 Removal Installation TO FREE BEARING 19321 1 REACTION RING FROM RING Po CLUTSH HUB Fig 219 Releasing Bearing From Locating Ring 1 PAED BEARING LOCATING RING WITH SNAP RING PLIER 3 Remove Torx head screws that attach access 2 ACCESS HOLE cover and gasket to overdrive case Fig 217 4 Remove access cover and gasket Fig 218 21 100 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 6 Lift gear case up and off geartrain assembly Fig 220 J9321 360 Fig 220 Removing Gear Case From Geartrain Assembly 1 GEARTRAIN ASSEMBLY 2 GEAR CASE 7 Remove snap ring that retains rear bearing on output shaft 8 Remove rear bearing from output shaft Fig 221 J9321 362 Fig 221 Rear Bearing Removal 1 OUTPUT SHAFT 2 REAR BEARING 3 SNAP RING DIRECT CLUTCH HUB AND SPRING DISASSEMBLY WARNING THE NEXT STEP IN DISASSEMBLY INVOLVES COMPRESSING THE DIRECT CLUTCH SPRING IT IS EXTREMELY IMPORTANT THAT PROPER EQUIPMENT BE USED TO COMPRESS THE SPRING AS SPRING FORCE 15 APPROXI MATELY 830 POUNDS USE SPRING COMPRESSOR WJ TOOL 6227 1 AND A HYDRAULIC SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 5 6 INCHES THE PRESS MUST ALSO HAVE A BED THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED RELEASE CLUTCH SPRING TENSION SLOWLY AND COMPLETELY TO AVOID PERSO
28. WJ DISASSEMBLY AND ASSEMBLY Continued J9121 163 Fig 198 Supporting Sun Gear On Wood Block 1 SUN GEAR 2 DRIVING SHELL 3 WOOD BLOCK 9121 164 __ 2121 1648 Fig 199 Installing Sun Gear Lock Ring 1 LOCK RING GROOVE 2 SUN GEAR LOCK RING 3 DRIVING SHELL 4 REAR THRUST PLATE 14 Install front planetary gear on output shaft and in driving shell Fig 202 15 Install front thrust washer on front planetary gear Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated 16 Assemble front annulus gear and support if necessary Be sure support snap ring is seated 17 Install front annulus on front planetary Fig 202 18 Position thrust plate on front annulus gear support Fig 203 Note that plate has two tabs on it These tabs fit in notches of annulus hub TRANSMISSION AND TRANSFER CASE 21 95 2 T Fig 200 Installing Assembled Sun Gear And Driving Shell On Output Shaft 1 SUN GEAR DRIVING SHELL ASSEMBLY 2 OUTPUT SHAFT J9121 166 Fig 201 Installing Rear Thrust Washer On Front Planetary Gear 1 FRONT PLANETARY GEAR 2 REAR TABBED THRUST WASHER 19 Install thrust washer in front annulus Fig 204 Align flat on washer with flat on planetary hub Also be sure washer tab is facing up 20 Install front annulus snap ring Fig 205 Use snap ring pliers to avoid distorting ring during installati
29. chatter can result from the use of improper fluid FLUID ADDITIVES Fluid additives other than approved fluo rescent leak detection dyes are not to be used in this transmission EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid Air in the fluid will cause fluid pressures to be low and develop slower than normal If the transmission is overfilled the gears churn the fluid into foam This aerates the fluid and causing the same conditions occurring with a low level In either case air bubbles cause fluid overheating oxi dation and varnish buildup which interferes with valve dutch and servo operation Foaming also causes fluid expansion which can result in fluid over flow from the transmission vent or fill tube Fluid overflow can easily be mistaken for a leak if tion is not careful CAUSES OF BURNT FLUID Burnt discolored fluid is a result of overheating which has two primary causes 1 A result of restricted fluid flow through the main and or auxiliary cooler This condition is usu ally the result of a faulty or improperly installed drainback valve a damaged main cooler or severe restrictions in the coolers and lines caused by debris or kinked lines 2 Heavy duty operation with a vehicle not prop erly equipped for this type of operation Trailer tow ing or similar high load operation will overheat the transmission fluid if the vehicle is im
30. 10 Remove 1 2 shift valve and spring Fig 92 11 Remove 2 3 shift valve and spring from valve body Fig 92 12 Remove pressure plug cover Fig 92 13 Remove line pressure plug sleeve throttle pressure plug and spring Fig 92 J9321 154 Fig 89 Check Ball Locations In Upper Housing 1 SMALL DIAMETER CHECK BALLS 6 2 LARGE DIAMETER CHECK BALL 1 J9121 179 Fig 90 Shuttle Valve E Clip And Secondary Spring Location 1 E CLIP 2 SECONDARY SPRING AND GUIDES 3 SHUTTLE VALVE 3RANSMISSION AND TRANSFER CASE 21 57 DISASSEMBLY AND ASSEMBLY Continued J9421 217 Fig 91 Shuttle And Boost Valve Components 1 SPRING 8 SHUTTLE VALVE COVER 2 RETAINER 9 SHUTTLE VALVE 3 BOOST VALVE 10 SHUTTLE VALVE PRIMARY SPRING 4 BOOST VALVE PLUG 11 GOVERNOR PLUG COVER 5 SPRING GUIDES 12 THROTTLE PLUG 6 E CLIP 13 UPPER HOUSING 7 SHUTTLE VALVE SECONDARY SPRING 14 BOOST VALVE COVER 21 58 TRANSMISSION AND TRANSFER CASE l nVT WJ DISASSEMBLY AND ASSEMBLY Continued J9321 157 Fig 92 Upper Housing Shift Valve And Pressure Plug Locations 1 UPPER HOUSING 8 RETAINER 2 1 2 SHIFT VALVE AND SPRING 9 1 2 SHIFT CONTROL VALVE AND SPRING 3 2 3 SHIFT VALVE AND SPRING 10 PRESSURE PLUG COVER 4 2 3 THROTTLE PLUG 11 LINE PRESSURE PLUG 5 LIMIT VALVE HOUSING 12 PLUG SLEEVE 6
31. 163 2 Mark pump housing and support assembly for alignment reference 21 84 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 3 Remove bolts attaching pump body to support Fig 164 J9321 211 Fig 163 Removing Pump Seal Ring 1 PUMP HOUSING SEAL RING 80 483 7 Fig 164 Pump Support Bolts 1 REACTION SHAFT SUPPORT 2 PUMP J9321 213 Fig 165 Separating Pump Housing From Reaction Shaft Support 1 REACTION SHAFT SUPPORT 2 PUMP HOUSING J9321 214 Fig 166 Pump Gear Removal 1 REACTION SHAFT SUPPORT 2 INNER GEAR 3 OUTER GEAR 4 Separate support from pump housing Fig 165 5 Remove inner and outer gears from reaction shaft support Fig 166 6 If pump seal was not removed during transmis sion disassembly remove seal with punch and ham mer 7 Remove front clutch thrust washer from sup port hub Fig 167 OIL PUMP BUSHING REPLACEMENT 1 Remove pump bushing with Tool Handle C 4171 and Bushing Remover SP 3551 from Tool Set 3887 Fig 168 2 Install new pump bushing with Tool Handle C 4171 and Bushing Installer SP 5117 Fig 168 Bushing should be flush with pump housing bore 80 483 8 Fig 167 Support Hub Thrust Washer 1 BUSHING 2 REACTION SHAFT SUPPORT 3 THRUST WASHER 4 HUB WJ DISASSEMBLY AND ASSEMBLY Continued 3 Stake new pump bushing in two places with blunt punch
32. 265 Overdrive Piston Thrust Plate Selection b Lubricate overdrive piston seals with Door Ease or equivalent c Install piston over Seal Guide 8114 2 and inside Guide Ring 8114 1 d Push overdrive piston retainer e Verify that the locating lugs entered the lug bores in the retainer 6 Install intermediate shaft spacer on intermedi ate shaft 7 Install overdrive piston thrust plate on over drive piston 8 Install overdrive piston thrust bearing on over drive piston 9 Install transmission speed sensor and O ring seal in overdrive case Fig 208 into position in CLEANING AND INSPECTION VALVE BODY Clean the valve housings valves plugs springs and separator plates with a standard parts deaning solution only Do not use gasoline kerosene or any type of caustic solution Do not immerse any of the electrical components in deaning solution Clean the governor solenoid and sensor and the dual solenoid and harness assembly by wiping them off with dry shop towels only Dry all except the electrical parts with compressed air Make sure all passages are clean and free from obstructions Do not use rags or shop towels to dry or wipe off valve body components Lint from these materials can stick to valve body parts interfere with valve operation and clog filters and fluid passages Wipe the governor pressure sensor and solenoid valve with dry lint free shop towels only The O rings on the sensor and
33. Be sure support snap ring is seated and that shoulder side of support faces rearward Fig 192 WJ DISASSEMBLY AND ASSEMBLY Continued J9421 177 Fig 190 Front Planetary And Annulus Gear Disassembly 1 FRONT ANNULUS 2 THRUST WASHER 3 THRUST PLATE 4 FRONT THRUST WASHER 5 FRONT PLANETARY N Q LL 1 4 J9421 178 Fig 191 Removing Driving Shell Rear Planetary And Rear Annulus 1 REAR ANNULUS 2 REAR PLANETARY 3 DRIVING SHELL 4 OUTPUT SHAFT TRANSMISSION AND TRANSFER CASE 21 93 5 Install assembled rear planetary and annulus gear on output shaft Fig 193 Verify that assembly is fully seated on shaft 6 Install front thrust washer on rear planetary gear Fig 194 Use enough petroleum jelly to hold washer on gear Be sure all four washer tabs are seated in slots 7 Install spacer on sun gear Fig 195 8 Install thrust plate on sun gear Fig 196 Note that driving shell thrust plates are interchangeable Use either plate on sun gear and at front rear of shell J9121 156 Fig 192 Assembling Rear Annulus And Planetary Gear 1 REAR ANNULUS GEAR 2 TABBED THRUST WASHER 3 REAR PLANETARY 3 Install rear thrust washer on rear planetary gear Use enough petroleum jelly to hold washer in place Also be sure all four washer tabs are properly engaged in gear slots 4 Install rear annulus over and onto rear plane tary gear F
34. Clutch Pack Snap Ring Installation 1 SPECIAL TOOL 6227 1 2 DIRECT CLUTCH PACK SNAP RING WJ DISASSEMBLY AND ASSEMBLY Continued J9321 401 Fig 252 Clutch Hub Retaining Ring Installation 1 SPECIAL TOOL 6227 1 2 CLUTCH HUB RETAINING RING GEAR CASE ASSEMBLY 1 Position park pawl and spring in case and install park pawl shaft Verify that end of spring with 90 bend is hooked to pawl and straight end of spring is seated against case 2 Install pawl shaft retaining bolt Tighten bolt to 27 N m 20 ft Ibs torque 3 Install park lock reaction plug Note that plug has locating pin at rear Fig 253 Be sure pin is seated in hole in case before installing snap ring 4 Install reaction plug snap ring Fig 254 Com press snap ring only enough for installation do a 2 2 J9121 338 Fig 253 Reaction Plug Locating Pin And Snap Ring 1 REACTION PLUG SNAP RING DO NOT OVERCOMPRESS TO INSTALL 2 LOCATING PIN 3 PARK LOCK REACTION PLUG 2 2 5 Install new seal gear case On 4x4 gear use Tool Handle C 4171 and Installer C 3860 A to seat seal in case On 4 x 2 gear case use same Han dle C 4171 and Installer C 3995 A to seat seal in case 6 Verify that tab ends of rear bearing locating ring extend into access hole in gear case Fig 255 TRANSMISSION AND TRANSFER CASE 21 109 Al 8921 240 Fig 254 Reaction Plug And Snap Ring Installation 1 R
35. Shop towels used for wiping off tools and hands must be made from lint free material Lint will stick to transmission parts and could interfere with valve operation or even restrict fluid passages 21 74 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued Lubricate the transmission components with Mopar transmission fluid during reassembly Use Mopar Door Ease or Ru Glyde on seals and O rings to ease installation Petroleum jelly can also be used to hold thrust washers thrust plates and gaskets in position during assembly However do not use chassis grease bear ing grease white grease or similar lubricants on any transmission part These types of lubricants can eventually block or restrict fluid passages and inter fere with valve operation Use petroleum jelly only Do not force parts into place The transmission components and subassemblies are easily installed by hand when properly aligned If a part seems extremely difficult to install it is either misaligned or incorrectly assembled Also ver ify that thrust washers thrust plates and seal rings are correctly positioned before assembly These parts can interfere with proper assembly if mis positioned The planetary geartrain front rear clutch assem blies and oil pump are all much easier to install when the transmission case is upright 1 Install rear servo piston spring and retainer Fig 131 Install spring on top of servo piston and install ret
36. Solenoid O ring 1 PRESSURE SOLENOID 2 O RING 3 GOVERNOR 80a0c4fa Fig 52 Pressure Sensor and 1 RETAINING CLIP 2 GOVERNOR BODY 3 GOVERNOR PRESSURE SENSOR TRANSMISSION FLUID TEMPERATURE THERMISTOR 80315868 Fig 51 Governor Body Gasket 1 GOVERNOR BODY 2 GASKET VALVE BODY The valve body can be removed for service without having to remove the transmission assembly The valve body can be disassembled for cleaning and inspection of the individual components Refer to Disassembly and Assembly section for proper proce dures The only replaceable valve body components are Manual lever Manual lever washer seal E dip and shaft seal e Manual lever detent ball e Throttle lever Fluid filter e Pressure adjusting screw bracket e Governor pressure solenoid e Governor pressure sensor e Converter clutch overdrive solenoid assembly and harness includes sump temperature thermistor e Governor housing gasket e Solenoid case connector O rings The remaining valve body components are serviced only as part of a complete valve body assembly REMOVAL 1 Shift transmission into NEUTRAL 2 Raise vehicle 3 Remove gearshift and throttle levers from shaft of valve body manual lever 4 Disconnect wires at solenoid case connector Fig 53 5 Position drain pan under transmission oil pan 6 Remove transmission oil pan and gask
37. TRANSFER CASE 21 97 DISASSEMBLY AND ASSEMBLY Continued AK N J9121 170 Fig 206 Installing Planetary Selective Snap Ring 1 SELECTIVE SNAP RING 2 SNAP RING PLIERS J9121 171 Fig 207 Checking Planetary Geartrain End Play 1 OUTPUT SHAFT 2 REAR ANNULUS GEAR 3 FEELER GAUGE OVERDRIVE UNIT DISASSEM BLY 1 Remove transmission speed sensor and O ring seal from overdrive case Fig 208 2 Remove overdrive piston thrust bearing Fig 209 Fig 208 Transmission Speed Sensor Removal Installation 1 SOCKET AND WRENCH 2 SPEED SENSOR 3 O RING J9321351 Fig 209 Overdrive Piston Thrust Bearing Removal Installation 1 THRUST BEARING 2 OVERDRIVE PISTON 3 THRUST PLATE OVERDRIVE PISTON DISASSEMBLY 1 Remove overdrive piston thrust plate Fig 210 Retain thrust plate It is a select fit part and may possibly be reused 21 98 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 19121 297 Fig 210 Overdrive Piston Thrust Plate Removal Installation 1 OVERDRIVE PISTON 2 OVERDRIVE PISTON SPACER SELECT FIT 2 Remove intermediate shaft spacer Fig 211 Retain spacer It is a select fit part and may possibly be reused 2 55 J9121 298 SS 23 3 Fig 211 Intermediate Shaft Spacer Location 1 INTERMEDIATE SHAFT 2 INTERMEDIATE SHAFT SPACER SELECT FIT 3 Remove overdrive
38. TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS Continued 21 128 LON H LNT H3183ANOO HV39 3AIHG NI Or TnVHGAH 48014608 NI HOLO3T3S m LT NOILVOIH amp TI OL HOLNTD LNOYA 3ATVA 0 E E U3lH3ANOO 1 1 5 isd 8 0 3unssaud 111 dud 201 GIONd10S 4 dfi3201 19008 108 141 8 7 6 x T FATWA 3KTVA 3ILLOBHL 2 NOILONS 3ATVA isd 9 9 3Hnss3Hd Fan yH31H83ANOO NIMI v HATVA 1OHINOO 141 8 2 1 3ATVA LJIHS 2 1 2 3AT1VA 7114 AINO t e MAS isd 76 0 3unssatd 3ATVA ATLLNHS nid 3 FATWA L4IHS 6 2 09 0 31LLOHHL 3unssaud HONHJAOO 3ATVA 3unssaud INT 31LLOHHL ss Oo O o o HOLfYIO 1 HO1fT 19 GQION310S 9 3AIHQH3AO OAH3S 1NOUJ OAH3S HV3H 129 21 TRANSMISSION AND TRANSFER CASE WJ SCHEMATICS AND DIAGRAMS Continued 28914808 1 84 8 0 dHd 25 6 3unssaud aan JH31H3ANOO isd 6 0 55 31110HH
39. TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING Continued This process of elimination can be used to identify a slipping unit and check operation Proper use of the Clutch and Band Application Chart is the key Although road test analysis will help determine the slipping unit the actual cause of a malfunction usu ally cannot be determined until hydraulic and air pressure tests are performed Practically any condi tion can be caused by leaking hydraulic circuits or sticking valves Unless a malfunction is obvious such as no drive in D range first gear do not disassemble the trans mission Perform the hydraulic and air pressure tests to help determine the probable cause HYDRAULIC PRESSURE TEST Hydraulic test pressures range from a low of one psi 6 895 kPa governor pressure to 300 psi 2068 kPa at the rear servo pressure port in reverse An accurate tachometer and pressure test gauges are required Test Gauge C 3292 has a 100 psi range Test Gauge C 3293 SP has a 300 psi range and is used where pressures exceed 100 psi Pressure Test Port Locations Test ports are located at both sides of the transmis sion case Fig 7 Line pressure is checked at the accumulator port on the right side of the case The front servo pressure port is at the right side of the case just behind the filler tube opening The rear servo and governor pressure ports are at the right rear of the transmission case The overdrive dutch pressure
40. a Clearance between outer gear and reaction shaft housing should be 0 010 to 0 063 mm 0 0004 to 0 0025 in Clearance between inner gear and reaction shaft housing should be 0 010 to 0 063 mm 0 0004 to 0 0025 in Both clearances can be measured at the same time by Installing the pump gears the pump housing Position an appropriate piece of Plasti gage across both gears Align the plastigage to a flat area on the reaction shaft housing IV Install the reaction shaft to the pump housing V Separate the reaction shaft housing from the pump housing and measure the Plastigage following the instructions supplied with it b Clearance between inner gear tooth and outer gear should be 0 08 to 0 19 mm 0 0035 to 0 0075 in Measure with an appropriate feeler gauge Clearance between outer gear and pump housing should also be 0 010 to 0 19 mm 0 0035 to 0 0075 in Measure clearance with an appropriate feeler gauge FRONT CLUTCH Clean and inspect the front dutch components Replace the clutch discs if warped worn scored burned or charred or if the facing is flaking off Replace the steel plates if heavily scored warped or broken Be sure the driving lugs on the plates are in good condition The lugs must not be bent cracked or damaged in any way Replace the clutch spring and spring retainer if either is distorted warped or broken TRANSMISSION AND TRANSFER CASE 2
41. and align bolt holes in retainer gasket and case Fig 160 Then install and tighten retainer bolts to 17 N m 13 ft Ibs torque 8 Install new seals on over drive piston 9 Stand transmission case upright on bellhous ing 10 Position Guide Ring 8114 1 on outer edge of overdrive piston retainer 11 Position Seal Guide 8114 2 on inner edge of overdrive piston retainer 12 Install overdrive piston in overdrive piston retainer by aligning locating lugs on overdrive piston to the two mating holes in retainer lt T SS SSS 2 SE 0 LI J9321 464 Fig 160 Aligning Overdrive Piston Retainer 1 PISTON RETAINER 2 GASKET 3 RETAINER BOLTS a Aligning locating lugs on overdrive piston to the two mating holes in retainer WJ DISASSEMBLY AND ASSEMBLY Continued b Lubricate overdrive piston seals with Door Ease or equivalent c Install piston over Seal Guide 8114 2 and inside Guide Ring 8114 1 dj Push overdrive piston retainer e Verify that the locating lugs entered the lug bores in the retainer into position in NOTE INSTALL THE REMAINING TRANSMISSION COMPONENTS AND OVERDRIVE UNIT FRONT SERVO PISTON DISASSEMBLY 1 Remove seal ring from rod guide Fig 161 2 Remove small snap ring from servo piston rod Then remove piston rod spring and washer from pis ton 3 Remove and discard servo component O ring and seal rings
42. bushings pump clutch retainer or clogged filter Line pressure high Output shaft plugged sticky regulator valve Line pressure low Sticky regulator valve clogged filter worn pump AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATION Air pressure testing can be used to check transmis sion front rear clutch and band operation The test can be conducted with the transmission either in the vehicle or on the work bench as a final check after overhaul Governor pressure too high at idle speed Governor pressure low at all mph figures Lubrication pressure low at all throttle positions WJ Air pressure testing requires that the oil pan and valve body be removed from the transmission The servo and clutch apply passages are shown Fig 8 80a3b18b Fig 8 Air Pressure Test Passages REAR SERVO APPLY FRONT SERVO APPLY PUMP SUCTION FRONT CLUTCH APPLY FRONT SERVO RELEASE 6 LINE PRESSURE TO ACCUMULATOR 7 PUMP PRESSURE 8 TO CONVERTER 9 REAR CLUTCH APPLY 10 FROM CONVERTER 11 TO COOLER Front Clutch Air Test Place one or two fingers on the clutch housing and apply air pressure through front dutch apply pas sage Piston movement can be felt and a soft thump heard as the dutch applies Rear Clutch Air Test Place one or two fingers on the clutch housing and apply air pressure through rear clutch apply passage Piston movement can b
43. can all be tested with a 12 volt test lamp or a volt ohmmeter Check continuity of each component when diagnosis indicates this is neces sary Refer to Group 8W Wiring Diagrams for component locations and circuit information Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range BRAKE TRANSMISSION SHIFT INTERLOCK 1 Verify that the key can only be removed in the PARK position 2 When the shift lever is in PARK And the shift handle pushbutton is in the OUT position the igni tion key cylinder should rotate freely from OFF to LOCK When the shifter is in any other gear or neu tral position the ignition key cylinder should not rotate to the LOCK position 3 Shifting out of PARK should be possible when the ignition key cylinder is in the OFF position 4 Shifting out of PARK should not be possible while applying 25 Ib maximum handle pushbutton force and ignition key cylinder is in the RUN or START positions unless the foot brake pedal is depressed approximately 1 2 inch 12mm 5 Shifting out of PARK should not be possible when the ignition key cylinder is in the ACCESSORY or LOCK positions 6 Shifting between any gears NEUTRAL or into PARK may be done without depressing foot brake pedal with ignition switch in RUN or START posi tions and vehide stationary or in motion GEARSHIFT CABLE 1 The floor shifter lever and gate positions should be in alignment w
44. differential or axle shafts b If propeller shaft does not turn and transmis sion is noisy stop engine Remove oil pan and check for debris If pan is dear remove transmis sion and check for damaged drive plate converter oil pump or input shaft If propeller shaft does not turn and transmis sion is not noisy perform hydraulic pressure test to determine if problem is hydraulic or mechanical PARK NEUTRAL POSITION SWITCH The center terminal of the park neutral position switch is the sense starter circuit terminal It pro vides the ground for the starter solenoid circuit when the transmission selector lever is in PARK or NEU TRAL positions only The outer terminals on the switch are for the backup lamp circuit SWITCH TEST To test the switch remove the wiring connector Test for continuity between the center terminal and the transmission case Continuity should exist when the transmission is in PARK or NEUTRAL only Con tinuity should not exist any other time or with the transmission in any other gear Shift the transmission into REVERSE and test continuity at the switch outer terminals Continuity should exist when the transmission is in REVERSE only Continuity should not exist between the outer terminals and the case Check gearshift linkage adjustment before replac ing a switch that tests faulty OVERDRIVE ELECTRICAL CONTROLS The overdrive off switch valve body solenoid case con nectors and related wiring
45. fit on the output shaft to be sure OVERDRIVE UNIT Clean the geartrain and case components with sol vent Dry all parts except the bearings with com pressed air Allow bearings to air dry Do not use shop towels for wiping parts dry unless the towels are made from a lint free material A suf ficient quantity of lint from shop towels cloths rags etc could plug the transmission filter and fluid pas sages Discard the old case gasket and seals Do not attempt to salvage these parts They are not reus able Replace any of the overdrive unit snap rings if distorted or damaged Minor nicks or scratches on components can be smoothed with crocus cloth However do not attempt to reduce severe scoring on any components with abrasive materials Replace severely scored compo nents do not try to salvage them Check condition of the park lock components and the overdrive case Replace the case if cracked scored or damaged Replace the park lock pawl plug or spring if worn or damaged Be sure the bullet at the end of the park lock rod is in good condition Replace the rod if the bullet is worn or the rod itself is bent or distorted Do not attempt to straighten the rod Check the bushings in the overdrive case Replace the bushings if severely scored or worn Also replace the case seal if loose distorted or damaged Examine the overdrive and direct clutch discs and plates Replace the discs if the facing is worn severely scor
46. gauge tool c Extend sliding scale of dial caliper downward through gauge tool slot until scale contacts end of Gauge Alignment Tool 6312 Lock scale in place Remove dial caliper tool and note distance mea sured Fig 262 d Select proper thickness end play spacer from spacer chart based on distance measured Fig 263 e Remove Gauge Alignment Tool 6312 OD THRUST PLATE SELECTION 1 Place overdrive unit in vertical position Mount it on blocks or in workbench with appropriate size mounting hole cut into it Be sure unit is facing upward for access to direct clutch hub Also be sure output shaft is not loaded and internal components are moved rearward for accurate measurement 2 Determine correct thickness overdrive piston thrust plate as follows a Position Gauge Tool 6311 across face of over drive case Then position Dial Caliper C 4962 over gauge tool Fig 264 b Measure distance to clutch hub thrust bear ing seat at four points 90 apart Then average measurements by adding them and dividing by 4 c Select and install required thrust plate from information in thrust plate chart Fig 265 TRANSMISSION AND TRANSFER CASE 21 111 J9221 47 Fig 262 Shaft End Play Measurement 1 SPECIAL TOOL 6312 2 SPECIAL TOOL 6311 3 SPECIAL TOOL C 4962 End Play Measure Spacer Thickness ment Inches Inches 7336 7505 158 159 7506 7675 175 176 7676 7855 193 194 7856 8
47. geartrain with both hands during removal Do not allow machined surfaces on interme diate shaft or overdrive piston retainer to become nicked or scratched 28 If overdrive unit is not to be serviced install Alignment Shaft 6227 2 into the overdrive unit to prevent misalignment of the overdrive clutches dur ing service of main transmission components 29 Loosen rear band adjusting screw 4 5 turns 30 Remove low reverse drum snap ring Fig 127 J9121 214 Fig 123 Removing Intermediate Shaft Thrust Washer 1 INTERMEDIATE SHAFT THRUST WASHER 2 INPUT SHAFT 3 REAR CLUTCH RETAINER HUB 21 72 TRANSMISSION AND TRANSFER CASE _ DISASSEMBLY AND ASSEMBLY Continued 9121 215 Fig 124 Removing Intermediate Shaft Thrust Plate 1 INTERMEDIATE SHAFT HUB 19121 217 2 INTERMEDIATE SHAFT THRUST PLATE Fig 126 Removing Planetary Geartrain And Intermediate Shaft Assembly e 9 1 PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT ASSEMBLY Fig 125 Front Band Removal Installation 1 DRIVING SHELL 2 FRONT BAND 31 Remove low reverse drum and reverse band 9121 351 32 Remove overrunning clutch roller and spring assembly as a unit Fig 128 Fig 127 Removing Low Reverse Drum Snap Ring 1 LOW REVERSE DRUM 2 HUB OF OVERDRIVE PISTON RETAINER 3 LOW REVERSE DRUM SNAP RING WJ DISASSEMBLY AND ASSEMBLY Continued
48. governor plugs 3 4 solenoid 3 4 shift valve 3 4 timing valve STUCK IN LOW GEAR 1 Throttle Linkage Misadjusted 1 Adjust linkage and repair linkage if worn or WILL NOT UPSHIFT Stuck damaged Check for binding cable or missing return spring 2 Gearshift Linkage Misadjusted 2 Adjust linkage and repair linkage if worn or damaged 3 Governor Component Electrical 3 Check operating pressures and test with Fault DRB scan tool repair faulty component 4 Front Band Out of Adjustment 4 Adjust Band 5 Clutch or Servo Malfunction 5 Air pressure check operation of clutches and bands Repair faulty component CREEPS IN NEUTRAL 1 Gearshift Linkage Misadjusted 1 Adjust linkage 2 Rear Clutch Dragging Warped 2 Disassemble and repair 3 Valve Body Malfunction 3 Perform hydraulic pressure test to determine cause and repair as required BUZZING NOISE 1 Fluid Level Low 1 Add fluid and check for leaks 2 Shift Cable Misassembled 2 Route cable away from engine and bell housing 3 Valve Body Misassembled 3 Remove disassemble inspect valve body Reassemble correctly if necessary Replace assembly if valves or springs are damaged Check for loose bolts or screws 4 Pump Passages Leaking 4 Check pump for porous casting scores on mating surfaces and excess rotor clearance Repair as required Loose pump bolts 5 Cooling System Cooler 5 Flow check cooler circuit Repair as needed Plugged 6 Overrunning
49. is properly seated in groove 14 Lubricate lip of pump oil seal and O ring seal with transmission fluid J9321 183 Fig 175 Pump Oil Seal Installation 1 PUMP BODY 2 PUMP SEAL 3 SPECIAL TOOL C 4193 FRONT CLUTCH NOTE The 44RE uses five plates and discs for the front clutch TRANSMISSION AND TRANSFER CASE 21 87 DISASSEMBLY 1 Remove waved snap ring and remove pressure plate dutch plates and dutch discs 2 Compress clutch piston spring with Compressor Tool C 3575 A Fig 176 Be sure legs of tool are seated squarely on spring retainer before compress ing spring 3 Remove retainer snap ring and remove com pressor tool 4 Remove spring retainer and dutch spring Note position of retainer on spring for assembly reference 5 Remove dutch piston from dutch retainer Remove piston by rotating it up and out of retainer 6 Remove seals from clutch piston and clutch retainer hub Discard both seals as they are not reus able A 49121 147 Fig 176 Compressing Front Clutch Piston Spring 1 FRONT CLUTCH SPRING 2 COMPRESSOR TOOL C 3575 A 3 RETAINER SNAP RING 4 SPRING RETAINER 21 88 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued ASSEMBLY 1 Soak clutch discs in transmission fluid while assembling other clutch parts 2 Install new seals on piston and in hub of retainer Be sure lip of each seal faces interior of clutch retainer 3 Lubricat
50. on sun gear Fig 243 Slide bearing onto gear and seat it against spring plate as shown Bearing fits one way only If it does not seat squarely against spring plate remove and reposition bearing 14 Install assembled sun gear spring plate and thrust bearing Fig 244 Be sure sun gear and thrust bearing are fully seated before proceeding J9121 326 Fig 243 Planetary Thrust Bearing Installation 1 SPRING PLATE 2 PLANETARY THRUST BEARING 3 SUN GEAR J9121 327 Fig 244 Sun Gear Installation 1 SUN GEAR AND SPRING PLATE ASSEMBLY WJ 15 Mount assembled output shaft annulus gear and clutch drum in shop press Direct clutch spring hub and clutch pack are easier to install with assem bly mounted in press 16 Align splines in hubs of planetary gear and overrunning dutch with Alignment tool 6227 2 Fig 245 Insert tool through sun gear and into splines of both hubs Be sure alignment tool is fully seated before proceeding 17 Install direct dutch spring Fig 246 Be sure spring is properly seated on spring plate n J9321 395 Fig 245 Alignment Tool Installation 1 SPECIAL TOOL 6227 2 2 PRESS PLATES 3 ASSEMBLED DRUM AND ANNULUS GEAR 4 SUN GEAR NOTE The 44RE transmission has 8 direct clutch discs and 7 clutch plates 18 Assemble and install direct dutch pack on hub as follows a Assemble dutch pack components or Fig 247 b Install direct clutch rea
51. on the pressure and clutch plates are also in good condition The lugs must not be bent cracked or damaged in any way Replace the piston spring and wave spring if either part is distorted warped or broken Check the lug grooves in the clutch retainer The clutch and pressure plates should slide freely in the slots Replace the retainer if the grooves are worn or damaged Also check action of the check balls in the retainer and piston Each check ball must move freely and not stick Replace the retainer bushing if worn scored or doubt exists about bushing condition Inspect the piston and retainer seal surfaces for nicks or scratches Minor scratches can be removed with crocus cloth However replace the piston and or retainer if the seal surfaces are seriously scored Check condition of the fiber thrust washer and metal output shaft thrust washer Replace either washer if worn or damaged Check condition of the seal rings on the input shaft and clutch retainer hub Replace the seal rings only if worn distorted or damaged The input shaft front seal ring is teflon with chamfered ends The rear ring is metal with interlocking ends Check the input shaft for wear or damage Replace the shaft if worn scored or damaged in any way PLANETARY GEARTRAIN Clean the planetary components in solvent and dry them with compressed air Check sun gear and driving shell condition Replace the gear if damaged or if the bushings are scored or
52. piston from retainer Fig 212 J9121 299 Fig 212 Overdrive Piston Removal 1 PISTON RETAINER 2 OVERDRIVE PISTON OVERDRIVE CLUTCH PACK DISASSEMBLY 1 Remove overdrive dutch pack wire retaining ring Fig 213 2 Remove overdrive clutch pack Fig 214 NOTE The 44RE transmission utilizes four clutch discs and three clutch plates 3 Note position of dutch pack components for assembly reference 9321352 Fig 213 Removing Overdrive Clutch Pack Retaining Ring 1 OVERDRIVE CLUTCH PACK RETAINING RING 21 99 TRANSMISSION AND TRANSFER CASE WJ DISASSEMBLY AND ASSEMBLY Continued J9321 357 Fig 214 Overdrive Clutch Pack Removal Fig 217 Access Cover Screw Removal Installation 1 OVERDRIVE CLUTCH PACK 1 TORX SCREWDRIVER T25 2 ACCESS COVER SCREWS OVERDRIVE GEARTRAIN DISASSEMBLY 1 Remove overdrive clutch wave spring Fig 215 J9321 358 Fig 218 Access Cover And Gasket Removal Installation s 1 ACCESS COVER AND GASKET Fig 215 Overdrive Clutch Wave Spring Removal Installation 5 Expand output shaft bearing snap ring with 1 WAVE SPRING expanding type snap ring pliers Then push output shaft forward to release shaft bearing from locating ring Fig 219 2 Remove overdrive clutch reaction snap ring Fig 216 Note that snap ring is located in same groove as wave spring op
53. recommended fluid Fig 28 Checking Torque Converter Seating 1 SCALE 2 STRAIGHTEDGE 21 36 5 15510 AND TRANSFER CASE REMOVAL AND INSTALLATION Continued YOKE SEAL REPLACEM ENT REMOVAL 1 Raise vehide 2 Mark propeller shaft and axle yoke for align ment reference 3 Disconnect and remove propeller shaft 4 Remove old seal with Seal Remover C 3985 B Fig 29 from overdrive housing INSTALLATION 1 Place seal in position on overdrive housing 2 Drive seal into overdrive housing with Seal Installer C 3995 A Fig 30 3 Carefully guide propeller shaft slip yoke into housing and onto output shaft splines Align marks made at removal and connect propeller shaft to rear axle pinion yoke x J9521 57 Fig 29 Removing Overdrive Housing Yoke Seal 1 SPECIAL TOOL 3985 2 SEAL Fig 30 Installing Overdrive Housing Yoke Seal 1 SPECIAL TOOL 3995 OR C 3972 A 2 SPECIAL TOOL C 4471 J9521 58 PARK NEUTRAL POSITION SWITCH REM OVAL 1 Raise and position drain pan under Switch 2 Disconnec switch wires 3 Remove switch from case INSTALLATION 1 Move shift lever to Park and Neutral positions Verify that switch operating lever fingers are cen tered in switch opening in case Fig 31 eR LU Dy be ae 77 f lt 4 80b170f4 Fig 31 Park Neutral Position Switch 1 NEUT
54. retaining nuts from the floor pan studs Fig 34 80ba79cc Fig 34 Shift Cables at Floor Pan 1 SEAL PLATES 2 TRANSMISSION SHIFT CABLE 3 TRANSFER CASE SHIFT CABLE 9 Remove the shifter cable through the floor pan opening INSTALLATION 1 Route the shift cable through hole in floor pan 2 Install the shift cable seal plate retaining nuts on the floor pan studs Fig 35 Torque the nuts to 7 65 165 80ba79cc Fig 35 Shift Cables at Floor Pan 1 SEAL PLATES 2 TRANSMISSION SHIFT CABLE 3 TRANSFER CASE SHIFT CABLE 3 Install the shift cable in the shifter bracket assembly 21 38 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued 4 Place the floor shifter in the PARK position 5 Loosen the adjustment screw on the shifter cable Fig 36 80ba79cb Fig 36 Transmission Shift Cable at Shifter SHIFT LEVER PIN ADJUSTMENT SCREW SHIFT CABLE SHIFTER ASSEMBLY BRACKET Q 6 Snap the shift cable onto the shift lever pin Located on the shifter assembly Fig 36 7 Raise the vehicle on a hoist 8 Install the shift cable on the shift cable support bracket Fig 37 9 Place the transmission shift lever in the PARK position Park is the rearmost detent posi tion on the transmission manual shift lever Fig 37 10 Snap the shifter cable on the shift control lever Fig 37 CAUTION Be certain shift ca
55. shift back to third occurs The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 110 C 230 F The thermistor is part of the governor pressure sensor assembly and is immersed in transmission fluid at all times TRANSMISSION SPEED SENSOR The speed sensor Fig 5 is located in the over drive gear case The sensor is positioned over the park gear and monitors transmission output shaft rotating speed Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face Input signals from the sensor are sent to the transmission control module for processing The vehicle speed sensor also serves as a backup for the WJ DESCRIPTION AND OPERATION Continued transmission speed sensor Signals from this sensor are shared with the powertrain control module J9321 411 Fig 5 Transmission Output Speed Sensor 1 TRANSMISSION OUTPUT SHAFT SPEED SENSOR 2 SEAL THROTTLE POSITION SENSOR TPS The TPS provides throttle position input signals to the PCM This input signal is used to determine overdrive and converter clutch shift schedule and to select the proper governor curve POWERTRAIN CONTROL MODULE The PCM controls operation of the converter clutch overdrive clutch and governor pressure sole noid The control module determines transmission shift points based on input signals from the transmission thermistor transmission out
56. solenoid valve are the only service able components Be sure the vent ports in the sole noid valve are open and not blocked by dirt or debris Replace the valve and or sensor only when DRB scan tool diagnosis indicates this is necessary Or if either part has sustained physical damage dented deformed broken etc CAUTION Do not turn the small screw at the end of the solenoid valve for any reason Turning the screw in either direction will ruin solenoid calibra tion and result in solenoid failure In addition the filter on the solenoid valve is NOT serviceable Do not try to remove the filter as this will damage the valve housing Inspect the throttle and manual valve levers and shafts Do not attempt to straighten a bent shaft or correct a loose lever Replace these components if worn bent loose or damaged in any way Inspect all of the valve body mating surfaces for scratches nicks burrs or distortion Use a straight edge to check surface flatness Minor scratches may be removed with crocus cloth using only very light pressure Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth Position the crocus cloth on a surface plate sheet of plate glass or equally flat sur face If distortion is severe or any surfaces are heavily scored the valve body will have to be replaced WJ CLEANING AND INSPECTION Continued CAUTION Many of the valves and plugs s
57. to check engagement b Align and seat valve body on case Be sure manual lever shaft and overdrive connector are fully seated in case Also be sure valve body wiring is not pinched or kinked c Install and start all valve body attaching bolts by hand Then tighten bolts evenly in a diag onal pattern to 12 105 in 165 torque Do not overtighten valve body bolts This could result in distortion and cross leakage after installation CAUTION It is possible for the park rod to displace into a cavity just above the pawl sprag during installation Make sure the rod is actually engaged in the pawl and has not displaced into the cavity 33 Install new filter on valve body Tighten filter screws to 4 N m 35 in 165 34 Adjust front and rear bands 36 Install magnet in oil pan Magnet goes on small protrusion at corner of pan 37 Position new oil pan gasket on case and install oil pan Tighten pan bolts to 17 N m 13 ft Ibs 38 Install new valve body manual shaft seal in case Fig 153 Lubricate seal lip and manual shaft with petroleum jelly Start seal over shaft and into case Seat seal with 15 16 inch deep well socket Fig 153 Installing Manual Lever Shaft Seal 1 15 16 SOCKET 2 SEAL 39 Install throttle valve and shift selector levers on valve body manual lever shaft WJ DISASSEMBLY AND ASSEMBLY Continued OVERRUNNING CLUTCH CAM OVERDRIVE PISTON RETAINER DISASSEMBLY NOT
58. 011 211 212 J9121 341 Fig 263 Intermediate Shaft End Play Spacer Selection 3 Leave Alignment Tool 6227 2 in place Tool will keep planetary and dutch hub splines in alignment until overdrive unit is ready for installation on trans mission 4 Transmission speed sensor can be installed at this time if desired However it is recommended that sensor not be installed until after overdrive unit is secured to transmission OVERDRIVE PISTON ASSEMBLY 1 Install new seals on over drive piston 2 Stand transmission case upright on bellhous ing 3 Position Guide Ring 8114 1 on outer edge of overdrive piston retainer 4 Position Seal Guide 8114 2 on inner edge of overdrive piston retainer 5 Install overdrive piston in overdrive piston retainer by aligning locating lugs on overdrive piston to the two mating holes in retainer a Aligning locating lugs on overdrive piston to the two mating holes in retainer 21 112 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued J9221 48 Fig 264 Overdrive Piston Thrust Plate Measurement 1 SPECIAL TOOL 6311 2 DIRECT CLUTCH HUB THRUST BEARING SEAT 3 SPECIAL TOOL C 4962 End Play Measure Spacer Thickness ment Inches Inches 1 7500 1 7649 1 7650 1 7799 1 7800 1 7949 1 7950 1 8099 1 8100 1 8249 1 8250 1 8399 1 8400 1 8549 1 8550 1 8699 1 8700 1 8849 1 8850 1 8999 19121 342 Fig
59. 1 115 Check the lug grooves in the dutch retainer The steel plates should slide freely in the slots Replace the retainer if the grooves are worn or damaged Check action of the check ball in the retainer Fig 268 The ball must move freely and not stick NOTE Inspect the clutch retainer bushings care fully Fig 269 The retainer bushings are NOT ser viceable It will be necessary to replace the retainer if either bushing is scored or worn Inspect the piston and retainer seal surfaces for nicks or scratches Minor scratches can be removed with crocus doth However replace the piston and or retainer if the seal surfaces are seriously scored J9121 368 Fig 268 Front Clutch Piston Retainer Check Ball Location 1 RETAINER CHECK BALL J9321 223 Fig 269 Retainer Bushing Location Inspection 1 FRONT CLUTCH RETAINER BUSHINGS NON SERVICEABLE 21 116 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION Continued REAR CLUTCH Clean the clutch components with solvent and dry them with compressed air Do not use rags or shop towels to dry any of the clutch parts Lint from such materials will adhere to component surfaces and could restrict or block fluid passages after assembly Replace the clutch discs if warped worn scored burned charred the lugs are damaged or if the fac ing is flaking off Replace the top and bottom pres sure plates if scored warped or cracked Be sure the driving lugs
60. 33 Compress front servo rod guide about 1 8 inch with Valve Spring Compressor C 3422 B Fig 129 34 Remove front servo rod guide snap ring Exercise caution when removing snap ring Servo bore can be scratched or nicked if care is not exercised 35 Remove compressor tools and remove front servo rod guide spring and servo piston J9121 222 Fig 128 Overrunning Clutch Assembly Removal 1 OVERRUNNING CLUTCH CAM 2 REAR BAND REACTION PIN 3 OVERRUNNING CLUTCH ASSEMBLY J9121 136 Fig 129 Compressing Front Servo Rod Guide 1 SPRING COMPRESSOR TOOL C 3422 B 2 ROD GUIDE SNAP RING TRANSMISSION AND TRANSFER CASE 21 73 36 Compress rear servo spring retainer about 1 16 inch with Valve Spring Compressor C 3422 B Fig 130 37 Remove rear servo spring retainer snap ring Then remove compressor tools and remove rear servo spring and piston 38 Inspect transmission components NOTE TO SERVICE THE OVERRUNNING CLUTCH CAM OR OVERDRIVE PISTON RETAINER REFER TO OVERRUNNING CLUTCH CAM SERVICE IN THIS SECTION J9121 345 Fig 130 Compressing Hear Servo Spring 1 FRONT SERVO SNAP RING 2 REAR SERVO SNAP RING 3 SPECIAL TOOL ASSEMBLY Do not allow dirt grease or foreign material to enter the case or transmission components during assembly Keep the transmission case and compo nents dean Also make sure the tools and workbench area used for assembly operations are equally clean
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62. ADAPTER IS USED 44RE TRANSMISSION e Back off adjusting screw 4 turns e Hold adjusting screw in place and tighten lock nut to 34 N m 25 ft Ibs torque 5 Position new gasket on oil pan and install pan on transmission Tighten pan bolts to 17 N m 13 ft Ibs torque 6 Lower vehicle and refill transmission with Mopar ATF Plus 3 Type 7176 fluid VALVE BODY CONTROL PRESSURE ADJUSTMENTS There are two control pressure adjustments on the valve body e Line Pressure e Throttle Pressure Line and throttle pressures are interdependent because each affects shift quality and timing As a 21 122 TRANSMISSION AND TRANSFER CASE ADJ USTMENTS Continued 51 52 J9321 382 Fig 279 Rear Band Adjusting Screw Location 1 ADJUSTING SCREW 2 REAR BAND LEVER 3 LOCKNUT result both adjustments must be performed properly and in the correct sequence Adjust line pressure first and throttle pressure last LINE PRESSURE ADJUSTMENT Measure distance from the valve body to the inner edge of the adjusting screw with an accurate steel scale Fig 280 Distance should be 33 4 mm 1 5 16 in If adjustment is required turn the adjusting screw in or out to obtain required distance setting NOTE The 33 4 mm 1 5 16 in setting is an approximate setting Manufacturing tolerances may make it necessary to vary from this dimension to obtain desired pressure One complete turn of the
63. BE SUPPORT BRACKET RETAINING NUT 3 Remove the transmission dipstick tube support bracket nut from the turbocharger heatshield Fig 14 4 Position a drainpan under the transmission 5 Pull the transmission dipstick tube from the transmission housing 6 Raise the vehide on a hoist 7 Remove the 2 lower fan shroud retaining bolts 21 30 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued CAUTION Mark the position of the driveshaft in relation to its companion flange prior to disassem bly Driveshaft must be reinstalled in the same posi tion it was in prior to disassembly ails TN qu 80bc4e91 Fig 16 Rear Driveshaft Supported 1 REAR DRIVESHAFT 80bc4e92 Fig 15 Front Driveshaft Retaining Bolts 1 TRANSFER CASE 2 FRONT DRIVESHAFT RETAINING BOLTS 3 REFERENCE MARK 8 Remove the front driveshaft retaining bolts Fig 15 and remove the driveshaft from the transfer case companion flange Support the driveshaft with mechanics wire 9 Remove the rear driveshaft retaining bolts and remove the driveshaft from the transfer case compan ion flange Support the driveshaft with mechanics wire Fig 16 10 Disconnect the transfer case shift cable from the shifter arm Fig 17 11 Disconnect the vent tube from the transfer case Fig 17 12 Remove the transmission oil pan and drain the transmission fluid Reinstall th
64. BTSI is a cable and solenoid operated system It interconnects the automatic transmission floor mounted shifter to the steering column ignition switch Fig 6 The system locks the shifter into the PARK position The Interlock system is engaged whenever the ignition switch is in the LOCK or ACCESSORY position An additional electrically acti vated feature will prevent shifting out of the PARK position unless the brake pedal is depressed at least one half an inch A magnetic holding device in line with the park lock cable is energized when the igni tion is in the RUN position When the key is in the RUN position and the brake pedal is depressed the shifter is unlocked and will move into any position The interlock system also prevents the ignition switch from being turned to the LOCK or ACCES SORY position Fig 6 unless the shifter is fully locked into the PARK position TRANSMISSION AND TRANSFER CASE 21 9 DIAGNOSIS AND TESTING AUTOMATIC TRANSMISSION DIAGNOSIS Automatic transmission problems can be a result of poor engine performance incorrect fluid level incor rect linkage or cable adjustment band or hydraulic control pressure adjustments hydraulic system mal functions or electrical mechanical component mal functions Begin diagnosis by checking the easily accessible items such as fluid level and condition linkage adjustments and electrical connections A road test will determine if further diagnosis is neces sary
65. CM 21 6 TRANSMISSION AND TRANSFER CASE DESCRIPTION AND OPERATION Continued GOVERNOR PRESSURE SOLENOID VALVE The solenoid valve is a duty cycle solenoid which regulates the governor pressure needed for upshifts and downshifts It is an electro hydraulic device located in the governor body on the valve body trans fer plate Fig 3 The inlet side of the solenoid valve is exposed to normal transmission line pressure The outlet side of the valve leads to the valve body governor circuit The solenoid valve regulates line pressure to pro duce governor pressure The average current sup plied to the solenoid controls governor pressure One amp current produces zero kPa psi governor pres sure Zero amps sets the maximum governor pres sure The powertrain control module PCM turns on the trans control relay which supplies electrical power to the solenoid valve Operating voltage is 12 volts DC The PCM controls the ground side of the sole noid using the governor pressure solenoid control cir cuit J9321 408A Fig 3 Governor Pressure Solenoid Valve 1 SOLENOID FILTER 2 GOVERNOR PRESSURE SOLENOID GOVERNOR PRESSURE SENSOR The governor pressure sensor measures output pressure of the governor pressure solenoid valve Fig 4 The sensor output signal provides the necessary feedback to the PCM This feedback is needed to ade quately control governor pressure GOVERNOR BODY AND TRANSFER PLATE The transfer pla
66. Clutch Damaged 6 Replace clutch 3RANSMISSION AND TRANSFER CASE 21 21 DIAGNOSIS AND TESTING Continued SLPS IN REVERSE 2 6 Hydraulic Pressure Too Low 6 Perform hydraulic pressure tests to determine cause 7 Rear Servo Leaking 7 Air pressure check clutch servo operation and repair as required 8 Band Linkage Binding 8 Inspect and repair as required SLIPS IN FORWARD 1 Fluid Level Low 1 Add fluid and check for leaks DRIVE RANGES 2 Fluid Foaming 2 Check for high oil level bad pump gasket or seals dirt between pump halves and loose pump bolts Replace pump if necessary 3 Throttle Linkage Misadjusted 3 Adjust linkage 4 Gearshift Linkage Misadjusted 4 Adjust linkage 5 Rear Clutch Worn 5 Inspect and replace as needed 6 Low Hydraulic Pressure Due to 6 Perform hydraulic and air pressure tests to Worn Pump Incorrect Control determine cause Pressure Adjustments Valve Body Warpage or Malfunction Sticking Leaking Seal Rings Clutch Seals Leaking Servo Leaks Clogged Filter or Cooler Lines 7 Rear Clutch Malfunction 7 Air pressure check clutch servo operation Leaking Seals or Worn Plates and repair as required 8 Overrunning Clutch Worn Not 8 Replace Clutch Holding Slips in 1 Only SLIPS IN LOW GEAR D Overrunning Clutch Faulty Replace overrunning clutch ONLY BUT NO IN 1 POSITION GROWLING GRATING 1 Drive Plate Broken 1 Replace O
67. E TO SERVICE THE OVERRUNNING CLUTCH CAM AND THE OVERDRIVE PISTON RETAINER THE TRANSMISSION GEARTRAIN AND OVERDRIVE UNIT MUST BE REMOVED FROM THE TRANSMIS SION 1 Remove the overdrive piston Fig 154 2 Remove the overdrive piston retainer bolts 3 Remove overdrive piston retainer 4 Remove case gasket 5 Mark the position of the overrunning clutch cam in the case Fig 155 6 Remove the overrunning clutch cam bolts 7 Remove the overrunning clutch cam J9121 210 Fig 154 Overdrive Piston Removal 1 OVERDRIVE CLUTCH PISTON 2 INTERMEDIATE SHAFT 3 SELECTIVE SPACER 4 PISTON RETAINER ASSEMBLY 1 Examine bolt holes in overrunning clutch cam Note that one hole is not threaded Fig 156 This hole must align with blank area in clutch cam bolt circle Fig 157 Mark hole location on clutch cam and blank area in case with grease pencil paint stripe or scribe mark for assembly reference 2 Mark location of non threaded hole in clutch cam and blank area in bolt circle with grease pencil 3 Align and install overrunning clutch and cam in case Fig 158 Be sure cam is correctly installed Bolt holes in cam are slightly counter sunk on one side Be sure this side of cam faces rearward toward piston retainer 21 81 TRANSMISSION AND TRANSFER CASE Fig 155 Overrunning Clutch Cam Removal 1 ALIGN MARKS IDENTIFYING NON THREADED HOLE IN CAM AND CASE 2 OVERRUNNING CLUTCH A
68. E SPRING 3RANSMISSION AND TRANSFER CASE 21 53 DISASSEMBLY AND ASSEMBLY Continued J9321 155 Fig 78 Upper Housing Control Valve Locations 1 UPPER HOUSING 8 MANUAL VALVE 2 REGULATOR VALVE 9 1 2 GOVERNOR PLUG 3 SWITCH VALVE 10 GOVERNOR PLUG COVER 4 REGULATOR VALVE SPRING 11 THROTTLE PLUG 5 KICKDOWN VALVE 12 2 3 GOVERNOR PLUG 6 KICKDOWN DETENT 13 SHUTTLE VALVE PRIMARY SPRING 7 THROTTLE VALVE AND SPRING MP J9321 433 Fig 79 Accumulator Housing Screw Locations 1 LOOSEN THIS SCREW Fig 80 3 4 Shift And Converter Clutch Valve 2 REMOVE THESE SCREWS Springs And Plug 3 3 4 ACCUMULATOR HOUSING 1 ACCUMULATOR HOUSING 2 CONVERTER CLUTCH VALVE SPRING 3 CLUTCH VALVE PLUG 4 3 4 SHIFT VALVE SPRING 21 54 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued J9321 434 Fig 81 Accumulator Housing Valve Springs And Plug 1 3 4 SHIFT VALVE SPRING 2 CONVERTER CLUTCH VALVE SPRING AND PLUG 3 3 4 ACCUMULATOR HOUSING J9521 101 Fig 82 Boost Valve Tube Brace 1 BOOST VALVE TUBE 2 TUBE BRACE DOUBLE TAB 27 Remove boost valve connecting tube Fig 83 Disengage tube from upper housing port first Then rock opposite end of tube back and forth to work it out of lower housing CAUTION Do not use tools to loosen or pry the connecting tube out of the valve body housings L
69. EACTION PLUG SNAP RING 2 SNAP RING PLIERS 7 Support geartrain on Tool 6227 1 Fig 256 Be sure tool is securely seated in clutch hub 8 Install overdrive gear case on geartrain Fig 256 Fig 255 Correct Hear Bearing Locating Ring Position 1 CASE ACCESS HOLE 2 TAB ENDS OF LOCATING RING 9 Expand front bearing locating ring with snap ring pliers Fig 257 Then slide case downward until locating ring locks in bearing groove and release snap ring 10 Install locating ring access cover and gasket in overdrive unit case Fig 258 OVERDRIVE CLUTCH ASSEMBLY 1 Install overdrive dutch reaction ring first Reaction ring is flat with notched ends Fig 259 21 110 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued J9321 360 Fig 256 Overdrive Gear Case Installation 1 GEARTRAIN ASSEMBLY 2 GEAR CASE PUSH OUTPUT SHAFT FORWARD TO FREE BEARING FROM RING Fig 257 Seating Locating Ring In Rear Bearing 1 Sele BEARING LOCATING RING WITH SNAP RING PLIER 2 ACCESS HOLE 2 Install wave spring on top of reaction ring Fig 260 Reaction ring and wave ring both fit in same ring groove Use screwdriver to seat each ring securely in groove Also ensure that the ends of the two rings are offset from each other NOTE The 44RE transmission has 4 overdrive clutch discs and 3 plates 3 Assemble overdrive clutch pack 4 Install overd
70. F 13 Disconnect alligator clips from battery Recon nect flusher lines to cover plate and remove flushing adapters from cooler lines ALUMINUM THREAD REPAIR Damaged or worn threads in the aluminum trans mission 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 equiva lent 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 suppli ers TRANSMISSION AND TRANSFER CASE 21 29 REMOVAL AND INSTALLATION TRANSMISSION CAUTION The transmission and torque converter must be removed as an assembly to avoid compo nent damage The converter drive plate pump bushing or oil seal can be damaged if the con verter is left attached to the driveplate during removal Be sure to remove the transmission and torque converter as an assembly REM OVAL 1 Open the hood and disconnect the negative bat tery cable 2 Remove the 2 upper fan shroud retaining bolts lt SA 2 SY b N FP 80bc4e7c Fig 14 Transmission Dipstick Tube Support Bracket Position amp Orientation 1 TRANSMISSION DIPSTICK TUBE 2 TURBOCHARGER EXHAUST MANIFOLD HEATSHIELD 3 TRANSMISSION DIPSTICK TU
71. F Plus 3 type 7176 transmission fluid Allow discs to soak for 10 20 minutes 2 Install new pilot bushing and dutch hub bush ing in output shaft if necessary Fig 235 Lubricate bushings with petroleum jelly or transmission fluid J9121 321 Fig 235 Output Shaft Pilot Bushing 1 OUTPUT SHAFT HUB 2 OVERRUNNING CLUTCH HUB BUSHING 3 INTERMEDIATE SHAFT PILOT BUSHING 3 Install annulus gear on output shaft if removed Then install annulus gear retaining snap ring Fig 236 4 Align and install dutch drum on annulus gear Fig 237 Be sure drum is engaged in annulus gear lugs 5 Install dutch drum outer retaining ring Fig 237 6 Slide dutch drum forward and install inner retaining ring Fig 238 7 Install rear bearing and snap ring on output shaft Fig 239 Be sure locating ring groove in bear ing is toward rear 8 Install overrunning clutch on hub Fig 240 Note that clutch only fits one way Shoulder on clutch should seat in small recess at edge of hub 9 Install thrust bearing on overrunning dutch hub Use generous amount of petroleum jelly to hold bearing in place for installation Bearing fits one way only Be sure bearing is seated squarely against hub Reinstall bearing if it does not seat squarely J9021 89 Fig 236 Annulus Gear Installation 1 SNAP RING 2 OUTPUT SHAFT FRONT BEARING 3 ANNULUS GEAR J9321 393 Fig 237 Clutch Drum And Outer Retaini
72. Fig 169 Remove burrs from stake points with knife blade afterward J9221 242 Fig 168 Removing Oil Pump Bushing 1 SPECIAL TOOL C 4171 2 SPECIAL TOOL SP 3551 3 BUSHING 4 SPECIAL TOOL SP 5117 5 BUSHING 6 SPECIAL TOOL C 4171 7 PUMP HOUSING Fig 169 Staking Oil Pump Bushing 1 NARROW BLADE 2 BLUNT PUNCH 3 TWO STAKES TRANSMISSION AND TRANSFER CASE 21 85 REACTION SHAFT SUPPORT BUSHING REMOVAL 1 Assemble Bushing Remover Tools SP 1191 3633 and 5324 Fig 170 Do not clamp any part of reaction shaft or support in vise 2 Hold Cup Tool SP 3633 firmly against reaction shaft and thread remover SP 5324 into bushing as far as possible by hand Then thread remover tool 3 4 additional turns into bushing with a wrench 3 Turn remover tool hex nut down against remover cup to pull bushing from shaft Clean all chips from shaft after bushing removal 4 Lightly grip old bushing in vise or with pliers and back remover tool out of bushing 5 Assemble Bushing Installer Tools C 4171 and SP 5325 Fig 170 6 Slide new bushing onto Installer Tool SP 5325 7 Position reaction shaft support upright on a dean smooth surface 8 Align bushing in bore Then tap bushing into place until Bushing Installer SP 5325 bottoms 9 Clean reaction shaft support thoroughly after installing bushing BUSHING REMOVAL BUSHING INSTALLATION 5 J9221 243 Fig 170 Replacing Reac
73. Fig 187 Installing Rear Clutch Thrust Washer 1 REAR CLUTCH RETAINER 2 REAR CLUTCH THRUST WASHER PLANETARY GEARTRAIN OUTPUT SHAFT DISASSEMBLY 1 Remove planetary snap ring Fig 188 2 Remove front annulus and planetary assembly from driving shell Fig 188 3 Remove snap ring that retains front planetary gear in annulus gear Fig 189 4 Remove tabbed thrust washer and tabbed thrust plate from hub of front annulus Fig 190 5 Separate front annulus and planetary gears Fig 190 WJ 6 Remove front planetary gear front thrust washer from annulus gear hub 7 Separate and remove driving shell rear plane tary and rear annulus from output shaft Fig 191 8 Remove front planetary rear thrust washer from driving shell 9 Remove tabbed thrust washers from rear plan etary gear 10 Remove lock ring that retains sun gear in driving shell Then remove sun gear spacer and thrust plates J9421 175 Fig 188 Front Annulus And Planetary Assembly Removal 1 DRIVING SHELL 2 FRONT ANNULUS AND PLANETARY ASSEMBLY 3 PLANETARY SNAP RING J9421 176 Fig 189 Front Planetary Snap Ring Removal 1 FRONT ANNULUS GEAR 2 PLANETARY SNAP RING ASSEMBLY 1 Lubricate output shaft and planetary compo nents with transmission fluid Use petroleum jelly to lubricate and hold thrust washers and plates in posi tion 2 Assemble rear annulus gear and support if dis assembled
74. G Continued CONDITION POSSIBLE CAUSES CORRECTION NO REVERSE D 1 Gearshift Linkage Cable 1 Repair or replace linkage parts as needed RANGES OK Misadjusted Damaged 2 Park Sprag Sticking 2 Replace overdrive annulus gear 3 Rear Band Misadjusted Worn 3 Adjust band replace 4 Valve Body Malfunction 4 Remove and service valve body Replace valve if any valves or valve bores are worn or damaged 5 Rear Servo Malfunction 5 Remove and disassemble transmission Replace worn damaged servo parts as necessary 6 Direct Clutch in Overdrive Worn 6 Disassemble overdrive Replace worn or damaged parts 7 Front Clutch Burnt 7 Remove and disassemble transmission Replace worn damaged clutch parts as required HAS FIRST REVERSE 1 Governor Circuit Electrical 1 Test using DRB scan tool and repair as ONLY NO 1 2 OR 2 3 Fault required UPSHIFT 2 Valve Body Malfunction 2 Repair stuck 1 2 shift valve or governor plug 3 Front Servo Kickdown Band 3 Repair replace Damaged Burned MOVES IN 2ND OR 3RD 1 Valve Body Malfunction 1 Remove clean and inspect Look for stuck GEAR ABRUPTLY 1 2 valve or governor plug DOWNSHIFTS TO LOW 2 Governor Components Sticking 2 Remove clean and inspect Replace faulty parts NO LOW GEAR MOVES 1 Governor Components Sticking 1 Remove clean inspect and repair as IN 2ND OR 3RD GEAR required ONLY 2 Governor Circuit Electrical 2 Test with DRB scan tool and repair as
75. ION This engine is equipped with a engine speed sensor Located in the top of the bellhousing Care must be taken not to damage the sensor or corresponding wires during transmission removal and installation CAUTION Check the torque converter hub and hub drive notches for sharp edges burrs scratches or nicks Polish the hub and notches with 320 400 grit sandpaper if necessary The hub must be smooth to avoid damaging the pump seal at torque converter installation CAUTION Lubricate the front pump seal and install at least one quart of the approved transmission fluid directly into the torque converter prior to its installation 1 Install the torque converter in the transmis sion Refer to the procedure in this group for detailed instructions 2 Lubricate the rear of the crankshaft or the con verter pilot hub with lithium grease 3 Position the transmission converter assembly on a transmission jack and secure with chains NOTE Be sure the engine block mounted dowel pins are installed and protrude far enough to hold the transmission in alignment 4 Using the transmission jack position the trans mission assembly so the engine block mounted dowel pins are perfectly aligned with the corresponding holes in the transmission bellhousing CAUTION Be certain the torque convertor is prop erly installed in the transmission If the torque con vertor is not installed correctly the engine will not rotate upon installatio
76. L 3unssaud HONH3AOD 189 6 29 3unssaud 0311997 H LNT H31H3ANOO HV39 3AIHG NI AO 14 aaxoo Nn HVAD JAHA NI HOLO3 3S 3AT1VA dn1901 3ATVA dfi 31201 GION3108S df14201 105 AuddaAo SATVA 141 5 t FATWA 7 6 v HILNTID 3AIHQU3AO 1 NOLLVOINENT OL SATWA HOLIMS ZAIVA 15008 JAVA TILLOYHL Cn 3ATVA xs FATWA 5 CL 3ATVA ATLLNHS 3 TlLLOHHL 3NT1VA HOLT TO LNOtid OAU3S LNOYS 5 uVdd dari 110 YALYAANOD 3nouoL N33uos 3ATVA 3ATVA 13IHS 2 1 9nd uONH3AOD MS 3ATVA L3IHS 6 2 51 HONH3AOS HO1fY1O GION3 10S 9 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS Continued 21 130 98914608 isd 29 48 auns 1 NOILONS isd 001 0 3unssaHd JILLOYHL 09 0 55 HONH3AOD isd 0 1 96 3unssaud 0311997 LON H LNT H3183ANOO 3AIHG DITNVYGAH HV39 3AIHQH3AO JAHA NI H3A31 HOLO3 13S NOILVOIHS TI LN H4 H3lH3ANOO 3no0uHol NOLLVOINSNT OL JATVA
77. Line pressure at Closed throttle 372 414 kPa 54 60 psi accumulator Third gear only No more than 21 kPa 3 psi lower than line pressure 3 psi Rear servo 1 range No more than 21 kPa 3 psi lower than line pressure R range 1103 kPa 160 psi at idle builds to 1862 kPa 270 psi at 1600 rpm Governor D range closed throttle Pressure should respond smoothly to changes in mph and return to 0 7 kPa 0 1 5 psi when stopped with transmission in D 1 2 Pressure above 7 kPa 1 5 psi at stand still will prevent transmission from downshifting SPECIAL TOOLS RE TRANSMISSIONS EN Gauge Bar 6311 Spring Compressor and Alignment Shaft 6227 _ TRANSMISSION AND TRANSFER CASE 21 137 SPECIAL TOOLS Continued Extension Housing Pilot C 3288 B Puller Slide Hammer C 3752 Gauge Throttle Setting C 3763 g Seal Installer C 3860 A 80114429 Dial Indicator C 3339 Y Seal Remover C 3985 B Spring Compressor C 3422 B 21 138 TRANSMISSION AND TRANSFER CASE wi SPECIAL TOOLS Continued 27 Installer C 3995 A 227 Nut Bushing Remover SP 1191 From kit C 3887 J Universal Handle C 4171 Cup Bushing Remover SP 3633 From kit C 3887 J Seal Installer C 4193 A 6 Remover Bushing SP 3551 Dial Caliper C 4962 Installer Bushing SP 5117
78. MISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 39121 149 Fig 181 Removing Installing Input Shaft Snap Ring 1 REAR CLUTCH RETAINER 2 INPUT SHAFT SNAP RING 3 SNAP RING PLIERS ASSEM BLY 1 Soak dutch discs in transmission fluid while assembling other dutch parts 2 Install new seal rings on clutch retainer hub and input shaft if necessary Fig 182 a Be sure dutch hub seal ring is fully seated in groove and is not twisted 3 Lubricate splined end of input shaft and dutch retainer with transmission fluid Then press input shaft into retainer Use a suitably sized press tool to support retainer as close to input shaft as possible 4 Install input shaft snap ring Fig 181 5 Invert retainer and press input shaft in oppo site direction until snap ring is seated 6 Install new seals on clutch piston Be sure lip of each seal faces interior of dutch retainer 7 Lubricate lip of piston seals with generous quantity of Mopar Door Ease Then lubricate retainer hub and bore with light coat of transmission fluid 8 Install dutch piston in retainer Use twisting motion to seat piston in bottom of retainer A thin strip of plastic about 0 020 thick can be used to guide seals into place if necessary CAUTION Never push the clutch piston straight in This will fold the seals over causing leakage and clutch slip In addition never use any type of metal tool to help ease the pis
79. NAL INJURY 1 Mount geartrain assembly in shop press Fig 222 2 Position Compressor Tool 6227 1 on clutch hub Fig 222 Support output shaft flange with steel press plates as shown and center assembly under press ram 3 Apply press pressure slowly Compress hub and spring far enough to expose clutch hub retaining ring and relieve spring pressure on clutch pack snap ring Fig 222 4 Remove direct clutch pack snap ring Fig 223 5 Remove direct clutch hub retaining ring Fig 224 6 Release press load slowly and completely Fig 225 7 Remove Special Tool 6227 1 Then remove clutch pack from hub Fig 225 LA 9321 398 Fig 222 Geartrain Mounted In Shop Press 1 PRESS RAM 2 SPECIAL TOOL C 3995 A OR SIMILAR TOOL 3 CLUTCH HUB 4 PLATES 5 PRESS BED 6 SPECIAL TOOL 6227 1 WJ DISASSEMBLY AND ASSEMBLY Continued J9321 364 Fig 223 Direct Clutch Pack Snap Ring Removal 1 CLUTCH HUB 2 SPECIAL TOOL 6227 1 3 DIRECT CLUTCH PACK SNAP RING 4 PRESS PLATES 5 CLUTCH DRUM J9321 363 Fig 224 Direct Clutch Hub Retaining Ring Removal 1 SPECIAL TOOL 6227 1 2 CLUTCH HUB RETAINING RING 3 PRESS BED 4 PRESS PLATES TRANSMISSION AND TRANSFER CASE 21 101 J9321 365 Fig 225 Direct Clutch Pack Removal 1 SPECIAL TOOL 6227 1 2 DIRECT CLUTCH HUB 3 DIRECT CLUTCH PACK Geartrain Disassembly 1 Remove di
80. NG 14 BOOST VALVE COVER 21 64 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued J9321 155 Fig 103 Upper Housing Control Valve Locations 1 UPPER HOUSING 8 MANUAL VALVE 2 REGULATOR VALVE 9 1 2 GOVERNOR PLUG 3 SWITCH VALVE 10 GOVERNOR PLUG COVER 4 REGULATOR VALVE SPRING 11 THROTTLE PLUG 5 KICKDOWN VALVE 12 2 3 GOVERNOR PLUG 6 KICKDOWN DETENT 13 SHUTTLE VALVE PRIMARY SPRING 7 THROTTLE VALVE AND SPRING 3RANSMISSION AND TRANSFER CASE 21 65 DISASSEMBLY AND ASSEMBLY Continued J9321 157 Fig 104 Upper Housing Shift Valve And Pressure Plug Locations 1 UPPER HOUSING 8 RETAINER 2 1 2 SHIFT VALVE AND SPRING 9 1 2 SHIFT CONTROL VALVE AND SPRING 3 2 3 SHIFT VALVE AND SPRING 10 PRESSURE PLUG COVER 4 2 3 THROTTLE PLUG 11 LINE PRESSURE PLUG 5 LIMIT VALVE HOUSING 12 PLUG SLEEVE 6 LIMIT VALVE COVER 13 THROTTLE PRESSURE SPRING AND PLUG 7 LIMIT VALVE AND SPRING 21 66 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued BOOST VALVE TUBE AND BRACE 1 Position valve body assembly so lower housing is facing upward Fig 105 2 Lubricate tube ends and housing ports with transmission fluid or petroleum jelly 3 Start tube in lower housing port first Then swing tube downward and work opposite end of tube into upper housing port Fig 105 4 I
81. O D piston retainer 17 N m 13 ft Ibs 44RE Band adjustment Plug pressure test port 14 N m 10 ft Ibs from 72 in Ibs Bolt reaction shaft support 20 N m 15 ft Ibs Front band Back off 1 7 8 turns Locknut rear band 41 N m 30 ft Bolt valve body tocase 12 N m 100 in Ibs nee bany pack 41018 Screw solenoid wiring connector 4 N m Recommended fluid Mopar ATF Plus 3 type 35 in Ibs 7176 Screw solenoid to transfer plate 4 N m 35 in Ibs 21 136 TRANSMISSION AND TRANSFER CASE SPECIFICATIONS Continued THRUST WASHER SPACER SNAP RING DIMENSIONS Front clutch thrust washer reaction shaft 1 55 mm 0 061 in support hub Rear clutch thrust washer clutch retainer 0 061 in Intermediate shaft thrust plate shaft hub pilot 1 5 1 6 mm 0 060 0 063 in Output shaft thrust washer rear clutch hub Select fit to set end play Rear clutch pack snap ring 0 060 in 0 076 in 0 098 in Planetary geartrain snap ring at front of output shaft Select fit three thicknesses available Overdrive piston thrust plate Thrust plate and spacer are select fit Refer to size charts and selection procedures in Intermediate shaft spacer Overdrive Unit D amp A procedures PRESSURE TEST Overdrive clutch Fourth gear only Pressure should be 469 496 kPa 68 72 psi with closed throttle and increase to 620 896 kPa 90 130 psi at 1 2 to 3 4 throttle
82. OTE This test checks pump output line pressure and pressure regulation Use 100 psi Test Gauge C 3292 for this test 1 Leave vehide in place on hoist and leave Test Gauge C 3292 connected to accumulator port 2 Have helper start and run engine at 1000 rpm 3 Move transmission shift lever one detent rear ward from full forward position This is 2 range 4 Move transmission throttle lever from full for ward to full rearward position and read pressure on gauge WJ DIAGNOSIS AND TESTING Continued 5 Line pressure should be 54 60 psi 372 414 kPa with throttle lever forward and gradually increase to 90 96 psi 621 662 kPa as lever is moved rearward Test Three Transmission In D Range Third Gear NOTE This test checks pressure regulation and condition of the clutch circuits Both test gauges are required for this test 1 Turn OD switch off 2 Leave vehicle on hoist and leave Gauge C 3292 in place at accumulator port 3 Move Gauge C 3293 SP over to front servo port for this test 4 Have helper start and run engine at 1600 rpm for this test 5 Move transmission shift lever two detents rear ward from full forward position This is D range 6 Read pressures on both gauges as transmission throttle lever is gradually moved from full forward to full rearward position e Line pressure at accumulator in D range third gear should be 54 60 psi 372 414 kPa with throttle lever forward and increase as lev
83. R SCRAPING NOISES 2 Torque Converter Bolts Hitting 2 Dust shield bent Replace or repair Dust Shield 3 Planetary Gear Set Broken 3 Check for debris in oil pan and repair as Seized required 4 Overrunning Clutch Worn 4 Inspect and check for debris in oil pan Broken Repair as required 5 Oil Pump Components 5 Remove inspect and repair as required Scored Binding 6 Output Shaft Bearing or 6 Remove inspect and repair as required Bushing Damaged 7 Clutch Operation Faulty 7 Perform air pressure check and repair as required 8 Front and Rear Bands 8 Adjust bands Misadjusted 21 22 TRANSMISSION AND TRANSFER CASE l n PN 7 nH WJ DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION DRAGS OR LOCKS UP 1 Fluid Level Low 1 Check and adjust level 2 Clutch Dragging Failed 2 Air pressure check clutch operation and repair as required 3 Front or Rear Band 3 Adjust bands Misadjusted 4 Case Leaks Internally 4 Check for leakage between passages in case 5 Servo Band or Linkage 5 Air pressure check servo operation and Malfunction repair as required 6 Overrunning Clutch Worn 6 Remove and inspect clutch Repair as required 7 Planetary Gears Broken 7 Remove inspect and repair as required look for debris in oil pan NO 4 3 DOWNSHIFT 1 Circuit Wiring and or 1 Test wiring and connectors with test lamp Connectors Shorted and volt ohmmeter Repair wiring as necessary Rep
84. RAL CONTACT 2 MANUAL LEVER AND SWITCH PLUNGER IN REVERSE POSITION 3 PARK CONTACT 4 SWITCH 2 Install new seal on switch and install switch in case Tighten switch to 34 N m 25 ft Ibs torque 3 Test continuity of new switch with 12V test lamp 4 Connect switch wires and lower vehide 5 Top off transmission fluid level GEARSHIFT CABLE REM OVAL 1 Place the transmission gear selector in the PARK position 2 Raise the vehicle on a hoist 3 Disconnect the shift cable eyelet from the transmission shift lever Fig 32 WJ REMOVAL AND INSTALLATION Continued 80bc4e93 Fig 32 Shift Cable at Transmission 1 TRANSMISSION SHIFTER CABLE 2 THROTTLE VALVE CABLE 3 TRANSFER CASE SHIFTER CABLE 4 TRANSFER CASE SHIFTER CABLE BRACKET RETAINING BOLT 1 OF 2 5 THROTTLE VALVE CABLE BRACKET RETAINING BOLT 6 ELECTRICAL CONNECTORS 7 TRANSMISSION FLUID LINES 4 Remove the shift cable from the shift cable sup port bracket 5 Lower the vehicle from the hoist 6 Remove shift lever bezel and necessary console parts for access to shifter and cable assembly 80ba79cb Fig 33 Transmission Shift Cable at Shifter 1 SHIFT LEVER PIN 2 ADJUSTMENT SCREW 3 SHIFT CABLE 4 SHIFTER ASSEMBLY BRACKET TRANSMISSION AND TRANSFER CASE 21 37 7 Disconnect the shift cable from the shifter assembly Fig 33 8 Remove the shift cable seal plate
85. S 12 Position a transmission jack under the trans fer case 13 Lower the transmission assembly enough to gain access and remove the transfer case to trans mission retaining nuts 14 Remove the transfer case from the vehicle INSTALLATION NOTE If replacement transfer case is being installed be certain the counter weight is installed on the transfer case housing prior to installation 1 Install the transfer case on the transmission Torque the transfer case retaining nuts to 75 N m 55 ft 105 Fig 6 2 Install the vent tube on the transfer case Fig 6 3 Connect the transfer case shift cable on the shifter arm Fig 6 4 Using the jack raise the transmission assem bly into position and install the 8 transmission sup port crossmember retaining bolts Fig 7 Torque the bolts to 41 N m 30 ft 165 5 Install the rear driveshaft Torque the bolts to 32 N m 24 ft Ibs Be certain to install the drive shaft in the same position as before removal 21 142 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued im INN 80bc4e94 Fig 6 Transfer Case Position amp Orientation 1 TRANSFER CASE RETRAINING NUTS 2 TRANSFER CASE SHIFTER CABLE 3 TRANSFER CASE VENT HOSE 4 FLAT BLADED TOOL 5 TRANSFER CASE 6 TRANSMISSION ELECTRICAL CONNECTOR WJ 2 e 8 A 7 8 22 i r W LES 80bc4
86. SSEMBLY J9121 226 Fig 156 Location Of Non Threaded Hole In Clutch Cam 1 NON THREADED HOLE 2 OVERRUNNING CLUTCH CAM 4 Verify that non threaded hole in dutch cam is properly aligned Check alignment by threading a bolt into each bolt hole Adjust clutch cam position if necessary 5 Install and tighten overrunning dutch cam bolts to 17 N m 13 ft Ibs torque Note that clutch cam bolts are shorter than piston retainer bolts 6 Install new gasket at rear of transmission case Use petroleum jelly to hold gasket in place Be sure to align governor feed holes in gasket with feed pas sages in case Fig 159 Also install gasket before overdrive piston retainer Center hole in gasket is smaller than retainer and cannot be installed over retainer 21 82 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued J9121 541 Fig 157 Location Of Blank Area In Clutch Cam Bolt Circle 1 OVERRUNNING CLUTCH CAM SEAT IN CASE 2 NON THREADED HOLE IN CLUTCH CAM ALIGNS HERE BLANK AREA OF SEAT Fig 158 Overrunning Clutch Installation 1 ALIGN MARKS IDENTIFYING NON THREADED HOLE IN CAM AND CASE 2 OVERRUNNING CLUTCH ASSEMBLY 2 O oh 1 be J9121 349 Fig 159 Installing Aligning Case Gasket 1 CASE GASKET 2 BE SURE GOVERNOR TUBE FEED HOLES IN CASE AND GASKET ARE ALIGNED 7 Position overdrive piston retainer on transmis sion case
87. T HOUSING 2 DETENT SPRING 3 DETENT BALL 4 PENCIL MAGNET 4 J9321 430 Fig 76 Adjusting Screw Bracket Fastener 1 T25 TORX BIT 2 REMOVE THESE SCREWS FIRST 3 BRACKET 4 BRACKET 5 REMOVE THIS SCREW LAST WJ 20 Remove adjusting screw bracket line pressure adjusting screw pressure regulator valve spring and switch valve spring Fig 77 Do not remove throt tle pressure adjusting screw from bracket and do not disturb setting of either adjusting screw during removal 21 Turn upper housing over and remove switch valve regulator valve and spring and manual valve Fig 78 22 Remove kickdown detent kickdown valve and throttle valve and spring Fig 78 23 Loosen left side 3 4 accumulator housing attaching screw about 2 3 threads Then remove cen ter and right side housing attaching screws Fig 79 24 Carefully rotate 3 4 accumulator housing upward and remove 3 4 shift valve spring and con verter clutch valve plug and spring Fig 80 25 Remove left side screw and remove 3 4 accu mulator housing from valve body Fig 81 26 Bend back tabs on boost valve tube brace Fig 82 d Lem M PAD B pee 2 5 a 7 99 2 N J9321 431 Fig 77 Adjusting Screw Bracket And Spring 1 SWITCH VALVE SPRING 2 LINE PRESSURE SCREW 3 THROTTLE PRESSURE ADJUSTING SCREW 4 ADJUSTING SCREW BRACKET 5 PRESSURE REGULATOR VALV
88. TRANSMISSION AND TRANSFER CASE 21 1 TRANSMISSION AND TRANSFER CASE TABLE OF CONTENTS page 44RE AUTOMATIC TRANSMISSION 1 44RE AUTOMATIC TRANSMISSION TABLE OF CONTENTS page DESCRIPTION AND OPERATION 3 4 SHIFT SEQUENCE 8 44 RE TRANSMISSION 2 BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM 9 CAUSES OF BURNT FLUID 4 CONVERTER CLUTCH ENGAGEMENT 8 CONVERTER DRAINBACK VALVE 8 EFFECTS OF INCORRECT FLUID LEVEL 4 ELECTRONIC GOVERNOR 5 ELECTRONIC LOCK UP TORQUE 25545555456 ee teehee 5 FLUID CONTAMINATION 4 GEARSHIFT MECHANISM 5 GOVERNOR PRESSURE CURVES 7 HYDRAULIC CONTROL SYSTEM 7 OVERDRIVE OFF SWITCH 8 QUICK FILL VALVE 8 RECOMMENDED FLUID 4 SHIFT VALVE OPERATION 7 TRANSMISSION GEAR RATIOS 5 TRANSMISSION IDENTIFICATION 4 DIAGNOSIS AND TESTING AIR TESTING TRANSMISSION CLUTCH AND BAND 14 ANALYZING ROAD TEST 11 AUTOMATIC TRANSMISSION DIAGNOSIS 9 BRAKE TRANSMISSION SHIFT INTERLOCK 10 CONVERTER HOUSING FLUID LEAK DIAGNOSIS Re e 15 DIAGNOSIS TABLES AND CHARTS RE 5
89. TRANSMISSION AND TRANSFER CASE 21 45 7 Position valve body in case and work end of park lock rod into and through pawl sprag Turn pro peller shaft to align sprag and park lock teeth if nec essary The rod will dick as it enters pawl Move rod to check engagement CAUTION It is possible for the park rod to displace into a cavity just above the pawl sprag during installation Make sure the rod is actually engaged in the pawl and has not displaced into this cavity 8 Install accumulator springs and piston into case Then swing valve body over piston and outer spring to hold it in place 9 Align accumulator piston and outer spring manual lever shaft and electrical connector in case 10 Then seat valve body in case and install one or two bolts to hold valve body in place 11 Tighten valve body bolts alternately and evenly to 11 N m 100 in Ibs torque 12 Install new fluid filter on valve body Tighten filter screws to 4 N m 35 in Ibs torque 13 Install throttle and gearshift levers on valve body manual lever shaft 14 Check and adjust front and rear bands if nec essary 15 Connect solenoid case connector wires 16 Install oil pan and new gasket Tighten pan bolts to 17 N m 13 ft Ibs torque 17 Lower vehicle and fill transmission with Plus type 7176 fluid 18 Check and adjust gearshift and throttle valve cables if necessary J9321 389 Fig 55 Valve Body Harness Co
90. URE SHOULDER SIDE OF PLATE FACES UPWARD J9321 397 Fig 250 Direct Clutch Pack And Clutch Hub Installation 1 CLUTCH HUB 2 DIRECT CLUTCH PACK 3 CLUTCH DRUM WJ WARNING THE NEXT STEP ASSEMBLY INVOLVES COMPRESSING THE DIRECT CLUTCH HUB AND SPRING IT IS EXTREMELY IMPORTANT THAT PROPER EQUIPMENT BE USED TO COMPRESS THE SPRING AS SPRING FORCE IS APPROXIMATELY 830 POUNDS USE COMPRES SOR TOOL C 6227 1 AND A HYDRAULIC TYPE SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 6 INCHES THE PRESS MUST ALSO HAVE A BED THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED RELEASE CLUTCH SPRING TENSION SLOWLY AND COMPLETELY TO AVOID PERSONAL INJURY 20 Position Compressor Tool 6227 1 on clutch hub 21 Compress dutch hub and spring just enough to place tension on hub and hold it in place 22 Slowly compress dutch hub and spring Com press spring and hub only enough to expose ring grooves for dutch pack snap ring and clutch hub retaining ring 23 Realign dutch pack on hub and seat clutch discs and plates in dutch drum 24 Install direct clutch pack snap ring Fig 251 Be very sure snap ring is fully seated in clutch drum ring groove 25 Install clutch hub retaining ring Fig 252 Be very sure retaining ring is fully seated in sun gear ring groove 26 Slowly release press ram remove compressor tools and remove geartrain assembly J9321 400 Fig 251 Direct
91. USTMENTS BAND ADJUSTMENTS 120 BRAKE TRANSMISSION SHIFT INTERLOCK 117 GEARSHIFT 119 TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT 44 ERES 117 VALVE BODY doe es wh tached 121 SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS 122 SPECIFICATIONS 55 135 SPECIAL TOOLS RE 5 5 136 ranges except fourth gear The torque converter dutch is controlled by the Powertrain Control M od ule PCM The torque converter clutch is hydrauli cally applied and is released when fluid is vented from the hydraulic circuit by the torque converter control TCC solenoid on the valve body The torque converter clutch engages in fourth gear and in third gear when the O D switch is OFF Engagement occurs when the vehide is moving at a steady speed after the has warmed up The torque con verter dutch disengages when the accelerator is applied The 44 RE transmission is cooled by an inte gral fluid cooler inside the radiator TRANSMISSION AND TRANSFER CASE 21 3 DESCRIPTION AND OPERATION Continued J9321 407 Fig 1 44 RE Transmission am STIL EXE
92. Y 2 SLIDE HAMMER TOOLS C 3752 WJ 17 Loosen front band adjusting screw until band is completely loose 18 Squeeze front band together and remove band strut Fig 119 19 Remove front band lever Fig 120 20 Remove front band lever shaft plug if neces sary from converter housing 21 Remove front band lever shaft 2 X gt 921421 Fig 119 Removing Installing Front Band Strut 1 BAND LEVER 2 BAND STRUT 3 FRONT BAND Fig 120 Removing Installing Front Band Lever 1 FRONT BAND LEVER WJ DISASSEMBLY AND ASSEMBLY Continued 22 Remove front and rear clutch units as assem bly Grasp input shaft hold clutch units together and remove them from case Fig 121 23 Lift front clutch off rear clutch Fig 122 Set clutch units aside for overhaul 3 J9121 124 Fig 121 Removing Front Rear Clutch Assemblies 1 INPUT SHAFT 2 FRONT CLUTCH 3 REAR CLUTCH TRANSMISSION AND TRANSFER CASE 21 71 J9121 125 Fig 122 Separating Front Rear Clutch Assemblies 1 FRONT CLUTCH 2 REAR CLUTCH 24 Remove intermediate shaft thrust washer from front end of shaft or from rear dutch hub Fig 123 25 Remove output shaft thrust plate from inter mediate shaft hub Fig 124 26 Slide front band off driving shell Fig 125 and remove band from case 27 Remove planetary geartrain as assembly Fig 126 Support
93. adjusting screw changes line pressure approximately 1 2 3 psi 9 kPa Turning the adjusting screw counterdockwise increases pressure while turning the screw dockwise decreases pressure THROTTLE PRESSURE ADJUSTM ENT Insert Gauge Tool C 3763 between the throttle lever cam and the kickdown valve stem Fig 281 Push the gauge tool inward to compress the kick down valve against the spring and bottom the throt tle valve Maintain pressure against kickdown valve spring Turn throttle lever stop screw until the screw head Fig 280 Line Pressure Adjustment 1 WRENCH 2 1 5 16 INCH touches throttle lever tang and the throttle lever cam touches gauge tool NOTE The kickdown valve spring must be fully compressed and the kickdown valve completely bottomed to obtain correct adjustment J9521 109 Fig 281 Throttle Pressure Adjustment 1 HEX WRENCH IN THROTTLE LEVER ADJUSTING SCREW 2 SPECIAL TOOL C 3763 POSITIONED BETWEEN THROTTLE LEVER AND KICKDOWN VALVE SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS 21 123 TRANSMISSION AND TRANSFER CASE WJ SCHEMATICS AND DIAGRAMS Continued 9 14908 NOILONS 3ufiss38d NI FILLOYHL 5 XuVd NI YOLOA1SS NOIL aN 19 LNOH4 NOILVOIH8fYI OL H31H3ANOOD 3anouol 3ATVA 9 dfi M901 831009 HOLIMS
94. aft for assem bly alignment reference Fig 232 Use punch or scriber to mark gear and shaft 401227 J9121 292 Fig 230 Clutch Drum Inner Retaining Ring Removal 1 INNER RETAINING RING 2 DIRECT CLUTCH DRUM 3 ANNULUS GEAR TRANSMISSION AND TRANSFER CASE 21 103 DISASSEMBLY AND ASSEMBLY Continued J9121 293 J9321 448 Fig 231 Clutch Drum Outer Retaining Ring Removal Fig 233 Annulus Gear Snap Ring Removal 1 OUTER RETAINING RING 1 OUTPUT SHAFT 2 ANNULUS GEAR 1 3 SNAP RING J9221 46 Fig 232 Marking Annulus Gear And Output Shaft For Assembly Alignment Fig 234 Annulus Gear Removal 1 OUTPUT SHAFT 1 OUTPUT SHAFT 2 HAMMER 2 ANNULUS GEAR 3 PUNCH GEAR CASE AND PARK LOCK DISASSEM BLY 10 Remove snap ring that secures annulus gear 1 Remove locating ring from gear case on output shaft Fig 233 Use two screwdrivers to 2 Remove park pawl shaft retaining bolt and unseat and work snap ring out of groove as shown remove shaft pawl and spring 11 Remove annulus gear from output shaft Fig 3 Remove reaction plug snap ring and remove 234 Use rawhide or plastic mallet to tap gear off reaction plug shaft 4 Remove output shaft seal 21 104 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued ASSEMBLY GEARTRAIN AND DIRECT CLUTCH ASSEMBLY 1 Soak direc dutch and overdrive dutch discs in Mopar AT
95. ainer on top of spring 2 Install front servo piston assembly spring and rod guide Fig 132 3 Compress front rear servo springs with Valve Spring Compressor C 3422 B and install each servo snap ring Fig 133 Servo J9121 343 Fig 131 Rear Servo Components 1 SERVO PISTON 2 PISTON SPRING 3 SNAP RING 4 RETAINER 5 PISTON SEAL J9121 344 Fig 132 Front Servo Components 1 PISTON SEAL RINGS 2 SERVO PISTON 3 SNAP RING 4 ROD GUIDE 5 SPRING 6 ROD J9121 136 Fig 133 Compressing Front Rear Servo Springs 1 SPRING COMPRESSOR TOOL C 3422 B 2 ROD GUIDE SNAP RING 3RANSMISSION AND TRANSFER CASE 21 75 DISASSEMBLY AND ASSEMBLY Continued 4 Lubricate dutch cam rollers with transmission fluid 5 Install rear band in case Fig 134 Be sure twin lugs on band are seated against reaction pin Fig 135 Installing Low Reverse Drum 1 REAR BAND 2 LOW REVERSE DRUM J9121 348 Fig 134 Rear Band Installation 1 REAR BAND 6 Install low reverse drum and check overrun ning dutch operation as follows a Lubricate overrunning dutch race on drum hub with transmission fluid b Guide drum through rear band Tilt drum slightly and start race on drum hub into overrunning dutch rollers d Press drum rearward and turn it in dock wise direction until drum seats in overrunning du
96. anged a Attach Adapter 8266 7 to Handle 8266 8 b Attach dial indicator C 3339 to Handle 8266 8 c Install the assembled tool onto the input shaft of the transmission and tighten the retaining screw on Adapter 8266 7 to secure it to the input shaft d Position the dial indicator plunger against a flat spot on the oil pump and zero the dial indica tor e Move input shaft in and out and record read ing End play should be 0 56 2 31 mm 0 022 0 091 in 80 07005 Fig 150 Checking Input Shaft End Play 1 TOOL 8266 B 2 TOOL 8266 6 3 TOOL C 3339 21 80 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 30 Install accumulator piston and inner and outer springs Fig 151 31 Verify that valve body solenoid harness is secured in 3 4 accumulator housing cover plate 0 0 O C 93 y J9321 384 Fig 151 Accumulator Piston And Springs 1 GOVERNOR PRESSURE SENSOR 2 GOVERNOR PRESSURE SOLENOID 3 VALVE BODY 4 PARK ROD 5 ACCUMULATOR PISTON WJ 35 Install seal park neutral position switch Fig 152 Then install and tighten switch to 34 N m 25 ft Ibs J9121 106 Fig 152 Park Neutral Position Switch Seal Position 1 NEUTRAL SWITCH 2 SWITCH SEAL 32 Install valve body as follows a Align and carefully insert park rod into pawl Rod will make click noise as it enters pawl Move rod slightly
97. ansmission Control Cables at Transmission 1 TRANSMISSION SHIFTER CABLE 2 THROTTLE VALVE CABLE 3 TRANSFER CASE SHIFTER CABLE 4 TRANSFER CASE SHIFTER CABLE BRACKET RETAINING BOLT 1 OF 2 5 THROTTLE VALVE CABLE BRACKET RETAINING BOLT 6 ELECTRICAL CONNECTORS 7 TRANSMISSION FLUID LINES TRANSMISSION AND TRANSFER CASE 21 121 80b1712d Fig 277 Front Band Adjustment Screw Location 1 LOCK NUT 2 FRONT BAND ADJUSTER 3 Tighten the band adjusting screw to 8 N m 72 in Ibs torque with Inch Pound Torque Wrench C 3380 A a 3 in extension and 5 16 socket CAUTION If Adapter C 3705 is needed to reach the adjusting screw Fig 278 tighten the screw to only 5 N m 47 50 in Ibs torque 44RE TRANSMISSION e Back off front band adjusting screw 1 7 8 turns e Hold the center adjusting screw in position and torque the locknut to 41 N m 30 ft Ibs torque 4 Lower vehicle REAR BAND ADJUSTMENT The transmission oil pan must be removed for access to the rear band adjusting screw 1 Raise vehide 2 Remove transmission oil pan and drain fluid 3 Loosen band adjusting screw locknut 5 6 turns Fig 279 Be sure adjusting screw turns freely in lever 4 Tighten adjusting screw to 8 N m 72 in 165 torque J9121 233 Fig 278 Band Adjustment Adapter Tool 1 INCH POUND TORQUE WRENCH 2 5 16 SOCKET 3 ADAPTER C 3705 TIGHTEN ADJUSTING SCREW TO ONLY 5 N m 50 IN LBS IF
98. ansmission fluid temperatures The torque converter hub drives the transmission oil fluid pump The torque converter is a sealed welded unit that is not repairable and is serviced as an assembly CAUTION The torque converter must be replaced if a transmission failure results in large amounts of metal or fiber contamination in the fluid TRANSMISSION GEAR RATIOS Gear ratios are 1st 2 74 1 2nd 1 54 1 3rd 1 00 1 4th 0 69 1 Rev 2 21 GEARSHIFT MECHANISM The shift mechanism is cable operated and pro vides six shift positions The shift positions are e Park P Reverse R Neutral N Drive D Manual Second 2 e Manual Low 1 Manual low 1 range provides first gear only Overrun braking is also provided in this range Man ual second 2 range provides first and second gear only Drive range provides first second third and overdrive fourth gear ranges The shift into overdrive fourth gear range occurs only after the transmission has completed the shift into D third gear range No further movement of the shift mechanism is required to complete the 3 4 shift ELECTRONIC GOVERNOR Governor pressure is controlled electronically Com ponents used for governor pressure control include e Governor body Valve body transfer plate Governor pressure solenoid valve Governor pressure sensor Fluid temperature thermistor Throttle position sensor TPS Transmission speed sensor Powertrain control module P
99. as before removal Fig 26 Front Driveshaft Retaining Bolts 1 TRANSFER CASE 2 FRONT DRIVESHAFT RETAINING BOLTS 3 REFERENCE MARK 28 Install the front driveshaft Torque the bolts to 32 N m 24 ft Ibs Fig 26 Be certain to install the driveshaft in the same position as before removal 29 Install the 2 lower fan shroud retaining bolts Torque the bolts to 15 N m 132 in 165 30 Lower the vehide on the hoist 31 Install the transmission dipstick tube in the transmission housing 32 Install the transmission dipstick tube support bracket retaining nut Fig 27 Torque the nut to 25 N m 221 in Ibs 33 Install the 2 upper fan shroud retaining bolts Torque the bolts to 15 N m 132 in 165 34 Connect the negative battery cable WJ REMOVAL AND INSTALLATION Continued x amp Fa 25 C S SS nes s S 80bc4e7c Fig 27 Transmission Dipstick Tube Support Bracket Position amp Orientation 1 TRANSMISSION DIPSTICK TUBE 2 TURBOCHARGER EXHAUST MANIFOLD HEATSHIELD 3 TRANSMISSION DIPSTICK TUBE SUPPORT BRACKET RETAINING NUT TORQUE CONVERTER REMOVAL 1 Remove transmission and torque converter from vehicle 2 Place a suitable drain pan under the converter housing end of the transmission CAUTION Verify that transmission is secure on the lifting device or work surface the center of gravity of the transmissi
100. ay from or directly to the 3 4 valves The limit valve determines maximum speed at which a 3 2 part throttle kickdown can be made On transmissions without a limit valve maximum speed for a 3 2 kickdown is at detent position The 2 3 shuttle valve has two functions The first is fast front band release and smooth engagement during lift foot 2 3 upshifts The second is to regulate front clutch and band application during 3 2 down shifts 21 8 TRANSMISSION AND TRANSFER CASE DESCRIPTION AND OPERATION Continued The 3 4 timing valve is moved by line pressure coming through the 3 4 shift valve The timing valve holds the 2 3 shift valve in an upshift position The purpose is to prevent the 2 3 valve from up or down shifting before the 3 4 valve The 3 4 accumulator is mounted on the overdrive housing and performs the same function as the 2 3 accumulator it is used to smooth engagement during a 3 4 shift The switch valve directs fluid apply pressure to the converter clutch in one position and releases it in the opposite position It also directs oil to the cooling and lube circuits The switch valve regulates oil pressure to the torque converter by limiting maximum pressure to 130 psi OVERDRIVE OFF SWITCH The overdrive OFF control switch is located in the instrument panel The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function At key on overdrive operation is all
101. ble is routed correctly free of binding sharp edges and hot exhaust sys tem components 11 Lower the vehicle from the hoist 12 Verify the transmission and shifter are in the PARK position 13 Torque the adjustment screw to 7 N m 65 in 106 Fig 36 14 Verify correct shifter operation 15 Install the shift lever bezel and any console parts removed to access the shift control cable FLOOR SHIFTER REM OVAL 1 Shift the transmission into the PARK posi tion 80bc4e93 Fig 37 Shift Cable at Transmission TRANSMISSION SHIFTER CABLE THROTTLE VALVE CABLE TRANSFER CASE SHIFTER CABLE TRANSFER CASE SHIFTER CABLE BRACKET RETAINING BOLT 1 OF 2 THROTTLE VALVE CABLE BRACKET RETAINING BOLT ELECTRICAL CONNECTORS TRANSMISSION FLUID LINES Q 11 2 Remove the shift lever bezel and any necessary console parts for access to the shift lever assembly and shift cables 3 Disconnect the shift cable from the shifter and support bracket assembly Fig 38 80ba79cb Fig 38 Shift Cable at Shifter 1 SHIFT LEVER PIN 2 ADJUSTMENT SCREW 3 SHIFT CABLE 4 SHIFTER ASSEMBLY BRACKET WJ REMOVAL AND INSTALLATION Continued 4 Disconnect the brake transmission shift inter lock cable from the shifter BTSI lever and the shifter bracket assembly 5 Disconnect the transfer case shift cable from the transfer case shift lever pin Fig 39
102. ce Loose Leaks Damaged fittings and lines if necessary 2 Fill Tube where tube enters 2 Replace O ring seal Inspect tube for cracks case Leaks Damaged in fill tube 3 Pressure Port Plug Loose 3 Tighten to correct torque Replace plug or Loose Damaged reseal if leak persists 4 Pan Gasket Leaks 4 Tighten pan screws 150 in Ibs If leaks persist replace gasket 5 Valve Body Manual Lever Shaft 5 Replace shaft seal Seal Leaks Worn 6 Rear Bearing Access Plate 6 Replace gasket Tighten screws Leaks 7 Gasket Damaged or Bolts are 7 Replace bolts or gasket or tighten both Loose 8 Adapter Extension Gasket 8 Replace gasket Damaged Leaks Damaged 9 Neutral Switch Leaks Damaged 9 Replace switch and gasket 10 Converter Housing Area 10 Check for leaks at seal caused by worn Leaks seal or burr on converter hub cutting seal worn bushing missing oil return hole in front pump housing or hole plugged Check for leaks past O ring seal on pump or past pump to case bolts pump housing porous oil coming out vent due to overfill or leak past front band shaft access plug 11 Pump Seal Leaks Worn 11 Replace seal Damaged 12 Torque Converter Weld 12 Replace converter Leak Cracked Hub 13 Case Porosity Leaks 13 Replace case 21 26 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION 1 Overdrive Clutch Discs Plates 1 Remove unit and rebuild clutc
103. ceptable level is in crosshatch area b Correct maximum level is to MAX arrow mark c Incorrect level is at or below MIN line d If fluid is low add only enough Mopar ATF Plus 3 to restore correct level Do not overfill CAUTION Do not overfill the transmission Overfill ing may cause leakage out the pump vent which be mistaken for a pump seal leak Overfilling will also cause fluid aeration and foaming as the excess fluid is picked up and churned by the gear train This will significantly reduce fluid life 804948 Fig 11 Dipstick Fluid Level Marks Typical 1 DIPSTICK 2 MAXIMUM CORRECT FLUID LEVEL 3 ACCEPTABLE FLUID LEVEL FLUID AND FILTER REPLACEMENT Refer to the Maintenance Schedules in Group 0 Lubrication and Maintenance for proper service intervals The service fluid fill after a filter change is approximately 3 8 liters 4 0 quarts REM OVAL 1 Hoist and support vehicle on safety stands 2 Place a large diameter shallow drain pan beneath the transmission pan 3 Remove bolts holding front and sides of pan to transmission Fig 12 4 Loosen bolts holding rear of pan to transmis sion 5 Slowly separate front of pan away from trans mission allowing the fluid to drain into drain pan 6 Hold up pan and remove remaining bolt hold ing pan to transmission 7 While holding pan level lower pan away from transmission 8 Pour remaining fluid in pan into drain pa
104. cessary especially if shift problems had developed The transmission cooler and lines should be reverse flushed whenever a malfunction generates sludge and or debris The torque converter should also be replaced at the same time Failure to flush the cooler and lines will result in recontamination Flushing applies to auxiliary cool ers as well The torque converter should also be replaced whenever a failure generates sludge and debris This is necessary because normal converter flushing procedures will not remove all contami nants ELECTRONIC LOCK UP TORQUE CONVERTER The torque converter is a hydraulic device that couples the engine crankshaft to the transmission The torque converter consists of an outer shell with an internal turbine a stator an overrunning clutch an impeller and an electronically applied converter clutch Torque multiplication is created when the sta tor directs the hydraulic flow from the turbine to rotate the impeller in the direction the engine crank shaft is turning The turbine transfers power to the planetary gear sets in the transmission The transfer of power into the impeller assists torque multiplica tion At low vehide speed the overrunning dutch holds the stator stationary during torque multiplica tion and allows the stator to freewheel at high vehi TRANSMISSION AND TRANSFER CASE 21 5 de speed The converter dutch engagement reduces engine speed Clutch engagement also provides reduced tr
105. ction 2 Test TPS and replace as necessary Check with DRB scan tool 3 PCM Malfunction 3 Test PCM with DRB scan tool and replace controller if faulty 4 Overdrive Solenoid Malfunction 4 Replace solenoid 5 Valve Body Malfunction 5 Remove disassemble clean and inspect valve body components Make sure all valves and plugs slide freely in bores Polish valves with crocus cloth if needed WHINE NOISE RELATED 1 Fluid Level Low 1 Add fluid and check for leaks TO ENGINE SPEED 2 Shift Cable Incorrect Routing 2 Check shift cable for correct routing Should not touch engine or bell housing NO 3 4 UPSHIFT 1 O D Switch In OFF Position 1 Turn control switch to ON position 2 Overdrive Circuit Fuse Blown 2 Replace fuse Determine why fuse failed and repair as necessary shorts or grounds in circuit 3 O D Switch Wire Shorted Open 3 Check wires connections with 12V test lamp Cut and voltmeter Repair damaged or loose wire connection as necessary 4 Distance or Coolant Sensor 4 Test both sensors with test lamp or Malfunction volt ohmmeter and replace faulty sensor 5 TPS Malfunction 5 Check with DRB scan tool and replace if necessary 6 Neutral Switch to PCM Wire 6 Test switch as described in service section Shorted Cut and replace if necessary Engine no start 7 PCM Malfunction 7 Check with DRB scan tool and replace if necessary 8 Overdrive Solenoid Shorted 8 Replace solenoid if shor
106. ction plate on clutch hub first Note that one side of reaction plate is counterbored Be sure this side faces rear ward Splines at rear of hub are raised slightly Counterbore in plate fits over raised splines Plate should be flush with this end of hub Fig 248 Install first dutch disc followed by a steel plate until all discs and plates have been installed TRANSMISSION AND TRANSFER CASE 21 107 DISASSEMBLY AND ASSEMBLY Continued _ J9321 396 Fig 246 Direct Clutch Spring Installation 1 SPECIAL TOOL 6227 2 2 DIRECT CLUTCH SPRING 3 CLUTCH HUB 4 PRESS PLATES J9121 329 d Install pressure plate This is last dutch Fig 248 Correct Position Of Direct Clutch Reaction pack item to be installed Be sure plate is Plate installed with shoulder side facing upward REACTION PLATE COUNTERBORE 2 DIRECT CLUTCH REACTION PLATE FLUSH WITH END OF Fig 249 HUB 19 Install dutch hub and clutch pack on direct 3 CLUTCH HUB dutch spring Fig 250 Be sure hub is started on sun gear splines before proceeding J9521 50 Fig 247 44RE Direct Clutch Pack Components 1 CLUTCH DISCS 8 3 CLUTCH PLATES 7 2 PRESSURE PLATE 4 REACTION PLATE 21 108 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 19121 330 Fig 249 Correct Position Of Direct Clutch Pressure Plate 1 DIRECT CLUTCH PRESSURE PLATE 2 CLUTCH PACK 3 BE S
107. de diameter is scored worn or damaged Do not remove the clutch race from the low reverse drum under any circumstances Replace the drum and race as an assembly if either component is damaged Examine the overdrive piston retainer carefully for wear cracks scoring or other damage Be sure the retainer hub is a snug fit in the case and drum Replace the retainer if worn or damaged ACCUMULATOR Inspect the accumulator piston and seal rings Fig 266 Replace the seal rings if worn or cut Replace the piston if chipped or cracked Check condition of the accumulator inner and outer springs Fig 266 Replace the springs if the coils are cracked distorted or collapsed FRONT SERVO Clean the servo piston components with solvent and dry them with compressed air Wipe the band clean with lint free shop towels Replace the front band if distorted lining is burned flaking off or worn to the point where the grooves in the lining material are no longer visible Inspect the servo components Replace the springs if collapsed distorted or broken Replace the guide 4 19121 230 Fig 266 Accumulator Components 1 INNER SPRING 2 ACCUMULATOR PISTON 3 OUTER SPRING 4 SEAL RINGS rod and piston if cracked bent or worn Discard the servo snap ring if distorted or warped Check the servo piston bore for wear If the bore is severely scored or damaged it will be necessary to replace the case Replace any servo com
108. dfl24201 ne ff 3NTVA HOLIMS N33u5S 3ATVA 201 GION310S 16009 105 S 3ATVA IIHS t SATIVA 3TLLOHHI FATWA S 3ATVA TWANVA 6 AAIVA TOHINOO 141 8 2 1 S 3NT1VA L3IHS 2 1 9114 3AT1VA AINO HE 3A1VA 3T1LLOHS 1dIHS 2 Orid 3ATVA Orid 3 T1LLOHHL e Orid HONH3AOD YOLVINAINDOV H E H LNTO LNOH4 HV3H 1 GION310S HONH3JAOD OAH3S HV3H H21fY1O 3AIHQH3AO Ho1vInWnoov OAH3S 21 131 TRANSMISSION AND TRANSFER CASE WJ SCHEMATICS AND DIAGRAMS Continued 28010808 NOLLONS 189 09 5 aunssaud JH31H3ANOO isd 001 0 aunssasd ATLLOYHL isd 09 0 ayunssadd HONHHAOD isd o 1 6 3unssaud 0311997 H LNT H3183ANOO HV39 3AIHG NI DITNVYGAH G33901 9 1 NI H3A31 HOLO3 13S SATIVA 3NT1VA GION310 303901 105 3NT1VA LJIHS 7 6 3KT1VA Tila AJNO H E f v H LNTO 3AIHQU3AO H LNT 1NOtid YOLVINANDOV
109. e RUN position depress the B T 5 cable locking tab located on top of the cable connector Fig 44 at the steering column and pull the B T S I cable straight out 5 Remove the center console from the vehicle Refer to Group 23 Body for the procedure Disconnect the 5 cable from the shifter 5 lever and remove the cable from the shifter bracket Fig 45 7 Disconnect the S 1 cable from any rout ing clips 8 Remove the S cable from the vehicle TRANSMISSION AND TRANSFER CASE 21 41 REMOVAL AND INSTALLATION Continued VAR S 80ba79c2 Fig 45 Brake Transmission Interlock Cable 1 SHIFT MECHANISM 4 STEERING COLUMN ASSEMBLY 2 SHIFTER BTSI LEVER 5 INTERLOCK CABLE 3 ADJUSTMENT CLIP 21 42 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued 80ba79c2 Fig 46 Brake Transmission Shift Interlock 4 STEERING COLUMN ASSEMBLY 5 INTERLOCK CABLE 1 SHIFT MECHANISM 2 SHIFTER BTSI LEVER 3 ADJUSTMENT CLIP INSTALLATION 1 Position the cable in the vehide and secure in the original position with appropriate retaining dips 2 Install the B T S cable on the shifter bracket and connect at the shifter B T S lever Fig 46 3 Install the center console in the vehide Refer to Group 23 Body for the procedure 4 Push the T S cable strai
110. e felt and a soft thump heard as the dutch applies Front Servo Apply Air Test Apply air pressure to the front servo apply pas sage The servo rod should extend and cause the band to tighten around the drum Spring pressure should release the servo when air pressure is removed WJ DIAGNOSIS AND TESTING Continued Rear Servo Air Test Apply air pressure to the rear servo apply passage The servo rod should extend and cause the band to tighten around the drum Spring pressure should release the servo when air pressure is removed CONVERTER HOUSING FLUID LEAK DIAGNOSIS When diagnosing converter housing fluid leaks three items must be established before repair 1 Verify the correct fluid level in the transmis sion 2 Verify that a leak condition actually exists 3 Determined the true source of the leak Some suspected converter housing fluid leaks may not be leaks at all They may only be the result of residual fluid in the converter housing excessive fluid fill or excess fluid spilled during factory fill or fill after repair Converter housing leaks have several potential sources Through careful observation a leak source can be identified before removing the trans mission for repair Pump seal leaks tend to move along the drive hub and onto the rear of the con verter Pump O ring or pump body leaks follow the same path as a seal leak Fig 9 Pump vent or pump attaching bolt leaks are generally deposited on the in
111. e lips of piston and retainer seals with liberal quantity of Mopar Door Ease Then lubricate retainer hub bore and piston with light coat of trans mission fluid 4 Install clutch piston in retainer Fig 177 Use twisting motion to seat piston in bottom of retainer CAUTION Never push the clutch piston straight in This will fold the seals over causing leakage and clutch slip 5 Position spring in clutch piston Fig 178 6 Position spring retainer on top of piston spring Fig 179 Make sure retainer is properly installed Small raised tabs should be facing upward Semicircular lugs on underside of retainer are for positioning retainer in spring J9121 146 Fig 177 Front Clutch Piston Installation 1 CLUTCH PISTON 2 FRONT CLUTCH RETAINER J9321 466 Fig 178 Clutch Piston Spring Installation 1 RETAINER 2 CLUTCH SPRING 3 PISTON 7 Compress piston spring and retainer with Com pressor Tool C 3575 A Fig 176 Then install new snap ring to secure spring retainer and spring 8 Install clutch plates and discs Install steel plate then disc until all plates and discs are installed The front dutch uses 5 dutch discs and plates 9 Install pressure plate and waved snap ring Front dutch dearance should be 1 70 to 3 40 mm 0 067 to 0 134 in If clearance is incorrect dutch discs plates pressure plates and snap ring may have to be changed J9321 224 Fig 179 Correct Spri
112. e transmission oil pan 13 Remove the drainpan 14 Remove the 4 exhaust system support bracket retaining bolts from the transmission sup port crossmember Fig 18 15 Undip the wire harness from the transmis sion support crossmember 16 Position a jack under the transmission sup port crossmember 17 Remove the 8 transmission support cross member retaining bolts Fig 18 e X V MSN 7 2 KO q VM E PV LA 1 7 6 Lf 6 0 80bc4e94 Fig 17 Disconnecting Transfer Case Shift Linkage 1 TRANSFER CASE RETAINING NUTS 2 TRANSFER CASE SHIFTER CABLE 3 TRANSFER CASE VENT HOSE 4 FLAT BLADED TOOL 5 TRANSFER CASE 6 TRANSMISSION ELECTRICAL CONNECTOR WJ REMOVAL AND INSTALLATION Continued 80bc4e67 Fig 18 Transmission Support Crossmember Position amp Orientation 1 TRANSFER CASE 2 TRANSMISSION MOUNT RETAINING BOLTS 2 OF 4 3 EXHAUST SYSTEM SUPPORT BRACKET RETAINING BOLTS 4 CROSSMEMBER RETAINING BOLTS 5 TRANSMISSION 6 CROSSMEMBER RETAINING BOLTS 18 Position a transmission jack under the trans fer case 19 Lower the transmission assembly enough to gain access and remove the transfer case to trans mission retaining nuts 20 Remove the transfer case from the vehicle 21 Remove the jack from the transmission sup port crossmember 22 Remove the 4 transmission mount retai
113. e67 Fig 7 Transmission Support Crossmember Position amp Orientation 1 TRANSFER CASE 2 TRANSMISSION MOUNT RETAINING BOLTS 2 OF 4 3 EXHAUST SYSTEM SUPPORT BRACKET RETAINING BOLTS 4 CROSSMEMBER RETAINING BOLTS 5 TRANSMISSION 6 CROSSMEMBER RETAINING BOLTS 6 Install the front driveshaft Torque the bolts to 32 N m 24 ft Ibs Fig 8 Be certain to install the driveshaft in the same position as before removal 7 Install the 2 lower fan shroud retaining bolts Torque the bolts to 15 N m 132 in Ibs 8 Lower the vehicle on the hoist 9 Install the 2 upper fan shroud retaining bolts Torque the bolts to 15 N m 132 in Ibs 10 Fill the transmission fluid to specification 11 Connect the negative battery cable Fig 8 Front Driveshaft Retaining Bolts 1 TRANSFER CASE 2 FRONT DRIVESHAFT RETAINING BOLTS 3 REFERENCE MARK
114. ed or burned and flaking off Replace the clutch plates if worn heavily scored or cracked Check the lugs on the clutch plates for wear The WJ CLEANING AND INSPECTION Continued plates should slide freely in the drum Replace the plates or drum if binding occurs Check condition of the annulus gear direct clutch hub clutch drum and clutch spring Replace the gear hub and drum if worn or damaged Replace the spring if collapsed distorted or cracked Be sure the splines and lugs on the gear drum and hub are in good condition The clutch plates and discs should slide freely in these components Inspect the thrust bearings and spring plate Replace the plate if worn or scored Replace the bear ings if rough noisy brinnelled or worn Inspect the planetary gear assembly and the sun gear and bushings If either the sun gear or the bushings are damaged replace the gear and bush ings as an assembly The gear and bushings are not serviced separately The planetary carrier and pinions must be in good condition Also be sure the pinion pins are secure and in good condition Replace the carrier if worn or dam aged Inspect the overrunning dutch and race The race surface should be smooth and free of scores Replace the overrunning clutch assembly or the race if either assembly is worn or damaged in any way Inspect the output shaft and governor components Replace the shaft pilot bushing and inner bushing if damaged Replace eit
115. energized by the PCM The PCM energizes the over drive solenoid during the 3 4 upshift This causes the solenoid check ball to dose the vent port allowing line pressure from the 2 3 shift valve to act directly on the 3 4 upshift valve Line pressure on the 3 4 WJ shift valve overcomes valve spring pressure moving the valve to the upshift position This action exposes the feed passages to the 3 4 timing valve 3 4 quick fill valve 3 4 accumulator and ultimately to the overdrive piston Line pressure through the timing valve moves the overdrive piston into contact with the overdrive clutch The direct clutch is disengaged before the overdrive clutch is engaged The boost valve provides increased fluid for lubrication and torque convertor clutch capacity The 3 4 accumulator cushions overdrive clutch engagement to smooth 3 4 upshifts The accumulator is charged at the same time as apply pressure acts against the overdrive pis ton CONVERTER CLUTCH ENGAGEMENT Converter clutch engagement in third or fourth gear range is controlled by sensor inputs to the pow ertrain control module Inputs that determine clutch engagement are coolant temperature engine rpm vehicle speed throttle position and manifold vac uum The torque converter clutch is engaged by the dutch solenoid on the valve body The dutch can be engaged in third and fourth gear ranges depending on overdrive control switch position If the overdrive control switch is in the nor
116. er is moved rear ward If the torque convertor is allowed to lock up pressure can rise to 130 psi 900 kPa Be certain to maintain the correct RPM during testing e Front servo pressure in D range third gear should be within 3 psi 21 kPa of line pressure up to kickdown point Test Four Transmission In Reverse NOTE This test checks pump output pressure reg ulation and the front clutch and rear servo circuits Use 300 psi Test Gauge C 3293 SP for this test 1 Leave vehicle on hoist and leave gauge C3292 in place at accumulator port 2 Move 300 psi Gauge C 3293 SP back to rear servo port 3 Have helper start and run engine at 1600 rpm for test 4 Move transmission shift lever four detents rearward from full forward position This is Reverse range 5 Move transmission throttle lever fully forward then fully rearward and note reading at Gauge C 3293 SP 6 Pressure should be 145 175 psi 1000 1207 kPa with throttle lever forward and increase to 230 280 psi 1586 1931 kPa as lever is gradually moved rearward TRANSMISSION AND TRANSFER CASE 21 13 Test Five Governor Pressure NOTE This test checks governor operation by measuring governor pressure response to changes in vehicle speed It is usually not necessary to check governor operation unless shift speeds are incorrect or if the transmission will not downshift The test should be performed on the road or on a hoist that will allow the rear wheels t
117. et 7 Remove fluid filter from valve body 8 Remove bolts attaching valve body to transmis sion case 9 Lower valve body enough to remove accumula tor piston and springs 10 Work manual lever shaft and electrical con nector out of transmission case 11 Lower valve body rotate valve body away from case pull park rod out of sprag and remove valve body Fig 54 INSTALLATION 1 Check condition of O ring seals on valve body harness connector Fig 55 Replace seals on connec tor body if cut or worn 2 Check condition of manual lever shaft seal in transmission case Replace seal if lip is cut or worn Install new seal with 15 16 deep well socket Fig 56 2 Ta WJ REMOVAL AND INSTALLATION Continued J9321 387 Fig 53 Transmission Case Connector 1 SOLENOID CASE CONNECTOR 2 PARK NEUTRAL POSITION SWITCH CONNECTOR TERMINAL 49321 388 Fig 54 Valve Body 1 VALVE BODY 2 WIRE HARNESS 3 GOVERNOR PRESSURE SOLENOID 4 PARK ROD 5 GOVERNOR PRESSURE SENSOR 3 Check condition of seals on accumulator piston Fig 57 Install new piston seals if necessary 4 Place valve body manual lever in low 1 posi tion so ball on park lock rod will be easier to install in sprag 5 Lubricate shaft of manual lever with petroleum jelly This will ease inserting shaft through seal in case 6 Lubricate seal rings on valve body harness con nector with petroleum jelly
118. etting may be too long 3 Mount and Driveline Bolts 3 Check engine mount transmission mount propeller shaft rear spring to body bolts rear control arms crossmember and axle bolt torque Tighten loose bolts and replace missing bolts 4 U Joint Worn Broken 4 Remove propeller shaft and replace U Joint 5 Axle Backlash Incorrect 5 Check per Service Manual Correct as needed 6 Hydraulic Pressure Incorrect 6 Check pressure Remove overhaul or adjust valve body as needed 7 Band Misadjusted 7 Adjust rear band 8 Valve Body Check Balls 8 Inspect valve body for proper check ball Missing installation 9 Axle Pinion Flange Loose 9 Replace nut and check pinion threads before installing new nut Replace pinion gear if threads are damaged 10 Clutch band or planetary 10 Remove disassemble and repair component damaged transmission as necessary 11 Converter Clutch Faulty 11 Replace converter and flush cooler and line before installing new converter 3RANSMISSION AND TRANSFER CASE 21 17 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION DELAYED ENGAGEMENT 1 Fluid Level Low 1 Correct level and check for leaks FROM NEUTRAL TO 2 Filter 2 Filter Clogged 2 2 Change filter filter 3 EE ee Linkage Misadjusted 3 linkage and repair linkage if worn or damaged 4 Torque Converter Drain Back 4 If
119. fer plate Fig 97 4 Install brace plate Fig 97 Tighten brace attaching screws to 4 N m 35 in Ibs torque 5 Install remaining separator plate attaching screws Tighten screws to 4 N m 35 in 165 torque J9321 437 Fig 95 Rear Clutch And Rear Servo Check Ball Locations 1 REAR CLUTCH CHECK BALL 2 REAR SERVO CHECK BALL 3 TRANSFER PLATE 3RANSMISSION AND TRANSFER CASE 21 61 DISASSEMBLY AND ASSEMBLY Continued 6 Install and start all valve body screws by hand except for the screws to hold the boost valve tube brace Save those screws for later installation Then tighten screws evenly to 4 N m 35 in Ibs torque Start at center and work out to sides when tighten ing screws Fig 101 Fig 96 Separator Plate Filler Screen Installation 1 UPPER HOUSING SEPARATOR PLATE 2 FILTER SCREEN J9321 154 Fig 98 Check Ball Locations In Upper Housing 1 SMALL DIAMETER CHECK BALLS 6 2 LARGE DIAMETER CHECK BALL 1 J9321 150 3 2 Fig 97 Brace Plate 1 BRACE 2 TRANSFER PLATE 3 SEPARATOR PLATE UPPER AND LOWER HOUSING 1 Position upper housing so internal passages and check ball seats are facing upward Then install check balls in housing Fig 98 Seven check balls are used The single large check ball is approxi mately 8 7 mm 11 32 in diameter The single small check ball is approximately 4 8 mm 3 16 in in dia
120. ft handle push button is in the out position the igni tion key cylinder should rotate freely from off to lock When the shifter is in any other position the ignition key should not rotate from off to lock 3 Shifting out of park should be possible when the ignition key cylinder is in the off position 4 Shifting out of park should not be possible while applying 25 Ib max handle push button force and ignition key cylinder is in the run or start posi tions unless the foot brake pedal is depressed approximately 1 2 inch 12mm 5 Shifting out of park should not be possible when the ignition key cylinder is in the accessory or lock position 6 Shifting between any gears neutral or park may be done without depressing foot brake with igni tion switch in run or start positions and vehicle sta tionary or in motion 7 The floor shifter lever and gate positions should be in alignment with all transmission detent positions 8 Engine starts must be possible with floor shift lever in park or neutral positions only Engine starts must not be possible in any other gate positions other than park or neutral 9 With floor shift lever handle push button not depressed and lever detent in e PARK POSITION apply forward force on center of handle and remove pressure Engine start must be possible e PARK POSITION apply rearward force on cen ter of handle and remove pressure Engine start must be possible e NEUTRAL POSITION eng
121. ght into the square mounting hole in the steering column until cable snaps in place Fig 47 5 Connect the brake transmission shift interlock B T S I cable solenoid electrical connector Fig 47 6 Install the lower steering column shroud in the vehi de 7 Install the steering column opening cover Refer to Group 8E Instrument Panel Systems for the procedure 8 Verify correct B T S 1 cable operation GOVERNOR SOLENOID AND PRESSURE SENSOR REMOVAL 1 Hoist and support vehicle on safety stands 2 Remove transmission fluid pan and filter 3 Disengage wire connectors from pressure sen sor and solenoid Fig 48 4 Remove screws holding pressure solenoid retainer to governor body 5 Separate solenoid retainer from governor Fig 49 6 Pull solenoid from governor body Fig 50 7 Remove bolts holding governor body to valve body 8 Separate governor body from valve body Fig 51 9 Remove governor body gasket 10 Remove retainer holding pressure sensor to governor body 11 Pull pressure sensor from governor body Fig 52 5 55 AND TRANSFER CASE 21 43 REMOVAL AND INSTALLATION Continued 9 Align pressure solenoid to bore in governor body Fig 50 10 Push solenoid into governor body 11 Place solenoid retainer in position on governor Fig 49 12 Install screws to hold pressure solenoid retainer to governor body
122. h pack or Snap Rings Damaged 2 Overdrive Piston or Planetary 2 Remove and disassemble unit Replace Thrust Bearing Damaged either thrust bearing if damaged NOISY OPERATION IN FOURTH GEAR ONLY 3 Output Shaft Bearings 3 Remove and disassemble unit Replace Scored Damaged either bearing if damaged 4 Planetary Gears Worn Chipped 4 Remove and overhaul overdrive unit 5 Overdrive Unit Overrunning 5 Remove and overhaul overdrive unit Clutch Rollers Worn Scored SERVICE PROCEDURES FLUID LEVEL CHECK Transmission fluid level should be checked monthly under normal operation If the vehide is used for trailer towing or similar heavy load hauling check fluid level and condition weekly Fluid level is checked with the engine running at curb idle speed the transmission in NEUTRAL and the transmission fluid at normal operating temperature FLUID LEVEL CHECK PROCEDURE 1 Transmission fluid must be at normal operat ing temperature for accurate fluid level check Drive vehide if necessary to bring fluid temperature up to normal hot operating temperature of 82 C 180 F 2 Position vehicle on level surface 3 Start and run engine at curb idle speed 4 Apply parking brakes 5 Shift transmission momentarily into all gear ranges Then shift transmission back to Neutral 6 Clean top of filler tube and dipstick to keep dirt from entering tube 7 Remove dipstick Fig 11 and check fluid level as follows a Correct ac
123. hat diagnostic trouble codes have been resolved SHIFT LEVER POSITION Reverse REAR Drive Range H o First Second Third Fourth 2 Range Manual Second 1 Range Manual Low TRANSMISSION CLUTCHES AND BANDS FRONT FRONT REAR OVERRUN OVERDRIVE DIRECT OVERRUN CLUTCH BAND CLUTCH BAND CLUTCH CLUTCH CLUTCH CLUTCH X X TRANSMISSION AND TRANSFER CASE 21 11 Observe engine performance during the road test A poorly tuned engine will not allow accurate analy sis of transmission operation Operate the transmission in all gear ranges Check for shift variations and engine flare which indicates slippage Note if shifts are harsh spongy delayed early or if part throttle downshifts are sensitive Slippage indicated by engine flare usually means dutch band or overrunning dutch problems If the condition is advanced an overhaul will be necessary to restore normal operation A slipping dutch or band can often be determined by comparing which internal units are applied in the various gear ranges The Clutch and Band Applica tion chart provides a basis for analyzing road test results OVERDRIVE CLUTCHES CLUTCH AND BAND APPLICATION CHART ANALYZING ROAD TEST Refer to the Clutch and Band Application chart and note which elements are in use in the various gear ranges Note that the rear dutch is applied in all forward ranges D 2 1 The transmission overrunning dutch is app
124. he driveshaft with mechanics wire 6 Remove the rear driveshaft retaining bolts and remove the driveshaft from the transfer case compan ion flange Support the driveshaft with mechanics wire Fig 3 7 Disconnect the transfer case shift cable from the shifter arm Fig 4 8 Disconnect the vent tube from the transfer case Fig 4 9 Remove the transmission oil pan and drain the transmission fluid Reinstall the transmission oil pan 10 Position a jack under the transmission sup port crossmember and support the transmission and transfer case assembly 11 Remove the 8 transmission support cross member retaining bolts Fig 5 WJ REMOVAL AND INSTALLATION Continued 80 4 91 Fig Rear Driveshaft Supported 1 REAR DRIVESHAFT 80bc4e94 Fig 4 Disconnecting Transfer Case Shift Linkage 1 TRANSFER CASE RETRAINING NUTS 2 TRANSFER CASE SHIFTER CABLE 3 TRANSFER CASE VENT HOSE 4 FLAT BLADED TOOL 5 TRANSFER CASE 6 TRANSMISSION ELECTRICAL CONNECTOR TRANSMISSION AND TRANSFER CASE 21 141 SS c 80bc4e67 Fig 5 Transmission Support Crossmember Position amp Orientation 1 TRANSFER CASE 2 TRANSMISSION MOUNT RETAINING BOLTS 2 OF 4 3 EXHAUST SYSTEM SUPPORT BRACKET RETAINING BOLTS 4 CROSSMEMBER RETAINING BOLTS 5 TRANSMISSION 6 CROSSMEMBER RETAINING BOLT
125. her shaft bearing if rough or noisy Replace the bearing snap rings if distorted or cracked Check the machined surfaces on the output shaft These surfaces should clean and smooth Very minor nicks or scratches can be smoothed with crocus cloth Replace the shaft if worn scored or damaged in any Way Inspect the output shaft bushings The small bush ing is the intermediate shaft pilot bushing The large bushing is the overrunning clutch hub bushing Replace either bushing if scored pitted cracked or worn ADJ USTMENTS BRAKE TRANSMISSION SHIFT INTERLOCK The park interlock cable is part of the brake shift lever interlock system Correct cable adjustment is important to proper interlock operation The gear shift and park interlock cables must both be correctly adjusted in order to shift out of Park Park Interlock Cable Adjustment Procedure 1 Shift the transmission into the Park position 2 Rotate the ignition switch to the LOCK posi tion Be sure ignition key cylinder is in LOCK position Cable will not adjust correctly in any other position TRANSMISSION AND TRANSFER CASE 21 117 3 Remove shift lever bezel and or console assem bl y 4 Pull the cable lock button up to release cable 5 Pull cable rearward Then release cable and press lock button down until it snaps in place BTSI FUNCTION CHECK 1 Verify removal of ignition key allowed in park position only 2 When the shift lever is in park and the shi
126. ig 192 J9121 157 Fig 193 Installing Rear Annulus And Planetary On Output Shaft 1 REAR ANNULUS AND PLANETARY GEAR ASSEMBLY 2 OUTPUT SHAFT 21 94 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued J9121 158 J9121 161 Fig 194 Installing Rear Planetary Front Thrust Washer Fig 196 Installing Driving Shell Front Thrust Plate 1 FRONT TABBED THRUST WASHER On Sun Gear 2 REAR PLANETARY GEAR 1 SPACER 2 SUN GEAR 3 THRUST PLATE 11 Align rear thrust plate on driving shell and install sun gear lock ring Be sure ring is fully seated 1 sun gear ring groove Fig 199 12 Install assembled driving shell and sun gear on output shaft Fig 200 13 Install rear thrust washer on front planetary gear Fig 201 Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated J9121 159 Fig 195 Installing Spacer On Sun Gear 1 SUN GEAR 2 SUN GEAR SPACER 9 Hold sun gear in place and install thrust plate over sun gear at rear of driving shell Fig 197 10 Position wood block on bench and support sun gear on block Fig 198 This makes it easier to align and install sun gear lock ring Keep wood block die as it will also be used for geartrain end play 21 162 Fig 197 Installing Driving Shell Rear Thrust Plate 1 DRIVING SHELL 2 SUN GEAR 3 REAR THRUST PLATE
127. in this group DISASSEMBLY CAUTION Do not clamp any valve body compo nent in a vise This practice can damage the com ponent resulting in unsatisfactory operation after assembly and installation Do not use pliers to remove any of the valves plugs or springs and do not force any of the components out or into place The valves and valve body housings will be dam aged if force is used Tag or mark the valve body springs for reference as they are removed Do not allow them to become intermixed 1 Remove fluid filter 2 Disconnect wires from governor pressure sen sor and solenoid 3 Remove screws attaching governor body and retainer plate to transfer plate 4 Remove retainer plate governor body and gas ket from transfer plate 5 Disconnect wires from governor pressure sen sor if not done previously 6 Remove governor pressure sensor from gover nor body Sensor is retained in body with M shaped spring clip Remove clip with small pointed tool and slide sensor out of body 7 Remove governor pressure solenoid by pulling it straight out of bore in governor body Remove and discard solenoid O rings if worn cut or torn 8 Remove small shoulder bolt that secures sole noid harness case connector to 3 4 accumulator hous ing Fig 65 Retain shoulder bolt Either tape it to harness or thread it back into accumulator housing after connector removal 9 Unhook overdrive converter solenoid harness from 3 4 accumu
128. ine start must be possible e NEUTRAL POSITION ENGINE RUNNING AND BRAKES APPLIED Apply forward force on center of shift handle Transmission should not be able to shift into reverse detent TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT The transmission throttle valve is controlled by a cable attached to the throttle linkage on one end and the transmission throttle valve control lever on the transmission end Fig 271 21 118 TRANSMISSION AND TRANSFER CASE ADJ USTMENTS Continued 80ba79c2 Fig 270 Brake Transmission Shift Interlock Cable 1 SHIFT MECHANISM 2 SHIFTER BTSI LEVER 3 ADJUSTMENT CLIP 4 STEERING COLUMN ASSEMBLY 5 INTERLOCK CABLE A correctly adjusted throttle valve cable will cause the throttle valve control lever on the transmission to move simultaneously with the throttle linkage from the idle position Proper adjustment will allow simul taneous movement without causing the transmission throttle valve lever to either move ahead of or lag behind the throttle linkage bell crank lever Checking Throttle Valve Cable Adjustment 1 Disconnect the negative battery cable 2 Remove the intercooler outlet hose from the engine and position it out of the way 3 Raise the vehide on a hoist and verify that the transmission throttle valve control lever is at the idle position Fig 272 This position can be verified by observing the throttle valve lever tension spring Control leve
129. ith all transmission PARK NEUTRAL and gear detent positions 2 Engine starts must be possible with floor shift lever in PARK or NEUTRAL gate positions only Engine starts must not be possible in any other gear position 3 With floor shift lever handle push button not depressed and lever in a PARK position Apply forward force on cen ter of handle and remove pressure Engine starts must be possible b PARK position Apply rearward force on cen ter of handle and remove pressure Engine starts must be possible c NEUTRAL position N ormal position Engine starts must be possible d NEUTRAL position Engine running and brakes applied apply forward force on center of shift handle Transmission shall not be able to shift from neutral to reverse WJ DIAGNOSIS AND TESTING Continued THROTTLE VALVE CABLE Transmission throttle valve cable adjustment is extremely important to proper operation T his adjust ment positions the throttle valve which controls shift speed quality and part throttle downshift sensitivity If cable setting is too loose early shifts and slip page between shifts may occur If the setting is too tight shifts may be delayed and part throttle down shifts may be very sensitive Refer to the Adjust ments section for the proper adjustment procedure ROAD TESTING Before road testing be sure the fluid level and con trol cable adjustments have been checked and adjusted if necessary Verify t
130. l O ring and gasket Replace oil pump if cracked porous or damaged in any way Be sure to loosen the front band before installing the oil pump damage to the oil pump seal rings may occur if the band is still tightened to the front clutch retainer 6 Loosen kickdown lever pin access plug three turns Apply Loctite 592 or Permatex No 2 to plug threads and tighten plug to 17 N m 150 in 165 torque 7 Adjust front band 8 Lubricate pump seal and converter hub with transmission fluid or petroleum jelly and install con verter 9 Install dust shield 10 Lower vehicle transmission and converter housing 21 16 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING Continued DIAGNOSIS TABLES AND CHARTS RE TRANSMISSION The diagnosis charts provide additional reference when diagnosing a transmission fault The charts pro vide general information on a variety of transmission overdrive unit and converter dutch fault conditions WJ The hydraulic flow charts in the Schematics and Diagrams section of this group outline fluid flow and hydraulic circuitry Circuit operation is provided for neutral third fourth and reverse gear ranges Nor mal working pressures are also supplied for each of the gear ranges DIAGNOSIS CHARTS CONDITION POSSIBLE CAUSES CORRECTION HARSH ENGAGEMENT FROM NEUTRAL TO DRIVE OR REVERSE Loose 1 Fluid Level Low 1 Add Fluid 2 Throttle Linkage Misadjusted 2 Adjust linkage s
131. lace connectors and or harnesses as required 2 POM Malfunction 2 Check PCM operation with DRB scan tool Replace PCM only if faulty 3 TPS Malfunction 3 Check TPS with DRB scan tool at PCM 4 Lockup Solenoid Not Venting 4 Remove valve body and replace solenoid assembly if plugged or shorted 5 Overdrive Solenoid Not Venting 5 Remove valve body and replace solenoid if plugged or shorted 6 Valve Body Valve Sticking 6 Repair stuck 3 4 shift valve or lockup timing valve NO 4 3 DOWNSHIFT 1 Control Switch Open Shorted 1 Test and replace switch if faulty WHEN CONTROL 2 Overdrive Solenoid Connector 2 Test solenoids and replace if seized or SWITCH IS TURNED OFF Shorted shorted 3 PCM Malfunction 3 Test with DRB scan tool Replace PCM if faulty 4 Valve Body Stuck Valves 4 Repair stuck 3 4 lockup or lockup timing valve CLUNK NOISE FROM 1 Transmission Fluid Low 1 Add Fluid DRIVELINE ON CLOSED 2 Throttle Cable Misadjusted 2 Adjust cable THROTTLE 4 3 DOWNSHIFT 3 Overdrive Clutch Select Spacer 3 Replace overdrive piston thrust plate spacer Wrong Spacer 3RANSMISSION AND TRANSFER CASE 21 23 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION 3 4 UPSHIFT OCCURS 1 Overdrive Solenoid Connector 1 Test connector and wiring for loose IMMEDIATELY AFTER 2 3 or Wiring Shorted connections shorts or ground and repair as SHIFT needed 2 TPS Malfun
132. lanetary gear and overrunning clutch splines to rotate out of alignment If this occurs it will be nec essary to remove and disassemble overdrive unit to realign splines 11 Work overdrive unit forward on intermediate shaft until seated against transmission case 12 Install bolts attaching overdrive unit to trans mission unit Tighten bolts in diagonal pattern to 34 N m 25 ft lbs 13 Install speed sensor 14 Connect speed sensor and overdrive wires 15 Align and install propeller shaft OVERDRIVE HOUSING BUSHING REMOVAL 1 Remove overdrive housing yoke seal 2 Insert Remover 6957 into overdrive housing Tighten tool to bushing and remove bushing Fig 61 80a11095 Fig 61 Bushing Removal Typical 1 REMOVER 6957 2 EXTENSION HOUSING BUSHING 21 48 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued INSTALLATION 1 Align bushing oil hole with oil slot in overdrive housing 2 Tap bushing into place with Installer 6951 and Handle C 4171 3 Install new oil seal Installer C 3995 A Fig 62 in housing using Seal Fig 62 Overdrive Housing Seal Installation 1 SPECIAL TOOL C 3995 A OR C 3972 A 2 SPECIAL TOOL C 4471 J9521 58 OUTPUT SHAFT REAR BEARING REM OVAL 1 Remove overdrive unit from the vehide 2 Remove overdrive geartrain from housing 3 Remove snap ring holding output shaft rear bearing into overdrive housing Fig 63
133. lator cover plate Fig 66 10 Turn valve body over and remove screws that attach overdrive converter solenoid assembly to valve body Fig 67 11 Remove solenoid and harness assembly from valve body Fig 68 12 Remove boost valve cover Fig 69 13 Remove boost valve retainer valve spring and boost valve Fig 70 TRANSMISSION AND TRANSFER CASE 21 49 Fig 65 Solenoid Harness Case Connector Shoulder Bolt 1 SOLENOID HARNESS CASE CONNECTOR 2 3 4 ACCUMULATOR HOUSING e ug 4 E AO 9321 458 Fig 66 Unhooking Solenoid Harness From Accumulator Cover Plate 1 OVERDRIVE CONVERTER SOLENOID WIRE HARNESS 2 3 4 ACCUMULATOR COVER PLATE 21 50 TRANSMISSION AND TRANSFER CASE WJ DISASSEMBLY AND ASSEMBLY Continued J9321 467 Fig 69 Boost Valve Cover Location 1 BOOST VALVE HOUSING AND COVER 2 BOOST VALVE TUBE J9521 176 Fig 67 Solenoid Assembly Screws 1 OVERDRIVE CONVERTER CLUTCH SOLENOID ASSEMBLY 2 HARNESS J9321 468 Fig 70 Boost Valve Components 1 SPRING AND VALVE RETAINER 2 COVER SCREWS 3 BOOST VALVE COVER 4 BOOST VALVE PLUG 5 BOOST VALVE 6 BOOST VALVE SPRING 4 14 Secure detent ball and spring with Retainer Tool 6583 Fig 71 J2521 177 15 Remove park rod E clip and separate rod from manual lever Fig 72 Fig 68 Solenoid Assembl
134. lator housing firmly in place and install remaining two attaching screws Be sure springs and clutch valve plug are properly seated Fig 109 Tighten screws to 4 N m 35 Ibs VALVE BODY FINAL 1 Install boost valve valve spring retainer and cover plate Tighten cover plate screws to 4 N m 35 Ibs torque 2 Insert manual lever detent spring in upper housing 3 Position detent ball on end of spring Then hold detent ball and spring in detent housing with Retainer Tool 6583 Fig 110 WJ DISASSEMBLY AND ASSEMBLY Continued Fig 108 Converter Clutch And 3 4 Shift Valve Springs 1 RIGHT SIDE SCREW 2 3 4 ACCUMULATOR 3 3 4 SHIFT VALVE SPRING 4 CONVERTER CLUTCH VALVE SPRING J9321 160 J9521 180 Fig 109 Seating 3 4 Accumulator On Lower Housing 1 ACCUMULATOR BOX 2 CONVERTER CLUTCH VALVE PLUG 4 Install throttle lever in upper housing Then install manual lever over throttle lever and start manual lever into housing 5 Align manual lever with detent ball and man ual valve Hold throttle lever upward Then press down on manual lever until fully seated Remove detent ball retainer tool after lever is seated 6 Then install manual lever seal washer and E dip TRANSMISSION AND TRANSFER CASE 21 67 7 Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm is engaged in manual valve Fig 111 8 P
135. led in sequence shown 12 Install rear clutch thrust washer Fig 141 Use additional petroleum jelly to hold washer in place if necessary WJ DISASSEMBLY AND ASSEMBLY Continued Fig 141 Installing Rear Clutch Thrust Washer 1 REAR CLUTCH RETAINER 2 REAR CLUTCH THRUST WASHER FIBER 13 Align clutch discs in front clutch and install front clutch on rear clutch Fig 142 Rotate front clutch retainer back and forth until completely seated on rear clutch retainer 14 Coat intermediate shaft thrust washer with petroleum jelly Then install washer in rear clutch hub Fig 143 Use enough petroleum jelly to hold washer in place Be sure grooved side of washer faces rearward toward output shaft as shown Also note that washer only fits one way in clutch hub Note thickness of this washer It is a select fit part and is used to control transmission end play 7 2 9121 190 Fig 142 Assembling Front And Rear Clutch Units 1 TURN FRONT CLUTCH BACK amp FORTH UNTIL SEATED 2 REAR CLUTCH ASSEMBLY TRANSMISSION AND TRANSFER CASE 21 77 J9121 214 Fig 143 Installing Intermediate Shaft Thrust Plate 1 INTERMEDIATE SHAFT THRUST WASHER 2 INPUT SHAFT 3 REAR CLUTCH RETAINER HUB 15 Align drive teeth on rear clutch discs with small screwdriver Fig 144 This makes installation on front planetary easier 16 Raise front end of transmission upward as far as possible and suppo
136. lied in first gear D 2 and 1 ranges only The rear band is applied in 1 and R range only Note that the overdrive dutch is applied only in fourth gear and the overdrive direct dutch and over running clutch are applied in all ranges except fourth gear For example If slippage occurs in first gear in D and 2 range but not in 1 range the transmission overrunning dutch is faulty Similarly if slippage occurs in any two forward gears the rear clutch is slipping Applying the same method of analysis note that the front and rear clutches are applied simulta neously only in D range third and fourth gear If the transmission slips in third gear either the front dutch or the rear clutch is slipping If the transmission slips in fourth gear but not in third gear the overdrive clutch is slipping By select ing another gear which does not use these clutches the slipping unit can be determined For example if the transmission also slips in Reverse the front dutch is slipping If the transmission does not slip in Reverse the rear dutch is slipping If slippage occurs during the 3 4 shift or only in fourth gear the overdrive dutch is slipping Simi larly if the direct dutch were to fail the transmis sion would lose both reverse gear and overrun braking in 2 position manual second gear If the transmission will not shift to fourth gear the control switch overdrive solenoid or related wiring may also be the problem cause 21 12
137. lines at the transmission NOTE When flushing transmission cooler and lines ALWAYS reverse flush WJ SERVICE PROCEDURES Continued NOTE The converter drainback valve must be removed and an appropriate replacement hose installed to bridge the space between the transmis sion cooler line and the cooler fitting Failure to remove the drainback valve will prevent reverse flushing the system 5 Connect the BLUE pressure line to the OUT LET From cooler line 6 Connect the CLEAR return line to the INLET To cooler line 7 Turn pump ON for two to three minutes to flush cooler s and lines Monitor pressure readings and clear return lines Pressure readings should sta bilize below 20 psi for vehicles equipped with a sin gle cooler and 30 psi for vehicles equipped with dual coolers If flow is intermittent or exceeds these pres sures replace cooler 8 Turn pump OFF 9 Disconnect CLEAR suction line from reservoir at cover plate Disconnect CLEAR return line at cover plate and place it in a drain pan 10 Turn pump ON for 30 seconds to purge flush ing solution from cooler and lines Turn pump OFF 11 Place CLEAR suction line into a one quart container of Plus type 7176 automatic transmission fluid 12 Turn pump ON until all transmission fluid is removed from the one quart container and lines This purges any residual cleaning solvent from the trans mission cooler and lines Turn pump OF
138. ly The bushing replacement tools are included in Bushing Tool Set C 3887 B Pre sized service bushings are available for replacement purposes Only the sun gear bushings are not serviced Low cost of the sun gear assembly makes it easier to simply replace the gear and bush ings as an assembly Heli Coil inserts can be used to repair damaged stripped or worn threads in aluminum parts These inserts are available from most automotive parts suppliers Stainless steel inserts are recommended The use of crocus cloth is permissible where neces sary providing it is used carefully When used on shafts or valves use extreme care to avoid rounding off sharp edges Sharp edges are vital as they pre vent foreign matter from getting between the valve and valve bore Do not reuse oil seals gaskets seal rings or O rings during overhaul Replace these parts as a matter of course Also do not reuse snap rings or E dips that are bent or distorted Replace these parts as well Lubricate transmission parts with Plus 3 Type 7176 transmission fluid during over haul and assembly Use petroleum jelly Mopar Door Ease or Ru Glyde to prelubricate seals O rings and thrust washers Petroleum jelly can also be used to hold parts in place during reassembly TRANSMISSION CASE CLEANING AND INSPECTION Clean the case in a solvent tank Flush the case bores and fluid passages thoroughly with solvent Dry the case and all fluid pas
139. ly if any valves or bores are damaged 5 Transmission Overrunning 5 Remove and disassemble transmission Clutch Broken Replace overrunning clutch 6 Input Shaft Seal Rings 6 Remove and disassemble transmission Worn Damaged Replace seal rings and any other worn or damaged parts 7 Front Planetary Failed Broken 7 Remove and repair 21 18 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION NO DRIVE OR REVERSE 1 Fluid Level Low 1 Add fluid and check for leaks if drive is VEHICLE WILL NOT restored MOVE 2 Gearshift Linkage Cable 2 Inspect adjust and reassemble linkage as Loose Misadjusted needed Replace worn damaged parts 3 U Joint Axle Transfer Case 3 Perform preliminary inspection procedure for Broken vehicle that will not move Refer to procedure in diagnosis section 4 Filter Plugged 4 Remove and disassemble transmission Repair or replace failed components as needed Replace filter If filter and fluid contained clutch material or metal particles an overhaul may be necessary Perform lube flow test Flush oil Replace cooler as necessary 5 Oil Pump Damaged 5 Perform pressure test to confirm low pressure Replace pump body assembly if necessary 6 Valve Body Malfunctioned 6 Check and inspect valve body Replace valve body as assembly if any valve or bore is damaged Clean and reassemble correctly if all par
140. mal ON position the dutch will engage after the shift to fourth gear and above approximately 72 km h 45 mph If the control switch is in the OFF position the clutch will engage after the shift to third gear at approximately 56 km h 35 mph at light throttle QUICK FILL VALVE The 3 4 quick fill valve provides faster engagement of the overdrive dutch during 3 4 upshifts The valve temporarily bypasses the clutch piston feed orifice at the start of a 3 4 upshift This exposes a larger pas sage into the piston retainer resulting in a much faster dutch fill and apply sequence The quick fill valve does not bypass the regular clutch feed orifice throughout the 3 4 upshift Instead once a predeter mined pressure develops within the clutch the valve doses the bypass Clutch fill is then completed through the regular feed orifice CONVERTER DRAINBACK VALVE DESCRIPTION The drainback valve is located in the transmission cooler outlet pressure line OPERATION The valve prevents fluid from draining from the converter into the cooler and lines when the vehide is shut down for lengthy periods Production valves have a hose nipple at one end while the opposite end WJ DESCRIPTION AND OPERATION Continued is threaded for a flare fitting All valves have arrow or similar mark to indicate direction of flow through the valve BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM The Brake Transmission Shifter Ignition Interlock
141. meter The remaining 6 check balls are approxi mately 6 3 mm 1 4 in in diameter 12921 57 2 Position assembled transfer plate and upper Fig 99 Installing Transfer Plate On Upper Housing housing separator plate on upper housing Fig 99 1 FILTER SCREEN Be sure filter screen is seated in proper housing 2 TRANSFER PLATE SEPARATOR PLATE ASSEMBLY recess 3 UPPER HOUSING 3 Install the ECE check ball into the transfer plate Fig 85 The ECE check ball is approximately 4 8 mm 3 16 in in diameter 4 Position lower housing separator plate on transfer plate Fig 100 5 Install lower housing on assembled transfer plate and upper housing Fig 101 21 62 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued J9321 441 Fig 100 Lower Housing Separator Plate 1 BE SURE TO ALIGN BORES 2 TRANSFER PLATE 3 LOWER HOUSING OVERDRIVE SEPARATOR PLATE 4 J9321 442 Fig 101 Installing Lower Housing On Transfer Plate And Upper Housing 1 VALVE BODY SCREWS 13 2 LOWER HOUSING 3 UPPER HOUSING 4 TRANSFER PLATE UPPER HOUSING VALVE AND PLUG Refer to Fig 102 Fig 103 and Fig 104 to per form the following steps 1 Lubricate valves plugs springs with dean transmission fluid 2 Assemble regulator valve line pressure plug sleeve throttle plug and spring Insert assembly in upper housing and install cover plate Tighten cover plate screws to 4
142. mission 1 TRANSMISSION SHIFTER CABLE 2 THROTTLE VALVE CABLE 3 TRANSFER CASE SHIFTER CABLE 4 TRANSFER CASE SHIFTER CABLE BRACKET RETAINING BOLT 1 OF 2 5 THROTTLE VALVE CABLE BRACKET RETAINING BOLT 6 ELECTRICAL CONNECTORS 7 TRANSMISSION FLUID LINES TRANSMISSION AND TRANSFER CASE 21 119 80bc4e93 Fig 272 Throttle Valve Cable at Transmission 1 TRANSMISSION SHIFTER CABLE 2 THROTTLE VALVE CABLE 3 TRANSFER CASE SHIFTER CABLE 4 TRANSFER CASE SHIFTER CABLE BRACKET RETAINING BOLT 1 OF 2 5 THROTTLE VALVE CABLE BRACKET RETAINING BOLT 6 ELECTRICAL CONNECTORS 7 TRANSMISSION FLUID LINES 3 Disconnect the throttle valve cable end B from the throttle bell crank lever C Carefully slide cable off stud Do not pry or pull cable off 4 Pry the T V cable lock A into the UP position Fig 274 This will unlock the cable and allow for readjustment 5 Apply just enough tension on the T V cable B to remove any slack in the braided cable Pulling to tight will cause the T V lever on the transmis sion to move out of its idle position which will result in an incorrect T V cable adjustment Slide the sheath of the T V cable D back and forth until the centerlines of the T V cable end B and the throttle bell crank lever C are aligned within one millimeter 1mm Fig 274 6 While holding the T V cable in the set position push the T V cable l
143. mplate and trim new gas ket to fit 5 Position new gasket over piston retainer and on transmission case Use petroleum jelly to hold gasket in place if necessary Do not use any type of sealer to secure gasket Use petroleum jelly only 8921 269 Fig 59 Trimming Overdrive Case Gasket 1 GASKET 2 SHARP KNIFE 6 Install selective spacer on intermediate shaft if removed Spacer goes in groove just rearward of shaft rear splines Fig 60 3 J9021 96 Fig 60 Intermediate Shaft Selective Spacer Location 1 SELECTIVE SPACER 2 SPACER GROOVE 3 INTERMEDIATE SHAFT 7 Install thrust bearing in overdrive unit sliding hub Use petroleum jelly to hold bearing in position CAUTION Be sure the shoulder on the inside diam eter of the bearing is facing forward TRANSMISSION AND TRANSFER CASE 21 47 8 Verify that splines in overdrive planetary gear and overrunning dutch hub are aligned with Align ment Tool 6227 2 Overdrive unit cannot be installed if splines are not aligned If splines have rotated out of alignment unit will have to be disassembled to realign splines 9 Carefully slide Alignment Tool 6227 2 out of overdrive planetary gear and overrunning clutch splines 10 Raise overdrive unit and carefully slide it straight onto intermediate shaft Insert park rod into park lock reaction plug at same time Avoid tilting overdrive during installation as this could cause p
144. n 9 Remove screws holding filter to valve body Fig 13 10 Separate filter from valve body and pour fluid in filter into drain pan 11 Dispose of used trans fluid and filter properly WJ SERVICE PROCEDURES Continued 80b170e7 Fig 12 Transmission Pan Typical 1 GASKET 2 3 TRANSMISSION INSPECTION 80b170e8 Fig 13 Transmission Filter Typical 1 TRANSMISSION 2 FILTER Inspect bottom of pan and magnet for excessive amounts of metal A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag If fluid and pan are contaminated with excessive amounts or debris refer to the diagnosis section of this group Check the adjustment of the front and rear bands adjust if necessary TRANSMISSION AND TRANSFER CASE 21 27 CLEANING 1 Using a suitable solvent clean pan and mag net 2 Using a suitable gasket scraper dean gasket material from gasket surface of transmission case and the gasket flange around the pan INSTALLATION 1 Place replacement filter in position on valve body 2 Install screws to hold filter to valve body Fig 13 Tighten screws to 4 N m 35 in 106 torque 3 Place new gasket in position on pan and install pan on transmission 4 Place pan in position on transmission 5 Install screws to hold pan to transmission Fig 12 Tighten bolts to 17
145. n Refer to the Torque Con verter removal and installation procedure in this group for the procedure 5 Install the 10 engine to transmission bell housing retaining bolts Torque the bolts to 102 N m 75 ft Ibs 6 Connect the engine speed sensor Located on the upper right side of the transmission bellhousing 5 55 AND TRANSFER CASE 21 33 REMOVAL AND INSTALLATION Continued NOTE When installing the torque convertor to driveplate retaining bolts the torque convertor can be rotated into position with a flat bladed screw driver through the starter motor access hole Then working through the torque convertor bolt access hole thread a longer than original bolt into the con vertor and pull the convertor up against the drive plate by hand Remove the longer bolt and install the original bolts one by one until all bolts are installed Then go back and torque all bolts to spec ification 7 Rotate the converter so the previously scribed alignment mark is aligned with the mark on the driveplate 80bc4e76 Fig 23 Exhaust System Inlet Pipe Retaining Bolts 1 EXHAUST SYSTEM INLET PIPE RETAINING BOLTS 2 ENGINE OIL PAN Fig 22 Torque Converter Bolt Access Hole 1 TORQUE CONVERTER BOLT ACCESS HOLE 2 ENGINE OIL PAN 3 TOP DEAD CENTER ALIGNMENT TOOL ACCESS HOLE 8 Working through the torque co
146. nd dry the valves and plugs should drop freely into the bores Valve body bores do not change dimensionally with use If the valve body functioned correctly when new it will continue to operate properly after cleaning and inspection It should not be necessary to replace a valve body assembly unless it is damaged in han dling The only serviceable valve body components are listed below The remaining valve body components are serviced only as part of a complete valve body assembly Serviceable parts are e dual solenoid and harness assembly e solenoid gasket e solenoid case connector O rings and shoulder bolt e switch valve and spring pressure adjusting screw and bracket assembly throttle lever manual lever and shaft seal throttle lever shaft seal washer and E clip fluid filter and screws detent ball and spring TRANSMISSION AND TRANSFER CASE 21 113 valve body screws governor pressure solenoid governor pressure sensor and retaining dip park lock rod and E dip TRANSMISSION GENERAL INFORM ATION Inspect the transmission bushings during overhaul Bushing condition is important as worn scored bush ings contribute to low pressures clutch slip and accelerated wear of other components However do not replace bushings as a matter of course Replace bushings only when they are actually worn or scored Use recommended tools to replace bushings The tools are sized and designed to remove install and seat bushings correct
147. ng Retainer Installed Position 1 SMALL TABS ON RETAINER FACE UPWARD REAR CLUTCH DISASSEMBLY 1 Remove fiber thrust washer from forward side of clutch retainer 2 Remove input shaft front rear seal rings 3 Remove selective clutch pack snap ring Fig 180 4 Remove top pressure plate dutch discs steel plates bottom pressure plate and wave snap ring and wave spring Fig 180 5 Remove dutch piston with rotating motion 6 Remove and discard piston seals 7 Remove input shaft snap ring Fig 181 It may be necessary to press the input shaft in slightly to relieve tension on the snap ring 8 Press input shaft out of retainer with shop press and suitable size press tool Use a suitably sized press tool to support the retainer as close to the input shaft as possible WJ DISASSEMBLY AND ASSEMBLY Continued TRANSMISSION AND TRANSFER CASE 21 89 J9121 53 Fig 180 Rear Clutch Components 1 PISTON SPRING 2 REAR CLUTCH PISTON 3 CLUTCH PISTON SEALS 4 OUTPUT SHAFT THRUST WASHER METAL 5 INPUT SHAFT SNAP RING 6 REAR CLUTCH RETAINER 7 INPUT SHAFT 8 REAR CLUTCH THRUST WASHER FIBER 9 SHAFT FRONT SEAL RING TEFLON 10 SHAFT REAR SEAL RING METAL 11 CLUTCH PACK SNAP RING SELECTIVE 12 RETAINER SEAL RING 13 CLUTCH PLATES 3 14 TOP PRESSURE PLATE 15 CLUTCH DISCS 4 16 BOTTOM PRESSURE PLATE 17 WAVE SPRING 21 90 TRANS
148. ng Ring Installation 1 ANNULUS GEAR 2 OUTER SNAP RING 3 CLUTCH DRUM 10 Install overrunning dutch in output shaft Fig 241 Insert snap ring pliers in hub splines Expand pliers to grip hub Then install assembly with counterclockwise twisting motion 11 Install planetary gear in annulus gear Fig 242 Be sure planetary pinions are fully seated in annulus gear before proceeding WJ DISASSEMBLY AND ASSEMBLY Continued J9321 394 Fig 2388 Clutch Drum Inner Retaining Ring Installation 1 ANNULUS GEAR 2 INNER SNAP RING 3 CLUTCH DRUM J9321 370 Fig 239 Rear Bearing And Snap Ring Installation 1 REAR BEARING 2 SNAP RING TRANSMISSION AND TRANSFER CASE 21 105 J9121 314 Fig 241 Overrunning Clutch Installation 1 CLUTCH DRUM 2 OVERRUNNING CLUTCH ASSEMBLY 3 EXPANDING TYPE SNAP RING PLIERS 4 CLUTCH DRUM 5 ANNULUS GEAR 6 h CLUTCH ASSEMBLY SEATED IN OUTPUT J9121 322 Fig 240 Assembling Overrunning Clutch And Hub 1 CLUTCH HUB 2 OVERRUNNING CLUTCH Fig 242 Planetary Gear Installation 1 PLANETARY GEAR 2 ANNULUS GEAR 21 106 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 12 Coat planetary thrust bearing and bearing contact surface of spring plate with generous amount of petroleum jelly This will help hold bearing in place during installation 13 Install planetary thrust bearing
149. ning bolts Fig 18 and remove the transmission support crossmember and mount from the vehicle 23 Remove the transfer case shift cable bracket from the transmission housing Fig 19 24 Disconnect the throttle valve cable at the ball and socket connection by gently pulling straight apart Fig 19 25 Remove the throttle valve cable bracket retaining fasteners and position the cable assembly out of the way Fig 19 26 Remove the spring from the shift lever arm Fig 19 27 Disconnect the shifter cable at the ball and socket connection by gently pulling straight apart Fig 19 28 Remove the shifter cable bracket retaining bolt from the transmission housing Fig 19 TRANSMISSION AND TRANSFER CASE 21 31 80bc4e93 Fig 19 Transmission Control Cables amp Fluid Lines 1 TRANSMISSION SHIFTER CABLE 2 THROTTLE VALVE CABLE 3 TRANSFER CASE SHIFTER CABLE 4 TRANSFER CASE SHIFTER CABLE BRACKET RETAINING BOLT 1 OF 2 5 THROTTLE VALVE CABLE BRACKET RETAINING BOLT 6 ELECTRICAL CONNECTORS 7 TRANSMISSION FLUID LINES 29 Remove the transmission fluid cooler lines from the transmission Fig 19 30 Disconnect all the transmission electrical con nectors and unclip the wire harness from the trans mission housing Fig 19 31 Remove the exhaust system inlet pipe retain ing bolts from the turbocharger down pipe Fig 20 Support the front portion of the exhaust system wi
150. nnector O Ring Seal 1 CONNECTOR O RINGS 2 VALVE BODY HARNESS CONNECTOR 3 HARNESS 21 46 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued Fig 56 Manual Lever Shaft Seal 1 15 16 SOCKET 2 SEAL J9121 230 Fig 57 Accumulator Piston Components 1 INNER SPRING 2 ACCUMULATOR PISTON 3 OUTER SPRING 4 SEAL RINGS OVERDRIVE UNIT REMOVAL 1 Shift transmission into Park 2 Raise vehicle 3 Mark propeller shaft universal joint s and axle pinion yoke for alignment reference at installation 4 Disconnect and remove propeller shaft s 5 Remove transmission oil pan remove gasket drain oil and reinstall pan If overdrive unit had malfunctioned or if fluid is contaminated remove entire transmission If diag nosis indicated overdrive problems only remove just the overdrive unit 7 Support transmission with transmission jack 8 Remove vehicle speed sensor 9 Remove bolts attaching overdrive unit to trans mission Fig 58 WJ CAUTION Support the overdrive unit with a jack before moving it rearward This is necessary to pre vent damaging the intermediate shaft Do not allow the shaft to support the entire weight of the over drive unit 57 Sake a 8 Ne E N 9021 83 Fig 58 Overdrive Unit Bolts 1 OVERDRIVE UNIT 2 ATTACHING BOLTS 7 10 Carefully work overdrive unit off i
151. nsert and seat each end of tube in housings 5 Slide tube brace under tube and into alignment with valve body screw holes Fig 106 6 Install and finger tighten three screws that secure tube brace to valve body housings Fig 106 7 Bend tube brace tabs up and against tube to hold it in position Fig 107 8 Tighten all valve body housing screws to 4 35 in 165 torque after tube and brace are installed Tighten screws in diagonal pattern starting at center and working outward J9521 107 Fig 106 Boost Valve Tube And Brace 1 BOOST VALVE TUBE 2 TUBE BRACE J9321 147 Fig 105 Boost Valve Tube 1 BOOST VALVE TUBE 2 LOWER HOUSING 3 DISENGAGE THIS END OF TUBE FIRST 4 UPPER HOUSING J9521 108 Fig 107 Securing Boost Valve Tube With Brace Tabs 1 BEND TABS UP AGAINST TUBE AS SHOWN 3 4 ACCUMULATOR 1 Position converter clutch valve and 3 4 shift valve springs in housing Fig 108 2 Loosely attach accumulator housing with right side screw Fig 108 Install only one screw at this time as accumulator must be free to pivot upward for ease of installation 3 Install 3 4 shift valve and spring 4 Install converter clutch timing valve and spring 5 Position plug on end of converter clutch valve spring Then compress and hold springs and plug in place with fingers of one hand 6 Swing accumulator housing upward over valve springs and plug 7 Hold accumu
152. ntermediate shaft Do not tilt unit during removal Keep it as level as possible 11 If overdrive unit does not require service immediately insert Alignment Tool 6227 2 in splines of planetary gear and overrunning clutch to prevent splines from rotating out of alignment If misalign ment occurs overdrive unit will have to be disassem bled in order to realign splines 12 Remove and retain overdrive piston thrust bearing Bearing may remain on piston or in clutch hub during removal 13 Position drain pan on workbench 14 Place overdrive unit over drain pan Tilt unit to drain residual fluid from case 15 Examine fluid for clutch material or metal fragments If fluid contains these items overhaul will be necessary 16 If overdrive unit does not require any service leave alignment tool in position Tool will prevent accidental misalignment of planetary gear and over running clutch splines INSTALLATION 1 Be sure overdrive unit Alignment Tool 6227 2 is fully seated before moving unit If tool is not seated and gear splines rotate out of alignment over drive unit will have to be disassembled in order to realign splines WJ REMOVAL AND INSTALLATION Continued 2 If overdrive piston retainer was not removed during service and original case gasket is no longer reusable prepare new gasket by trimming it 3 Cut out old case gasket around piston retainer with razor knife Fig 59 4 Use old gasket as te
153. nverter must also be replaced This will insure that metal partides or sludged oil are not later trans ferred back into the reconditioned or replaced trans mission The only recommended procedure for flushing cool ers and lines is to use Tool 6906 Cooler Flusher WARNING WEAR PROTECTIVE EYEWEAR THAT MEETS THE REQUIREMENTS OF OSHA AND ANSI 287 1 1968 WEAR STANDARD INDUSTRIAL RUB BER GLOVES KEEP LIGHTED CIGARETTES SPARKS FLAMES AND OTHER IGNITION SOURCES AWAY FROM THE AREA TO PREVENT THE IGNITION OF COMBUSTI BLE 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 CON TACT WITH YOUR EYES OR SKIN IF EYE CONTAM INATION 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 6906 1 Remove cover plate filler plug on Tool 6906 Fill reservoir 1 2 to 3 4 full of fresh flushing solution Flushing solvents are petroleum based solutions gen erally used to clean automatic transmission compo nents DO NOT use solvents containing acids water gasoline or any other corrosive liquids 2 Reinstall filler plug on Tool 6906 3 Verify pump power switch is turned OFF Con nec red alligator clip to positive battery post Connect black alligator clip to a good ground 4 Disconnect the cooler
154. nvertor bolt access hole Fig 22 install the 4 torque convertor to driveplate retaining bolts Torque the bolts to 32 N m 24 ft Ibs after all bolts are installed SPINE 9 Install the starter motor in the vehide Refer Fig 24 Transmission Control Cables amp Fluid Lines to Group 8B Starting Systems for the procedure 1 TRANSMISSION SHIFTER CABLE 10 Install the exhaust system inlet pipe and 2 THROTTLE VALVE CABLE retaining bolts Fig 23 Torque the bolts to 41 3 TRANSFER CASE SHIFTER CABLE 30 ft Ibs 4 TRANSFER CASE SHIFTER CABLE BRACKET RETAINING 11 Connect the transmission electrical connectors POLT V OR 2 d dip th h the t mission h 5 THROTTLE VALVE CABLE BRACKET RETAINING BOLT the wire narness tne transmissio ous 6 ELECTRICAL CONNECTORS ing 7 TRANSMISSION FLUID LINES 21 34 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued 12 Install the transmission fluid cooler lines on the transmission Fig 24 Torque the nuts to 18 N m 13 ft Ibs 13 Install the shifter cable bracket and retaining bolt Fig 24 14 Connect the shifter cable Fig 24 15 Install the spring on the shift lever arm Fig 24 16 Install the throttle valve cable bracket and retaining fasteners Fig 24 17 Connect the throttle valve cable Fig 24 18 Install the transfer case shift cable bracket on the transmission housing Fig 24
155. o JAWA dr 4901 GIONS10S SS TUUM T 110 B NOILIV2IHSITI HOLNID LNOtid HOLIMS Shiva 155087 sod EA 7057 C3 AuQESAO L ATLLOYHL YOLVINNINDDY H 3AIHQH3AO ea Prag IMYA H ailfod HL YOLYINANDDV 5 LNOYS o gt ij HONH3AOD IE Le 1 uvau GION310S OAH3S uVdu inued TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS Cont 21 126 HdV39 15414 3AIHG NI MO TH OC TOVHGAH 8PJQE08 ATLLOYHL LHVd 1
156. o 8 72 in lbs torque 22 Verify that solenoid wire harness is properly routed Fig 113 Solenoid harness must be clear of manual lever and park rod and not be pinched between accumulator housing and cover GOVERNOR BODY SENSOR AND SOLENOID 1 Turn valve body assembly over so accumulator side of transfer plate is facing down 2 Install new O rings on governor pressure sole noid and sensor 3 Lubricate solenoid and sensor O rings with dean transmission fluid 4 Install governor pressure sensor in governor body Then secure sensor with M shaped retaining dip 21 68 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued J9521 178 Fig 110 Detent Ball Spring 1 SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING J9121 54 Fig 111 Manual And Throttle Lever Alignment 1 THROTTLE LEVER 2 MANUAL LEVER VALVE ARM 3 MANUAL VALVE 4 KICKDOWN VALVE 5 Install governor pressure solenoid in governor body Push solenoid in until it snaps into place in body 6 Position governor plate 7 Install retainer plate on governor body and around solenoid Be sure solenoid connector is posi tioned in retainer cutout 8 Align screw holes in governor body and trans fer plate Then install and tighten governor body screws to 4 N m 35 in 106 torque 9 Connect harness wires to governor pressure solenoid and governor pressure sensor body gasket on transfer Fig 112 S
157. o function properly The valve must be installed in the pressure line Other wise flow will be blocked and would cause an over heating condition and eventual transmission failure OIL PUMP VOLUME CHECK After the new or repaired transmission has been installed fill to the proper level with Mopar ATF PLUS 3 Type 7176 automatic transmission fluid The volume should be checked using the following procedure 1 Disconnect the cooler outlet line at the rear of the transmission and place a drainpan under the disconnected line CAUTION With the fluid set at the proper level fluid collection should not exceed 1 quart or inter nal damage to the transmission may occur 2 Run the engine at curb idle speed with the shift selector in neutral 3 If fluid flow is intermittent or it takes more than 20 seconds to collect one quart of ATF PLUS 3 disconnect the cooler inlet line at the front of the transmission WJ 4 Refill the transmission to the proper level and recheck pump volume 5 If flow is found to be within acceptable limits replace the cooler Then fill transmission to the proper level using Mopar ATF PLUS 3 Type 7176 automatic transmission fluid 6 If fluid flow is still found to be inadequate check the line pressure using the Transaxle Hydrau lic Pressure Test procedure FLUSHING COOLERS AND TUBES When a transmission failure has contaminated the fluid the oil cooler s must be flushed The torque co
158. o rotate freely 1 Move 100 psi Test Gauge C 3292 to governor pressure port 2 Move transmission shift lever two detents rear ward from full forward position This is D range 3 Have helper start and run engine at curb idle speed Then firmly apply service brakes so wheels will not rotate 4 Note governor pressure e Governor pressure should be no more than 20 6 kPa 3 psi at curb idle speed and wheels not rotat ing e f pressure exceeds 20 6 kPa 3 psi a fault exists in governor pressure control system 5 Release brakes slowly increase engine speed and observe speedometer and pressure test gauge do not exceed 30 mph on speedometer Governor pres sure should increase in proportion to vehicle speed Or approximately 6 89 kPa 1 psi for every 1 mph 6 Governor pressure rise should be smooth and drop back to no more than 20 6 kPa 3 psi after engine returns to curb idle and brakes are applied to prevent wheels from rotating 7 Compare results of pressure test with analysis chart Test Six Transmission In Overdrive Fourth Gear NOTE This test checks line pressure at the over drive clutch in fourth gear range Use 300 psi Test Gauge C 3292 for this test The test should be per formed on the road or on a chassis dyno 1 Remove tachometer it is not needed for this test 2 Move 300 psi Gauge to overdrive dutch pres sure test port Then remove other gauge and reinstall test port plug 3 Lower
159. ock A into the down position Fig 274 This will lock the present T V cable adjustment 7 Reconnect the T V cable B to the throttle bell crank lever C Fig 274 8 Double check cable operation and adjustment Verify the transmission throttle valve lever and the throttle bell crank lever move simultaneously 9 Install the intercooler outlet hose on the engine 10 Connect the negative battery cable GEARSHIFT CABLE Check adjustment by starting the engine in Park and Neutral Gearshift cable adjustment is COR RECT if the engine starts only in the Park and Neu tral 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 Neu tral or if the engine will not start at all the park neutral position switch or transmission range sensor may be faulty Gearshift Adjustment Procedure 1 Shift the transmission into the Park position 2 Remove the shift lever bezel and floor console as necessary for access to the shift cable adjustment screw Fig 275 Located near the shifter assembly 3 Loosen the shift cable adjustment screw Fig 275 4 Raise the vehide on a hoist 5 Unsnap the cable eyelet from the transmission shift lever Fig 276 6 Verify the transmission shift lever is in Park position by moving lever fully rearward Last rear ward detent is Park position Fig 276 21 120 TRANSMISSION AND TRANSFER CASE
160. olenoid Harness Case Connector Shoulder Bolt 1 SOLENOID HARNESS CASE CONNECTOR 2 3 4 ACCUMULATOR HOUSING J e e AO 9321 458 Fig 113 Solenoid Harness Routing 1 OVERDRIVE CONVERTER SOLENOID WIRE HARNESS 2 3 4 ACCUMULATOR COVER PLATE 10 Perform Line Pressure and Throttle Pressure adjustments Refer to adjustment section of this group for proper procedures 11 Install fluid filter and pan 12 Lower vehicle 13 Fill transmission with recommended fluid and road test vehicle to verify repair WJ DISASSEMBLY AND ASSEMBLY Continued TRANSMISSION DISASSEMBLY 1 Clean transmission exterior with steam gun or with solvent Wear eye protection during cleaning operations 2 Place transmission in a vertical position 3 Measure and record input shaft end play read ings 4 Remove shift and throttle levers from valve body manual lever shaft 5 Place transmission in horizontal position 6 Remove transmission oil pan and gasket 7 Remove filter from valve body Fig 114 Keep filter screws separate from other valve body screws Filter screws are longer and should be kept with fil ter _ Fig 114 Oil Filter Removal 1 OIL FILTER 2 VALVE BODY 3 FILTER SCREWS 2 80017126 21 69 TRANSMISSION AND TRANSFER CASE 80517127 Fig 115 Valve Body Bolt Locations 1 VALVE BODY BOLTS 2 VALVE BODY BOLTS 8 Remove pa
161. on Also be sure ring is fully seated 21 Install planetary selective snap ring with snap ring pliers Fig 206 Be sure ring is fully seated 22 Turn planetary geartrain assembly over so driving shell is facing workbench Then support geartrain on wood block positioned under forward end of output shaft This allows geartrain compo nents to move forward for accurate end play check 21 96 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 23 Check planetary geartrain end play with feeler gauge Fig 207 Gauge goes between shoulder on output shaft and end of rear annulus support 24 Geartrain end play should be 0 12 to 1 22 mm 0 005 to 0 048 in If end play is incorrect snap ring 1 or thrust washers may have to be replaced Snap ring is available in three different thicknesses for adjustment purposes n J9121 168 Fig 204 Installing Front Annulus Thrust Washer 1 WASHER FLAT ALIGNS WITH FLAT ON PLANETARY HUB 2 FRONT ANNULUS THRUST WASHER 3 TAB FACES FRONT J9121 167 Fig 202 Installing Front Planetary And Annulus Gears 1 FRONT PLANETARY GEAR 2 FRONT THRUST WASHER 3 FRONT ANNULUS GEAR Fig 205 Installing Front Annulus Snap Ring 1 SNAP RING PLIERS 2 FRONT ANNULUS SNAP RING J9421 179 Fig 203 Positioning Thrust Plate On Front Annulus Support 1 FRONT ANNULUS 2 THRUST PLATE WJ TRANSMISSION AND
162. on will shift when the torque con verter is removed creating an unstable condition The torque converter is a heavy unit Use caution when separating the torque converter from the transmission 3 Pull the torque converter forward until the cen ter hub clears the oil pump seal 4 Separate the torque converter from the trans mission TRANSMISSION AND TRANSFER CASE 21 35 INSTALLATION Check converter hub and drive notches for sharp edges burrs scratches or nicks Polish the hub and notches with 320 400 grit paper or crocus cloth if nec essary The hub must be smooth to avoid damaging the pump seal at installation 1 Lubricate converter hub and oil pump seal lip with transmission fluid 2 Place torque converter in position on transmis sion CAUTION Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission 3 Align torque converter to oil pump seal open ing 4 Insert torque converter hub into oil pump 5 While pushing torque converter inward rotate converter until converter is fully seated in the oil pump gears 6 Check converter seating with a scale and straightedge Fig 28 Surface of converter lugs should be 1 2 in to rear of straightedge when con verter is fully seated 7 necessary temporarily secure converter with C clamp attached to the converter housing 8 Install the transmission in the vehicle 9 Fill the transmission with the
163. oosen and remove the tube by hand only 28 Turn valve body over so lower housing is fac ing upward Fig 84 In this position the two check balls in upper housing will remain in place and not fall out when lower housing and separator plate are removed 29 Remove screws attaching valve body lower housing to upper housing and transfer plate Fig WJ 84 Note position of boost valve tube brace for assembly reference 30 Remove lower housing and overdrive separa tor plate from transfer plate Fig 84 31 Remove the ECE check ball from the transfer plate Fig 85 The ECE check ball is approximately 4 8 mm 3 16 in in diameter 32 Remove transfer plate from upper housing Fig 86 33 Turn transfer plate over so upper housing sep arator plate is facing upward 34 Remove upper housing separator plate from transfer plate Fig 87 Note position of filter in sep arator plate for assembly reference 35 Remove rear clutch and rear servo check balls from transfer plate Note check ball location for assembly reference Fig 88 J9321 147 Fig 83 Boost Valve Tube 1 BOOST VALVE TUBE 2 LOWER HOUSING 3 DISENGAGE THIS END OF TUBE FIRST 4 UPPER HOUSING 80b170f8 Fig 84 Lower Housing 1 LOWER HOUSING 2 OVERDRIVE SEPARATOR PLATE 3 TRANSFER PLATE AND UPPER HOUSING 3RANSMISSION AND TRANSFER CASE 21 55 DISASSEMBLY AND ASSEMBLY Continued
164. osition line pressure adjusting screw in adjusting screw bracket 9 Install spring on end of line pressure regulator valve 10 Install switch valve spring on tang at end of adjusting screw bracket 11 Install manual valve 12 Install throttle valve and spring 13 Install kickdown valve and detent 14 Install pressure regulator valve 15 Install switch valve 16 Position adjusting screw bracket on valve body Align valve springs and press bracket into place Install short upper bracket screws first and long bottom screw last Verify that valve springs and bracket are properly aligned Then tighten all three bracket screws to 4 N m 35 in Ibs torque 17 Lubricate solenoid case connector O rings and shaft of manual lever with light coat of petroleum jelly 18 Obtain new fluid filter for valve body but do not install filter at this time 19 If line pressure and or throttle pressure adjustment screw settings were not disturbed con tinue with overhaul or reassembly However if adjustment screw settings were moved or changed readjust as described in Valve Body Control Pressure Adjustment procedure 20 Attach solenoid case connector to 3 4 accumu lator with shoulder type screw Connector has small locating tang that fits in dimple at top of accumula tor housing Fig 112 Seat tang in dimple before tightening connector screw 21 Install solenoid assembly and gasket Tighten solenoid attaching screws t
165. owed Pressing the switch once causes the overdrive OFF mode to be entered and the over drive OFF switch lamp to be illuminated Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off The overdrive OFF mode defaults to ON after the ignition switch is cyded OFF and ON The normal position for the control switch is the ON posi tion The switch must be in this position to energize the solenoid and allow a 3 4 upshift The control switch indicator light illuminates only when the over drive switch is turned to the OFF position or when illuminated by the transmission control module 3 4 SHIFT SEQUENCE The overdrive dutch is applied in fourth gear only The direct dutch is applied in all ranges except fourth gear Fourth gear overdrive range is electron ically controlled and hydraulically activated Various sensor inputs are supplied to the powertrain control module to operate the overdrive solenoid on the valve body The solenoid contains a check ball that opens and doses a vent port in the 3 4 shift valve feed pas sage The overdrive solenoid and check ball are not energized in first second third or reverse gear The vent port remains open diverting line pressure from the 2 3 shift valve away from the 3 4 shift valve The overdrive control switch must be in the ON position to transmit overdrive status to the PCM A 3 4 upshift occurs only when the overdrive solenoid is
166. pin Fig 42 6 Install the brake transmission interlock cable into the shifter assembly bracket and connect on the BTSI lever 7 Install the shift cable on the shifter bracket and snap in place Fig 43 80ba79cb Fig 43 Transmission Shift Cable at Shifter 1 SHIFT LEVER PIN 2 ADJUSTMENT SCREW 3 SHIFT CABLE 4 SHIFTER ASSEMBLY BRACKET 8 With the shifter in the PARK position loosen the shift cable adjustment screw 9 Snap the shift cable on the shift lever pin Fig 43 10 Torque the adjustment screw to 7 N m 65 in Ibs 11 Verify correct shifter operation 12 Install the shift lever bezel and any console parts removed for access to the shift lever assembly and shift cables BRAKE TRANSMISSION SHIFT INTERLOCK CABLE REM OVAL 1 Remove the steering column opening cover Refer to Group 8E Instrument Panel Systems for the procedure 2 Remove the lower steering column shroud from the vehicle 3 Disconnect the brake transmission shift inter lock B T S I cable solenoid electrical connector Fig 44 80b6b3a0 Fig 44 B T S Solenoid Connector Location 1 LEFT MULTIFUNCTION SWITCH CONNECTOR 2 LOWER CLOCKSPRING CONNECTORS 3 RIGHT MULTIFUNCTION SWITCH CONNECTOR 4 SHIFTER INTERLOCK CABLE CONNECTOR 5 SHIFTER INTERLOCK SOLENOID CONNECTOR 6 IGNITION SWITCH CONNECTOR RECEPTACLES 7 SKIM CONNECTOR 4 With the ignition switch in th
167. ponent if doubt exists about condition Do not reuse suspect parts REAR SERVO Remove and discard the servo piston seal ring Fig 267 Then dean the servo components with solvent and dry with compressed air Replace either spring if collapsed distorted or broken Replace the plug and piston if cracked bent or worn Discard the servo snap rings and use a new ones at assembly 0 9 5 J9121 64 Fig 267 Rear Servo Components SNAP RING PISTON SEAL PISTON PLUG SPRING RETAINER SNAP RING PISTON SPRING CUSHION SPRING PISTON GQ WJ CLEANING AND INSPECTION Continued OIL PUMP AND REACTION SHAFT SUPPORT 1 Clean pump and support components with sol vent and dry them with compressed air 2 Check condition of the seal rings and thrust washer on the reaction shaft support The seal rings do not need to be replaced unless cracked broken or severely worn 3 Inspect the pump and support components Replace the pump or support if the seal ring grooves or machined surfaces are worn scored pitted or damaged Replace the pump gears if pitted worn chipped or damaged 4 Inspect the pump bushing Then check the reaction shaft support bushing Replace either bush ing only if heavily worn scored or damaged It is not necessary to replace the bushings unless they are actually damaged 5 Install the gears in the pump body and mea sure pump component clearances as follows
168. port is at the left rear of the case Test One Transmission In Manual Low NOTE This test checks pump output pressure reg ulation and condition of the rear clutch and servo circuit Both test gauges are required for this test 1 Connect tachometer to engine Position tachom eter so it can be observed from driver seat if helper will be operating engine Raise vehicle on hoist that will allow rear wheels to rotate freely 2 Connect 100 psi Gauge C 3292 to accumulator port Then connect 300 psi Gauge C 3293 SP to rear servo port 3 Disconnect throttle and gearshift cables from levers on transmission valve body manual shaft 4 Have helper start and run engine at 1000 rpm 5 Move transmission shift lever fully forward into 1 range 6 Gradually move transmission throttle lever from full forward to full rearward position and note pressures on both gauges D e CLL Sy 80b170e6 Fig 7 Pressure Test Port Locations 1 OVERDRIVE CLUTCH TEST PORT 2 GOVERNOR TEST PORT 3 ACCUMULATOR TEST PORT 4 FRONT SERVO TEST PORT 5 REAR SERVO TEST PORT e Line pressure at accumulator port should be 54 60 psi 372 414 kPa with throttle lever forward and gradually increase to 90 96 psi 621 662 kPa as throttle lever is moved rearward e Rear servo pressure should be same as line pres sure within 3 psi 20 68 kPa Test Two Transmission In 2 Range N
169. properly equipped Such vehides should have an auxiliary transmission fluid cooler a heavy duty cooling sys tem and the engine axle ratio combination needed to handle heavy loads FLUID CONTAMINATION Transmission fluid contamination is generally a result of WJ DESCRIPTION AND OPERATION Continued e adding incorrect fluid e failure to clean dipstick and fill tube when checking level e engine coolant entering the fluid e internal failure that generates debris e overheat that generates sludge fluid break down e failure to reverse flush cooler and lines after repair e failure to replace contaminated converter after repair The use of non recommended fluids can result in transmission failure The usual results are erratic shifts slippage abnormal wear and eventual failure due to fluid breakdown and sludge formation Avoid this condition by using recommended fluids only The dipstick cap and fill tube should be wiped clean before checking fluid level Dirt grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand Take the time to wipe the cap and tube clean before withdraw ing the dipstick Engine coolant in the transmission fluid is gener ally caused by a cooler malfunction The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part If coolant has circulated through the transmission for some time an overhaul may also be ne
170. put shaft speed sensor crankshaft position sensor vehicle speed sensor throttle position sensor and battery temperature sen Sor GOVERNOR PRESSURE CURVES There are four governor pressure curves pro grammed into the transmission control module The different curves allow the control module to adjust governor pressure for varying conditions One curve is used for operation when fluid temperature is at or below 1 C 30 F A second curve is used when fluid temperature is at or above 10 C 50 F during nor mal city or highway driving A third curve is used during wide open throttle operation The fourth curve is used when driving with the transfer case in low range SHIFT VALVE OPERATION The shift valves are moved by a combination of throttle and governor pressure The governor pres sure is generated by electrical components The conditions under which a shift to fourth will not occur are Overdrive switch is Off TRANSMISSION AND TRANSFER CASE 21 7 e Transmission fluid temperature is below 10 C 50 F or above 121 C 250 F e Shift to third not yet completed Vehicle speed too low for 3 4 shift to occur Battery temperature below 5 HYDRAULIC CONTROL SYSTEM The hydraulic control system provides fully auto matic operation The system performs five basic func tions which are pressure supply pressure regulation flow control dutch band application and lubrication PRESSURE REGULATION The pre
171. r should be at its stop in the direction being pulled by the tension spring 4 Lower the vehicle on the hoist 5 Disconnect the throttle valve cable end B from the throttle bell crank lever C Carefully slide cable off stud Do not pry or pull cable off 6 Compare the position of cable end B to throt tle bell crank lever C Fig 273 e T V cable end B and throttle bell crank lever C should be aligned or centered on one another to within 1 mm 0 039 in in either direction Fig 273 e If cable end and attachment stud are mis aligned the cable will have to be adjusted as described in Throttle Valve Cable Adjustment proce dure 7 Reconnect the cable end B on the throttle bell crank lever Then with aid of a helper observe movement of transmission throttle lever and lever on throttle linkage e If the transmission throttle valve lever moves ahead of or lags behind the throttle lever cable adjustment will be necessary Or if the throttle lever prevents the transmission lever from returning to closed position cable adjustment will be necessary 8 Install the intercooler outlet hose on the engine 9 Connect the negative battery cable Throttle Valve Cable Adjustment Procedure 1 Disconnect the negative battery cable 2 Remove the intercooler outlet hose from the engine and position it out of the way WJ ADJ USTMENTS Continued 80bc4e93 Fig 271 Throttle Valve Cable at Trans
172. ransmission fluid level CAUTION Do not overfill transmission fluid leaks foaming and shifting problems can result 21 28 TRANSMISSION AND TRANSFER CASE SERVICE PROCEDURES Continued 9 Add fluid to bring level up to MAX arrow mark When fluid level is correct shut engine off release park brake remove funnel and install dipstick in fill tube CONVERTER DRAINBACK CHECK VALVE SERVICE The converter drainback check valve is located in the cooler outlet pressure line near the radiator tank The valve prevents fluid drainback when the vehicle is parked for lengthy periods The valve check ball is spring loaded and has an opening pressure of approximately 2 psi The valve is serviced as an assembly it is not repairable Do not clean the valve if restricted or contaminated by sludge or debris If the valve fails or if a transmission malfunction occurs that gener ates significant amounts of sludge and or clutch par ticles and metal shavings the valve must be replaced The valve must be removed whenever the cooler and lines are reverse flushed The valve can be flow tested when necessary The procedure is exactly the same as for flow testing a cooler If the valve is restricted installed backwards or in the wrong line it will cause an overheating condition and possible transmission failure CAUTION The drainback valve is a one way flow device It must be properly oriented in terms of flow direction for the cooler t
173. reak if overspread or twisted If new rings are being installed spread them only enough for instal lation Also be very sure the ring ends are securely hooked together after installation Otherwise the rings will either prevent pump installation or break during installation J9321 218 Fig 173 Hub Seal Ring Position 1 SEAL RINGS 2 SUPPORT HUB 8 Install reaction shaft support on pump housing Fig 172 9 Align reaction support on pump housing Use alignment marks made at disassembly Or rotate support until bolt holes in support and pump housing are all aligned holes are offset for one way fit Fig 174 Assembling Reaction Shaft Support And Pump Housing 1 PUMP HOUSING 2 REACTION SHAFT SUPPORT WJ DISASSEMBLY AND ASSEMBLY Continued 10 Install all bolts that attach support to pump housing Then tighten bolts finger tight 11 Tighten support to pump bolts to required torque as follows a Reverse pump assembly and install it in transmission case Position pump so bolts are fac ing out and are accessible Secure pump assembly in case with 2 or 3 bolts or with pilot studs c Tighten support to pump bolts to 20 N m 15 ft Ibs d Remove pump assembly from transmission case 12 Install new oil seal in pump with Special Tool 4193 and Tool Handle C 4171 Fig 175 Be sure seal lip faces inward 13 Install new seal ring around pump housing Be sure seal
174. rect clutch hub and spring Fig 226 2 Remove sun gear and spring plate Then remove planetary thrust bearing and planetary gear Fig 227 J9121 311 Fig 226 Direct Clutch Hub And Spring Removal 1 DIRECT CLUTCH SPRING 2 DIRECT CLUTCH HUB 3 Remove overrunning dutch assembly with expanding type snap ring pliers Fig 228 Insert pli ers into dutch hub Expand pliers to grip hub splines and remove clutch with counterclockwise twisting moti on 21 102 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued J9121 312 Fig 227 Removing Sun Gear Thrust Bearing And Planetary Gear 1 PLANETARY GEAR 2 PLANETARY THRUST BEARING 3 CLUTCH SPRING PLATE 4 SPRING PLATE SNAP RING 5 SUN GEAR 4 Remove thrust dutch hub 5 Remove overrunning dutch from hub 6 Mark position of annulus gear and direct dutch drum for assembly alignment reference Fig 229 Use small center punch or scriber to make alignment marks bearing from overrunning 8921 248 Fig 228 Overrunning Clutch Assembly Removal Installation 1 OVERRUNNING CLUTCH 2 NEEDLE BEARING 3 8921 249 Fig 229 Marking Direct Clutch Drum And Annulus Gear For Assembly Alignment 1 DIRECT CLUTCH DRUM 2 HAMMER 3 PUNCH 7 Remove direct clutch drum rear retaining ring Fig 230 8 Remove direct clutch drum outer retaining ring Fig 231 9 Mark annulus gear and output sh
175. rive clutch reaction plate first 5 Install first clutch disc followed by first clutch plate Then install remaining clutch discs and plates in same order 6 Install clutch pack pressure plate J9321 357 Fig 258 Locating Ring Access Cover And Gasket Installation 1 TORX SCREWDRIVER T25 2 ACCESS COVER SCREWS J9321 356 Fig 259 Overdrive Clutch Reaction Ring Installation 1 REACTION RING 2 CLUTCH HUB J9321 355 Fig 260 Overdrive Clutch Wave Spring Installation 1 WAVE SPRING 7 Install dutch pack wiretype retaining ring Fig 261 INTERMEDIATE SHAFT SPACER SELECTION 1 Place overdrive unit in vertical position Mount it on blocks or in workbench with appropriate size mounting hole cut into it Be sure unit is facing upward for access to direct dutch hub Also be sure output shaft is not loaded and internal components are moved rearward for accurate measurement WJ DISASSEMBLY AND ASSEMBLY Continued J9321 352 Fig 261 Overdrive Clutch Pack Retaining Ring Installation 1 OVERDRIVE CLUTCH PACK RETAINING RING 2 Determine correct thickness intermediate shaft spacer as follows a Insert Special Tool 6312 through sun gear planetary gear and into pilot bushing in output shaft Be sure tool bottoms against planetary shoulder b Position Gauge Tool 6311 across face of over drive case Fig 262 Then position Dial Caliper C 4962 over
176. rk neutral position switch 9 Remove hex head bolts attaching valve body to transmission case Fig 115 A total of 10 bolts are used Note different bolt lengths for assembly refer ence 10 Remove valve body assembly Push valve body harness connector out of case Then work park rod and valve body out of case Fig 116 11 Remove accumulator piston and inner and outer springs Fig 117 12 Remove pump oil seal with suitable pry tool or slide hammer mounted screw Fig 116 Valve Body Removal 1 GOVERNOR PRESSURE SENSOR 2 GOVERNOR PRESSURE SOLENOID 3 VALVE BODY 4 PARK ROD 5 ACCUMULATOR PISTON 21 70 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued J9121 208 Fig 117 Accumulator Piston And Springs 1 ACCUMULATOR PISTON 2 OUTER SPRING 3 INNER SPRING 13 Loosen front band adjusting screw locknut 4 5 turns Then tighten band adjusting screw until band is tight around front clutch retainer This prevents front rear dutches from coming out with pump and possibly damaging dutch or pump components 14 Remove oil pump bolts 15 Thread bolts of Slide Hammer Tools C 3752 into threaded holes in pump body flange Fig 118 16 Bump slide hammer weights outward to remove pump and reaction shaft support assembly from case Fig 118 9121 120 Fig 118 Removing Oil Pump And Reaction Shaft Support Assembly 1 OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBL
177. rt case with wood blocks F ront rear dutch and oil pump assemblies are easier to install if transmission is as close to upright position as possible 17 Slide front band into case 18 Install front and rear dutch units as assembly Fig 145 Align rear clutch with front annulus gear and install assembly in driving shell Be sure out put shaft thrust washer and thrust plate are not displaced during installation 19 Carefully work assembled clutches back and forth to engage and seat rear clutch discs on front annulus gear Also be sure front clutch drive lugs are fully engaged in slots of driving shell after installa tion 21 78 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued Fig 144 Aligning Rear Clutch Disc Lugs 1 REAR CLUTCH DISCS 2 USE SMALL SCREWDRIVER TO ALIGN CLUTCH DISC TEETH D J9121 124 Fig 145 Installing Front Rear Clutch Assemblies 1 INPUT SHAFT 2 FRONT CLUTCH 3 REAR CLUTCH 20 Assemble front band strut 21 Install front band adjuster strut and adjust ing screw Fig 146 22 Tighten band adjusting screw until band just grips dutch retainer Verify that front rear dutches are still seated before continuing 23 Check seal rings on reaction shaft support hub Verify that seal rings are hooked together and 9 J9121 197 Fig 146 Front Band Linkage Installation 1 BAND LEVER 2 BAND STRUT 3 FRONT BAND
178. sages with compressed air Be sure all solvent is removed from the case and that all fluid passages are clear 21 114 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION Continued NOTE Do not use shop towels or rags to dry the case or any other transmission component unless they are made from lint free materials Lint will stick to case surfaces and transmission components and circulate throughout the transmission after assem bly A sufficient quantity of lint can block fluid pas sages and interfere with valve body operation Inspect the case for cracks porous spots worn bores or damaged threads Damaged threads can be repaired with Helicoil thread inserts However the case will have to be replaced if it exhibits any type of damage or wear Lubricate the front band adjusting screw threads with petroleum jelly and thread the screw part way into the case Be sure the screw turns freely OVERRUNNING CLUTCH LOW REVERSE DRUM OVERDRIVE PISTON RETAINER Clean the overrunning clutch assembly clutch cam low reverse drum and overdrive piston retainer in solvent Dry them with compressed air after clean ing Inspect condition of each dutch part after cleaning Replace the overrunning dutch roller and spring assembly if any rollers or springs are worn or dam aged or if the roller cage is distorted or damaged Replace the cam if worn cracked or damaged Replace the low reverse drum if the clutch race roller surface or insi
179. side of the converter housing and not on the converter itself Fig 9 Pump seal or gasket leaks usually travel down the inside of the converter hous ing Front band lever pin plug leaks are generally deposited on the housing and not on the converter 6 J9021 35 Fig 9 Converter Housing Leak Paths 1 PUMP SEAL 2 PUMP VENT 3 PUMP BOLT 4 PUMP GASKET 5 CONVERTER HOUSING 6 CONVERTER 7 REAR MAIN SEAL LEAK TRANSMISSION AND TRANSFER CASE 21 15 TORQUE CONVERTER LEAK POINTS Possible sources of converter leaks are 1 Leaks at the weld joint around the outside diameter weld Fig 10 2 Leaks at the converter hub weld Fig 10 RH254 Fig 10 Converter Leak Points Typical 1 OUTSIDE DIAMETER WELD 2 TORQUE CONVERTER HUB WELD 3 STARTER RING GEAR 4 LUG CONVERTER HOUSING AREA LEAK CORRECTION 1 Remove the transmission and torque converter Refer to the procedure in this group 2 Tighten front band adjusting screw until band is tight around front clutch retainer This prevents front rear clutches from coming out when oil pump is removed 3 Remove oil pump and remove pump seal Inspect pump housing drainback and vent holes for obstructions Clear holes with solvent and wire 4 Inspect pump bushing and converter hub If bushing is scored replace it If converter hub is scored either polish it with crocus cloth or replace converter 5 Install new pump sea
180. solenoid relay and wiring for continuity LOCKS UP IN SECOND Shorted Open shorts or grounds Replace solenoid and relay AND OR THIRD GEAR if faulty Repair wiring and connectors as necessary HARSH 1 2 2 8 3 4 OR Lockup Solenoid Malfunction Remove valve body and replace solenoid 3 2 SHIFTS assembly 3RANSMISSION AND TRANSFER CASE 21 25 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION NO START IN PARK OR 1 Gearshift Linkage Cable 1 Adjust linkage cable NEUTRAL Misadjusted 2 Neutral Switch Wire Open Cut 2 Check continuity with test lamp Repair as required 3 Neutral Switch Faulty 3 Refer to service section for test and replacement procedure 4 Neutral Switch Connect Faulty 4 Connectors spread open Repair 5 Valve Body Manual Lever 5 Inspect lever assembly and replace if Assembly Bent Worn Broken damaged NO REVERSE OR SLIPS 1 Direct Clutch Pack front clutch 1 Disassemble unit and rebuild clutch pack IN REVERSE Worn 2 Rear Band Misadjusted 2 Adjust band 3 Front Clutch Malfunctioned 3 Air pressure test clutch operation Remove Burned and rebuild if necessary 4 Overdrive Thrust Bearing 4 Disassemble geartrain and replace Failure bearings 5 Direct Clutch Spring Collapsed 5 Remove and disassemble unit Check clutch Broken position and replace spring OIL LEAKS 1 Fluid Lines and Fittings 1 Tighten fittings If leaks persist repla
181. ssure regulator valve maintains line pres sure The amount of pressure developed is controlled by throttle pressure which is dependent on the degree of throttle opening The regulator valve is located in the valve body The throttle valve determines line pressure and shift speed Governor pressure increases tion to vehicle speed The throttle valve controls upshift and downshift speeds by regulating pressure according to throttle position Shift Valve Flow Control The manual valve is operated by the gearshift linkage and provides the operating range selected by the driver The 1 2 shift valve provides 1 2 or 2 1 shifts and the 2 3 shift valve provides 2 3 or 3 2 shifts The kickdown valve provides forced 3 2 or 3 1 downshifts depending on vehicle speed Downshifts occur when the throttle is opened beyond downshift detent position Detent is reached just before wide open throttle position The 2 3 valve throttle pressure plug provides 3 2 downshifts at varying throttle openings depending on vehicle speed The 1 2 shift control valve transmits 1 2 shift pres sure to the accumulator piston This controls kick down band capacity on 1 2 upshifts and 3 2 downshifts The 3 4 shift quick fill and timing valves plus the 3 4 accumulator are only actuated when the over drive solenoid is energized The solenoid contains a check ball that controls a vent port to the 3 4 valves The check ball either diverts line pressure aw
182. tch Fig 135 e Turn drum back and forth Drum should rotate freely in clockwise direction and lock J9121 351 counterclockwise direction as viewed from front of case Fig 136 Installing Low Reverse Drum Retaining 7 Install snap ring that secures low reverse drum Snap Ring to hub of overdrive piston retainer Fig 136 1 LOW REVERSE DRUM 8 Install rear band lever and pivot pin Fig 137 2 HUB OF OVERDRIVE PISTON RETAINER Align lever with pin bores in case and push pivot pin 3 LOW REVERSE DRUM SNAP RING into place 9 Install planetary geartrain assembly Fig 138 21 76 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 10 Install thrust plate on intermediate shaft hub J9121 352 Fig 137 Rear Band Lever And Pivot Pin Installation 21215 Fig 139 Installing Intermediate Shaft Thrust Plate 1 INTERMEDIATE SHAFT HUB 2 INTERMEDIATE SHAFT THRUST PLATE 2 LEVER PIVOT PIN Fig 140 Input Shaft Seal Ring Location 1 INPUT SHAFT 19121 27177 2 TEFLON SEAL RING 3 METAL SEAL RING Fig 138 Installing Planetary Geartrain 4 REAR CLUTCH RETAINER 1 PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT ASSEMBLY Fig 139 Use petroleum jelly to hold thrust plate in place 11 Check seal ring on rear clutch retainer hub and seal rings on input shaft Fig 140 Also verify that shaft seal rings are instal
183. te is designed to supply transmis sion line pressure to the governor pressure solenoid valve and to return governor pressure The governor pressure solenoid valve is mounted in the governor body The body is bolted to the lower side of the transfer plate Fig 4 The transfer plate channels line pressure to the solenoid valve through the governor body It also channels governor pressure from the solenoid valve to the governor circuit It is the solenoid valve that develops the necessary gover nor pressure 80a0c4fa Fig 4 Governor Pressure Sensor 1 RETAINING CLIP 2 GOVERNOR BODY 3 GOVERNOR PRESSURE SENSOR TRANSMISSION FLUID TEMPERATURE THERMISTOR TRANSMISSION FLUID TEMPERATURE THERMISTOR Transmission fluid temperature readings are sup plied to the transmission control module by the ther mistor The temperature readings are used to control engagement of the fourth gear overdrive clutch the converter clutch and governor pressure Normal resistance value for the thermistor at room tempera ture is approximately 1000 ohms The PCM prevents engagement of the converter dutch and overdrive clutch when fluid temperature is below approximately 10 50 F If fluid temperature exceeds 126 C 260 F the PCM causes a 4 3 downshift and engage the con verter clutch Engagement is according to the third gear converter clutch engagement schedule The overdrive OFF lamp in the instrument panel illuminates when the
184. ted or open and Open repair loose or damaged wires DRB scan tool 9 Solenoid Feed Orifice in Valve 9 Remove disassemble and clean valve Body Blocked body thoroughly Check feed orifice 10 Overdrive Clutch Failed 10 Disassemble overdrive and repair as needed 11 Hydraulic Pressure Low 11 Pressure test transmission to determine cause 12 Valve Body Valve Stuck 12 Repair stuck 3 4 shift valve 3 4 timing valve 13 O D Piston Incorrect Spacer 13 Remove unit check end play and install correct spacer 14 Overdrive Piston Seal Failure 14 Replace both seals 15 O D Check Valve Orifice 15 Check for free movement and secure Failed assembly in piston retainer Check ball bleed orifice 21 24 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION SLIPS IN OVERDRIVE 1 Fluid Level Low 1 Add fluid and check for leaks FOURTH GEAR 2 Overdrive Clutch Pack Worn 2 Remove overdrive unit and rebuild clutch pack 3 Overdrive Piston Retainer 3 Disassemble transmission remove retainer Bleed Orifice Blown Out and replace orifice 4 Overdrive Piston or Seal 4 Remove overdrive unit Replace seals if Malfunction worn Replace piston if damaged If piston retainer is damaged remove and disassemble the transmission 5 3 4 Shift Valve Timing Valve 5 Remove and overhaul valve body Replace Accumulator Malfunction accum
185. th mechanics wire Be certain to position the pipe out of the way of the torque converter bolt access hole Located in the transmission bellhousing 32 Disconnec the engine speed sensor Located on the upper right side of the transmission bellhous ing 33 Remove the starter motor from the vehicle Refer to Group 8B Starting Systems for the proce dure NOTE Mark the position of the torque convertor in relation to the driveplate so they can be reassem bled in there original position 34 Working through the torque convertor bolt access hole Fig 21 remove the 4 torque convertor to driveplate retaining bolts Rotate the engine in a dockwise direction to access the converter bolts 35 Place a jack under the transmission 21 32 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued 80bc4e76 Fig 20 Exhaust System Inlet Pipe Retaining Bolts 1 EXHAUST SYSTEM INLET PIPE RETAINING BOLTS 2 ENGINE OIL PAN o 80bc4e66 Fig 21 Torque Converter Bolt Access Hole 1 TORQUE CONVERTER BOLT ACCESS HOLE 2 ENGINE OIL PAN 3 TOP DEAD CENTER ALIGNMENT TOOL ACCESS HOLE CAUTION Be certain the engine speed sensor has been disconnected before proceeding WJ 36 Remove the 10 engine to transmission bell housing retaining bolts 37 Remove the transmission and torque con verter from the vehicle INSTALLATION CAUT
186. tion Shaft Support Bushing 1 SPECIAL TOOL SP 1191 2 SPECIAL TOOL SP 3633 3 SPECIAL TOOL C 4171 4 SPECIAL TOOL SP 5325 5 REACTION SHAFT 6 SPECIAL TOOL SP 5324 7 BUSHING ASSEMBLY 1 Lubricate gear bore in pump housing with transmission fluid 2 Lubricate pump gears with transmission fluid 3 Support pump housing on wood blocks Fig 171 4 Install outer gear in pump housing Fig 171 Gear can be installed either way it is not a one way fit 21 86 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 5 Install pump inner gear Fig 172 CAUTION The pump inner gear is a one way fit The bore on one side of the gear inside diameter l D is chamfered Be sure the chamfered side faces forward to front of pump J9321 219 Fig 171 Supporting Pump And Installing Outer Gear 1 OUTER GEAR 2 PUMP HOUSING 3 WOOD BLOCKS J9321 465 Fig 172 Pump Inner Gear Installation 1 OUTER GEAR 2 INNER GEAR 6 Install new thrust washer on hub of reaction shaft support Lubricate washer with transmission fluid or petroleum jelly 7 If reaction shaft seal rings are being replaced install new seal rings on support hub Fig 173 Lubricate seal rings with transmission fluid or petro leum jelly after installation Squeeze each ring until ring ends are securely hooked together WJ CAUTION The reaction shaft support seal rings will b
187. ton seals into place Metal tools will cut shave or score the seals 9 Install piston spring in retainer and on top of piston Fig 185 Concave side of spring faces down ward toward piston WJ 10 Install wave spring in retainer Fig 185 Be sure spring is completely seated in retainer groove J9121 538 Fig 182 Rear Clutch Retainer And Input Shaft Seal Ring Installation 1 REAR CLUTCH RETAINER HUB SEAL RING 2 INPUT SHAFT SEAL RINGS J9121 151 Fig 183 Input Shaft Seal Ring Identification 1 BE SURE RING ENDS ARE HOOKED TOGETHER AFTER INSTALLATION 2 METAL REAR SEAL RING 3 TEFLON FRONT SEAL RING SQUEEZE RING TOGETHER SLIGHTLY BEFORE INSTALLATION FOR BETTER FIT WJ DISASSEMBLY AND ASSEMBLY Continued J9121 152 Fig 184 Pressing Input Shaft Into Rear Clutch Retainer 1 INPUT SHAFT 2 REAR CLUTCH RETAINER 3 PRESS RAM J9121 153 Fig 185 Piston Spring Wave Spring Position 1 REAR CLUTCH RETAINER 2 PISTON SPRING 3 WAVE SPRING 4 CLUTCH PISTON TRANSMISSION AND TRANSFER CASE 21 91 11 Install bottom pressure plate Fig 180 Ridged side of plate faces downward toward piston and flat side toward clutch pack 12 Install first clutch disc in retainer on top of bottom pressure plate Then install a clutch plate fol lowed by a clutch disc until entire clutch pack is installed 4 discs and 3 plates are required Fig 180
188. ts are in good condition 7 Transmission Internal 7 Remove and disassemble transmission Component Damaged Repair or replace failed components as needed 8 Park Sprag not Releasing 8 Remove disassemble repair Check Stall Speed Worn Damaged Stuck 9 Torque Converter Damage 9 Inspect and replace as required SHIFTS DELAYED OR 1 Fluid Level Low High 1 Correct fluid level and check for leaks if low ERRATIC SHIFTS ALSO 2 Fluid Filter Clogged 2 Replace filter If filter and fluid contained HARSH AT TIMES clutch material or metal particles an overhaul may be necessary Perform lube flow test 3 Throttle Linkage Misadjusted 3 Adjust linkage as described in service section 4 Throttle Linkage Binding 4 Check cable for binding Check for return to closed throttle at transmission 5 Gearshift Linkage Cable 5 Adjust linkage cable as described in service Misadjusted section 6 Clutch or Servo Failure 6 Remove valve body and air test clutch and band servo operation Disassemble and repair transmission as needed 7 Governor Circuit Electrical 7 Test using DRB scan tool and repair as Fault required 8 Front Band Misadjusted 8 Adjust band 9 Pump Suction Passage Leak 9 Check for excessive foam on dipstick after normal driving Check for loose pump bolts defective gasket Replace pump assembly if needed TRANSMISSION AND TRANSFER CASE 21 19 DIAGNOSIS AND TESTIN
189. uch as the throttle valve shuttle valve plug 1 2 shift valve and 1 2 governor plug are made of coated alumi num Aluminum components are identified by the dark color of the special coating applied to the sur face or by testing with a magnet Do not sand alu minum valves or plugs under circumstances This practice could damage the special coating causing the valves plugs to stick and bind Inspect the valves and plugs for scratches burrs nicks or scores Minor surface scratches on steel valves and plugs can be removed with crocus doth but do not round off the edges of the valve or plug lands Maintaining sharpness of these edges is vitally important The edges prevent foreign matter from lodging between the valves and plugs and the bore Inspect all the valve and plug bores in the valve body Use a penlight to view the bore interiors Replace the valve body if any bores are distorted or scored Inspect all of the valve body springs The springs must be free of distortion warpage or broken coils Check the two separator plates for distortion or damage of any kind Inspect the upper housing lower housing 3 4 accumulator housing and transfer plate carefully Be sure all fluid passages are clean and clear Check condition of the upper housing and transfer plate check balls as well The check balls and ball seats must not be worn or damaged Trial fit each valve and plug in its bore to check freedom of operation When clean a
190. ulator seals Make sure all valves operate freely in bores and do not bind or stick Make sure valve body screws are correctly tightened and separator plates are properly positioned 6 Overdrive Unit Thrust Bearing 6 Disassemble overdrive unit and replace Failure thrust bearing NO 1 thrust bearing is between overdrive piston and clutch hub NO 2 thrust bearing is between the planetary gear and the direct clutch spring plate NO 3 thrust bearing is between overrunning clutch hub and output shaft 7 O D Check Valve Bleed Orifice 7 Check for function secure orifice insert in Failure O D piston retainer DELAYED 3 4 UPSHIFT 1 Fluid Level Low 1 Add fluid and check for leaks SLOW TO ENGAGE 2 Throttle Valve Cable 2 Adjust throttle valve cable Misadjusted 3 Overdrive Clutch Pack 3 Remove unit and rebuild clutch pack Worn Burnt 4 TPS Faulty 4 Test with DRB scan tool and replace TPS 5 Overdrive Clutch Bleed Orifice 5 Disassemble transmission and replace Plugged orifice 6 Overdrive Solenoid or Wiring 6 Test solenoid and check wiring for Shorted Open loose corroded connections or shorts grounds Replace solenoid if faulty and repair wiring if necessary 7 Overdrive Excess Clearance 7 Remove unit Measure end play and select proper spacer 8 O D Check Valve Missing or 8 Check for presence of check valve Repair Stuck or replace as required TORQUE CONVERTER Lockup Solenoid Relay or Wiring Test
191. uor FATWA dn X901 3ATVA 15008 3ATVA HOY Ino3H 105 im 3BATVA LAIHS v us HATVA 211081 3ATVA t E 1 3N1VA IVANY 3ATVA ONIAIL t 3ATVA T1OHINOO l13IHS 2 1 LIIHS 2 1 3NT1VA TOHLNOO LIIHS 0 1 Orid STLLOYHL LAIHS 6 2 _ 3A1VA 21110 i d HHL ond HONH3AOD HOLVINNINDOV 6 AS H LNT LNOtid 1 HOLNTO Hv3dH HOLf119 OAH3S GION310S HONH3AOD uoivinwnoov OAH3S LNOHJ TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS Continued 21 134 08 isd 8 0 ayunssaud 1114 5 isd 9 9 3unssaud Fan u83183ANOO 1 45 0 3unssa3ud HONH3AOSD isd 02 42 TIOHLNOO LAIHS 2 1 isd 6 0 3unssa3ud 31L1OHHL isd 3unssaud 3NI1 uV39 ONISSVd LAIHSNMOG 2 6 31LLOHHL TINA NAXOQX2I4 1103 uvao 5 NI H3A31 HOLO3T3S df1 1201 1 3K1VA HO1010 LNOHS OL 5 df141201 3ATVA HO lV I 93H 10 Audd3AO S 3
192. vehicle 4 Turn OD switch on 5 Secure test gauge so it can be viewed from drivers seat 6 Start engine and shift into D range 7 Increase vehide speed gradually until 3 4 shift occurs and note gauge pressure 8 Pressure should be 469 496 kPa 68 72 psi with closed throttle and increase to 620 827 kPa 90 120 psi at 1 2 to 3 4 throttle Note that pressure can increase to around 896 kPa 130 psi at full throttle 21 14 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING Continued 9 Return to shop or move off chassis dyno PRESSURE TEST ANALYSIS CHART TEST CONDITION INDICATION Line pressure OK during Pump and regulator any one test valve OK Line pressure OK in R Leakage in rear clutch but low in D 2 1 area seal rings clutch seals Overdrive clutch piston seal or check ball problem Pressure OK in 1 2 but Leakage in front clutch low in D3 and R area Pressure OK in 2 but low Leakage in rear servo in R and 1 Front servo pressure low Leakage in servo broken in 2 servo ring or cracked servo piston Pressure low in D Fourth Gear Range Clogged filter stuck regulator valve worn or faulty pump low oil level Pressure low in all positions Governor pressure solenoid valve system fault Refer to diagnostic book Faulty governor pressure solenoid transmission control module or governor pressure sensor Clogged fluid cooler or lines seal rings leaking worn pump
193. vehicle moves normally after 5 seconds Oil drains from torque converter after shifting into gear no repair is necessary into transmission sump If longer inspect pump bushing for wear Replace pump house 5 Rear Band Misadjusted 5 Adjust band 6 Valve Body Filter Plugged 6 Replace fluid and filter If oil pan and old fluid were full of clutch disc material and or metal particles overhaul will be necessary 7 Oil Pump Gears Worn 7 Remove transmission and replace oil pump Damaged 8 Governor Circuit and Solenoid 8 Test with DRB scan tool and repair as Valve Electrical Fault required 9 Hydraulic Pressure Incorrect 9 Perform pressure test remove transmission and repair as needed 10 Reaction Shaft Seal Rings 10 Remove transmission remove oil pump Worn Broken and replace seal rings 11 Rear Clutch Input Shaft Rear 11 Remove and disassemble transmission Clutch Seal Rings Damaged and repair as necessary 12 Regulator Valve Stuck 12 Clean 13 Cooler Plugged 13 Transfer case failure can plug cooler NO DRIVE RANGE 1 Fluid Level Low 1 Add fluid and check for leaks if drive is REVERSE Ok restored 2 Gearshift Linkage Cable 2 Repair or replace linkage components Loose Misadjusted 3 Rear Clutch Burnt 3 Remove and disassemble transmission and rear clutch and seals Repair replace worn or damaged parts as needed 4 Valve Body Malfunction 4 Remove and disassemble valve body Replace assemb
194. worn The bushings are not serviceable Replace the driving shell if worn cracked or dam aged Replace planetary gear sets if gears pinion pins or carrier are damaged in any way Replace the annulus gears and supports if either component is worn or damaged Inspect the geartrain spacers thrust plates snap rings and thrust washers Replace any of these parts that are worn distorted or damaged Do not attempt to reuse these parts The planetary gear thrust washers are different sizes The large diameter washers go on the front WJ planetary and the smaller washers go on the rear planetary All the washers have four locating tabs on them These tabs fit in the holes or slots provided in each planetary gear Inspect the output shaft carefully Pay particular attention to the machined bushing bearing surfaces on the shaft and the governor valve shaft bore at the shaft rear Replace the output shaft if the machined surfaces are scored pitted or damaged in any way Also replace the shaft if the splines are damaged or exhibits cracks at any location especially at the gov ernor valve shaft bore The annulus gears can be removed from their sup ports if necessary J ust remove the snap rings and separate the two parts when replacement is neces sary In addition the annulus gear bushings can be replaced if severely worn or scored However it is not necessary to replace the bushings if they only exhibit normal wear Check bushing

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