Page 847: General Service Information
BODY 23 - 1 BODY CONTENTS page page BODY COMPONENT SERVICE ....12 SEATS ........8 GENERAL SERVICE INFORMATION .
Page 848 23 - 2 BODY PAINT INDEX page page GENERAL INFORMATION PAINT CODE ......2 AFTERMARKET PAINT REPAIR PRODUCTS .
Page 849 BODY 23 - 3 GENERAL INFORMATION (Continued) AFTERMARKET PAINT REPAIR PRODUCTS EXTERIOR COLOR CHRY AKZO EXTERIOR SHERWIN CODE BASF DuPONT NOBEL COLOR WILLIAMS SIKKENS Flame Red Clear 4679 23043 B9326 46916 CHA93:PR4 Coat Chili Pepper Red 5361 28060 B9823 54470 CHA98:VEA Citron Pearl Coat 47694...
Page 850 23 - 4 BODY SERVICE PROCEDURES cloth. Use a plastic spreader to smooth-out the cloth and resin. Use firm pressure to remove air bubbles HARD TOP REPAIR and to smooth-out the cloth. (11) Allow the resin to cure. The hard top fiberglass material can be repaired. (12) Smooth-out the surface area to the contour of The required repair materials include: •...
Page 851 BODY 23 - 5 STATIONARY GLASS INDEX page page GENERAL INFORMATION REMOVAL AND INSTALLATION SAFETY PRECAUTIONS ....5 QUARTER GLASS ......6 WINDSHIELD .
Page 852 23 - 6 BODY REMOVAL AND INSTALLATION (Continued) (5) Using a cold knife, cut the urethane around the by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par- perimeter of the windshield (Fig. 1). allel 75 cm (2.5 ft.) apart (Fig. 3). (6) Remove the windshield glass from the frame WARNING: DO NOT USE SOLVENT BASED GLASS (Fig.
Page 853 BODY 23 - 7 REMOVAL AND INSTALLATION (Continued) glass. Next, make alignment marks on glass and top with a grease pencil. (4) Remove replacement quarter glass from open- ing. (5) Position the quarter glass inside up on a suit- able work surface. WARNING: DO NOT USE SOLVENT BASED GLASS CLEANER TO CLEAN QUARTER GLASS BEFORE APPLYING GLASS PREP AND PRIMER.
Page 854 23 - 8 BODY SEATS INDEX page page REMOVAL AND INSTALLATION REAR SEAT CUSHION COVER ... . . 11 BUCKET SEAT CUSHION COVER ... . 9 REAR SEATBACK COVER .
Page 855 BODY 23 - 9 REMOVAL AND INSTALLATION (Continued) Fig. 4 Recliner Release Cable Fig. 5 Seat Back Cover BUCKET SEAT CUSHION COVER (b) From the underside of the seat cushion, engage the seat track release cable. (3) Install the bolts attaching the recliner to the REMOVAL seat cushion frame.
Page 856 23 - 10 BODY REMOVAL AND INSTALLATION (Continued) (7) Install seatback. REAR SEATBACK COVER (8) Install seat. REMOVAL REAR SEATBACK (1) Remove rear seat. (2) Remove the seatback. REMOVAL (3) Disengage the hook and loop fasteners at the (1) Remove rear seat from vehicle. seatback lower corners (Fig.
Page 857 BODY 23 - 11 REMOVAL AND INSTALLATION (Continued) REAR SEAT CUSHION COVER REMOVAL (1) Remove rear seat. (2) Remove the seatback. (3) Disengage the J-straps at the rear cushion cor- ners. (4) Disengage the seat cushion cover zipper. (5) Carefully, remove the seat cushion frame from the cushion/cover.
Page 858 23 - 12 BODY BODY COMPONENT SERVICE INDEX page page SERVICE PROCEDURES HARD/SOFT TOP LATCH ....33 BODY LUBRICATION ..... 13 HOOD HINGE .
Page 859 BODY 23 - 13 SERVICE PROCEDURES REMOVAL AND INSTALLATION BODY LUBRICATION RADIATOR GRILLE PANEL All mechanisms and linkages should be lubricated REMOVAL when necessary. This will maintain ease of operation (1) Remove the front crossmember cover. and provide protection against rust and excessive (2) Remove the crossmember valence cover.
Page 860 23 - 14 BODY REMOVAL AND INSTALLATION (Continued) (4) Connect the head lamp, turn signal, marker HOOD lamp and horn wire harness connectors. (5) Install the bolts attaching the radiator support REMOVAL rods to the grille panel. (1) Raise and support the hood. (6) If A/C equipped: (2) Disconnect the underhood lamp wire harness (a) Connect the high and low pressure lines at...
Page 861 BODY 23 - 15 REMOVAL AND INSTALLATION (Continued) HOOD INSULATION PANEL HOOD SAFETY LATCH REMOVAL REMOVAL (1) Raise and support the hood. (1) Raise and support the hood. (2) Remove the insulation panel fasteners (Fig. 3). (2) Remove the bolt attaching the safety latch to (3) Remove the insulation panel from the hood.
Page 862 23 - 16 BODY REMOVAL AND INSTALLATION (Continued) COWL GRILLE AND SCREEN WINDSHIELD FRAME REMOVAL REMOVAL (1) Open the hood and remove the screws that (1) Unlatch top. attach the cowl grille and screen to the cowl (Fig. 6). (2) Remove the bolts attaching the sport bar to the (2) Remove the grille and screen from the cowl.
Page 863 BODY 23 - 17 REMOVAL AND INSTALLATION (Continued) NOTE: Ensure that the contact surface is dry and (3) Install the screws attaching the lower weather- free from any residue, poor adhesion will result. strip to the hinge pillars. (4) Tilt the windshield frame rearward to the full (2) Position the weatherstrip on the windshield vertical position.
Page 864 23 - 18 BODY REMOVAL AND INSTALLATION (Continued) BODY DECALS INSTALLATION (1) The area that will be covered by the decal must TJ decals (Fig. 11) are durable tape decals with a be cleaned with an cleaning solution to remove any adhesive backing.
Page 865 BODY 23 - 19 REMOVAL AND INSTALLATION (Continued) SIDE VIEW MIRROR (2) Position the mirror base at the door hinge. (3) Install the screws attaching the mirror base to the door hinge. REMOVAL (1) Remove the screws attaching the mirror to the FENDER FLARE door hinge (Fig.
Page 866 23 - 20 BODY REMOVAL AND INSTALLATION (Continued) (7) Disengage the front end lighting wire harness retainers on the fender. (8) Remove the battery tray. (9) Disengage the battery temperature sensor con- nector. (10) Disengage the vacuum line at the reservoir under the battery tray reinforcement bracket.
Page 867 BODY 23 - 21 REMOVAL AND INSTALLATION (Continued) (11) Position the front end lighting wire harness (7) Route the fog lamp (if equipped), park lamp into the retainers on the fender. Engage the retainers and side marker wire harness through the access to secure.
Page 868 23 - 22 BODY REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Position the trim panel on the door. (2) Press the push-in fasteners attaching trim panel to door into place. (3) Install the screws attaching trim panel to door. (4) Position the clip on regulator handle and install the handle on the regulator.
Page 869 BODY 23 - 23 REMOVAL AND INSTALLATION (Continued) The upper hinge is integrated with the windshield FULL DOOR OUTSIDE RELEASE HANDLE hinge. When removing it, support the windshield frame with an appropriate device prior to removal. REMOVAL (1) Remove the door trim panel. (2) Position the window in the full upward posi- tion.
Page 870 23 - 24 BODY REMOVAL AND INSTALLATION (Continued) INSTALLATION FULL DOOR LOCK CYLINDER REMOVAL (1) Remove trim panel. (2) Peel back waterdam. (3) Disconnect lock cylinder to latch rod. (4) Remove lock cylinder retaining clip. (5) Remove the lock cylinder from the door. INSTALLATION (1) Install the lock cylinder in the door.
Page 871 BODY 23 - 25 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Position the striker and the spacer on the body. (2) Install the screws attaching the striker and spacer to the body. FULL DOOR INSIDE HANDLE ACTUATOR REMOVAL (1) Remove the torx screw attaching the inside handle to the door.
Page 872 23 - 26 BODY REMOVAL AND INSTALLATION (Continued) FULL DOOR GLASS INSTALLATION (1) Position the glass in the door ensuring the glass is aligned in the glass run channel. REMOVAL (1) Remove the door trim panel and the waterdam. (2) Install the screws that attach the regulator (2) Pull the door glass run channel from the door arm guide to the glass.
Page 873 BODY 23 - 27 REMOVAL AND INSTALLATION (Continued) FULL DOOR GLASS RUN CHANNEL REMOVAL (1) Peel the weatherstrip from the channel. WEATHERSTRIP (2) Separate the weatherstrip from the door. (3) If necessary, remove the push-in fasteners REMOVAL attaching the weatherstrip channel to the door and (1) Lower the window.
Page 874 23 - 28 BODY REMOVAL AND INSTALLATION (Continued) FULL DOOR WINDOW REGULATOR HALF DOOR TRIM PANEL REMOVAL REMOVAL (1) Remove door trim panel. (1) Remove half door window. (2) Remove door glass. (2) Rotate window retainer sleeves 90°. Using a (3) Loosen the bolts in the slotted holes (Fig.
Page 875 BODY 23 - 29 REMOVAL AND INSTALLATION (Continued) HALF DOOR OUTSIDE HANDLE HALF DOOR LATCH REMOVAL REMOVAL (1) Remove trim panel. (1) Remove trim panel. (2) Disconnect the outside handle to latch rod (Fig. (2) Disconnect the lock cylinder to latch rod (Fig. 36).
Page 876 23 - 30 BODY REMOVAL AND INSTALLATION (Continued) (4) Position the door weatherstrip in place, apply adhesive as necessary. (5) Connect the outside handle to latch rod. (6) Connect the lock knob to latch rod. (7) Connect the lock cylinder to latch rod (Fig. 37). (8) Install trim panel.
Page 877 BODY 23 - 31 REMOVAL AND INSTALLATION (Continued) (4) Install the weatherstrip in the weatherstrip channel ensuring that the weatherstrip is fully engaged in the weatherstrip channel. (5) Install window retaining sleeve. (6) Install trim panel. HALF DOOR WINDOW REMOVAL (1) Open the door.
Page 878 23 - 32 BODY REMOVAL AND INSTALLATION (Continued) (4) Unzip quarter windows, disengage J-strap and remove quarter windows. (5) Starting at the rear of the upper door opening frame and working forward, disengage J-straps attaching the soft top to the door opening frame. (6) Unlatch top at windshield frame.
Page 879 BODY 23 - 33 REMOVAL AND INSTALLATION (Continued) Fig. 49 Soft Top (6) Working from front to rear, engage the J-straps HARD/SOFT TOP LATCH attaching the quarter window to the body. (7) Install rear window. REMOVAL (8) Engage J-straps above door opening frame. (1) Unlatch the top (Fig.
Page 880 23 - 34 BODY REMOVAL AND INSTALLATION (Continued) DOOR OPENING FRAME Vehicles equipped with a soft top require a door opening frame to complete the seal for the soft top door assembly. REMOVAL (1) Lower the top to the rearward position. (2) Turn the knobs located on top of the door open- ing frame counter clockwise and remove completely (Fig.
Page 881 BODY 23 - 35 REMOVAL AND INSTALLATION (Continued) Fig. 55 Turning Loop Cover Fig. 54 Seat Belt Buckle REAR SHOULDER/LAP BELT AND BUCKLE WARNING: INSPECT SHOULDER BELT, RETRACTOR AND BUCKLE. REPLACE THE BELT OR BUCKLE THAT IS EITHER CUT, FRAYED, TORN OR DAMAGED.
Page 882 23 - 36 BODY REMOVAL AND INSTALLATION (Continued) (5) Move the rear seat back to the latch position. REAR BUCKLE REMOVAL (1) Move the rear seat to the forward tumble posi- tion. (2) Grasp the carpet between the buckles and lift to access the anchor bolt.
Page 883 BODY 23 - 37 REMOVAL AND INSTALLATION (Continued) Fig. 61 Mini Floor Console Fig. 62 Full Floor Console INSTALLATION (3) Install shift boot/indicator bezel. (1) Position and align the console in the vehicle. (4) Return seats to normal position. (2) Install the bolts attaching the console to the (5) Install the shift handle.
Page 884 23 - 38 BODY REMOVAL AND INSTALLATION (Continued) SHIFT BOOT INSTALLATION (1) Slide the shift boot over the shift lever. (2) Position the shift knob on the lever and install REMOVAL (1) Using a trim stick, pry the shift boot from the the nut.
Page 885 BODY 23 - 39 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Position the seat on the rear floor panel and engage the seat frame pivot pins with the pivot brackets. (2) Install the hitch pins on the seat frame pivot pins. (3) Move the seat back to the latch position and engage the strikers with the latch brackets.
Page 886 23 - 40 BODY REMOVAL AND INSTALLATION (Continued) Fig. 68 Vehicle Carpet (3) Grasp wheelhouse carpet and remove from (7) Remove the bolts attaching the side support vehicle (Fig. 68). bars to the windshield frame. (8) Separate the side support bars from the vehi- INSTALLATION cle.
Page 887 BODY 23 - 41 REMOVAL AND INSTALLATION (Continued) (15) If necessary, remove the pads and covers from NOTE: To prevent water seepage, apply 3M Drip- the sport bar. Chek Sealant (or an equivalent product) to the underside of the sport bar base flanges and all the bolt heads before installation.
Page 888 23 - 42 BODY REMOVAL AND INSTALLATION (Continued) REAR VIEW MIRROR (5) Apply adhesive accelerator to the bracket con- tact surface on the windshield glass. Allow the accel- erator to dry for one minute. Do not touch the glass REMOVAL (1) Loosen the mirror set screw.
Page 889 BODY 23 - 43 REMOVAL AND INSTALLATION (Continued) (2) Install the screws that attach the sunvisor arm support brackets to the frame. Tighten the screws securely. WHEELHOUSE SPLASH SHIELD REMOVAL (1) Remove the plastic rivets that attach the splash shield to the wheelhouse (Fig. 73). (2) Remove the push-in fasteners attaching the splash shield to the wheelhouse.
Page 890 23 - 44 BODY REMOVAL AND INSTALLATION (Continued) (3) Open the tailgate and liftgate. (3) Remove wiper motor cover (right hinge only). (4) Remove support rod cylinders. (4) Remove the nut attaching the liftgate hinge to (5) Remove the bolts attaching the liftgate hinge to the liftgate glass.
Page 891 BODY 23 - 45 REMOVAL AND INSTALLATION (Continued) Fig. 79 Spare Tire Fig. 81 License Plate Bracket TAILGATE REMOVAL (1) Remove the spare tire. (2) Open the tailgate and remove the CHMSL con- tact cover (Fig. 82). (3) Disengage the CHMSL electrical connectors. (4) Remove the screws that attach the tailgate hinge to the tailgate.
Page 892 23 - 46 BODY REMOVAL AND INSTALLATION (Continued) TAILGATE HINGE Hinges may be serviced individually. If both are to be serviced, remove/install hinges one at a time. REMOVAL (1) Using a wax pencil, mark the position of the hinge on the body. (2) Remove the screws attaching the hinge to the body and tailgate (Fig.
Page 893 BODY 23 - 47 REMOVAL AND INSTALLATION (Continued) TAILGATE WEATHERSTRIP AND CHANNEL REMOVAL (1) Open the tailgate. (2) Remove the push-in fasteners attaching the weatherstrip to the top corners of the tailgate (Fig. 86). (3) Peel the weatherstrip from the upper tailgate corners.
Page 894 23 - 48 BODY REMOVAL AND INSTALLATION (Continued) (2) Slide the weatherstrip into the weatherstrip DOOR ADJUSTMENT channel. The doors are adjusted at the hinge attaching loca- (3) Clean the weatherstrip contact surface on the tions on either the body or the door. Enlarged holes tailgate with isopropyl alcohol, or equivalent.
Page 895 BODY 23 - 49 SPECIFICATIONS BODY LUBRICANTS COMPONENT SERVICE INTERVAL LUBRICANT Door Latches As Required Multi-Purpose Grease NLGI GC-LB (Water Resistant) (1) Hood Latch, Release Mechanism & As Required Multi-Purpose Grease NLGI GC-LB 2 Safety Latch (When Performing Other EP (2) Underhood Service) Hood Hinges As Required...
Page 896 23 - 50 BODY SPECIAL TOOLS BODY Remover, Moldings C-4829 Trim Stick C-4755...
Page 897: Tires And Wheels
TIRES AND WHEELS 22 - 1 TIRES AND WHEELS CONTENTS page page TIRES ........1 WHEELS .
Page 898 22 - 2 TIRES AND WHEELS DESCRIPTION AND OPERATION (Continued) not exceed speeds of 50 MPH. Refer to Owner’s Man- ual for complete details. TIRE INFLATION PRESSURES Under inflation will cause rapid shoulder wear, tire flexing, and possible tire failure (Fig. 2). Fig.
Page 899 TIRES AND WHEELS 22 - 3 DESCRIPTION AND OPERATION (Continued) drops. Check tire pressure frequently when ambient travel, interference with vehicle components may temperature varies widely. cause tire damage. Inflation pressures specified on the placards are WARNING: FAILURE TO EQUIP THE VEHICLE WITH cold inflation pressure.
Page 900 22 - 4 TIRES AND WHEELS DIAGNOSIS AND TESTING (Continued) Fig. 5 Tire Wear Patterns TIRE NOISE OR VIBRATION Radial-ply tires are sensitive to force impulses caused by improper mounting, vibration, wheel defects, or possibly tire imbalance. To find out if tires are causing the noise or vibra- tion, drive the vehicle over a smooth road at varying speeds.
Page 901 TIRES AND WHEELS 22 - 5 SERVICE PROCEDURES (Continued) Fig. 7 Dial Indicator Fig. 9 Remount Tire 180 Degrees Fig. 8 First Measurement On Tire (4) If runout is still excessive use the following procedures. (a) If the high spot is within 101.6 mm (4.0 in.) of the first spot and is still excessive, replace the tire.
Page 902 22 - 6 TIRES AND WHEELS SERVICE PROCEDURES (Continued) Install wheel on vehicle, and tighten to proper CLEANING AND INSPECTION torque specification. CLEANING TIRES Remove protective coating on tires before delivery of vehicle. This coating may cause deterioration of tires. To remove the protective coating applying warm water and let it soak for a few minutes.
Page 903 TIRES AND WHEELS 22 - 7 WHEELS INDEX page page DESCRIPTION AND OPERATION SERVICE PROCEDURES WHEEL ....... . 7 TIRE AND WHEEL BALANCE .
Page 904 22 - 8 TIRES AND WHEELS DIAGNOSIS AND TESTING (Continued) Fig. 3 Radial Runout Fig. 2 Checking Tire/Wheel/Hub Runout acceptable level, the tire can be rotated on the wheel. (See Method 2). METHOD 1 (RELOCATE WHEEL ON HUB) (1) Drive vehicle a short distance to eliminate tire flat spotting from a parked position.
Page 905 TIRES AND WHEELS 22 - 9 SERVICE PROCEDURES (Continued) WARNING: NEVER USE OIL OR GREASE ON Original equipment wheels are available through STUDS OR NUTS. INSTALLING WHEELS WITHOUT your dealer. Replacement wheels from any other source should be equivalent in: GOOD METAL-TO-METAL CONTACT OR USING •...
Page 906 22 - 10 TIRES AND WHEELS SERVICE PROCEDURES (Continued) Fig. 7 Dynamic Unbalance & Balance For static balancing, find location of heavy spot SPECIFICATIONS causing the imbalance. Counter balance wheel directly opposite the heavy spot. Determine weight TORQUE CHART required to counter balance the area of imbalance. Place half of this weight on the inner rim flange and DESCRIPTION TORQUE...
Page 907 TRANSMISSION AND TRANSFER CASE 21 - 1 TRANSMISSION AND TRANSFER CASE CONTENTS page page AUTOMATIC TRANSMISSION—30/32RH ..75 AX5 MANUAL TRANSMISSION ....1 AX15 MANUAL TRANSMISSION .
Page 908 21 - 2 TRANSMISSION AND TRANSFER CASE GENERAL INFORMATION (Continued) Fig. 1 AX5 Manual Transmission RECOMMENDED LUBRICANT Recommended lubricant for AX5 transmissions is Mopar 75W–90, API Grade GL–3 gear lubricant, or equivalent. Correct lubricant level is from the bottom edge, to no more than 6 mm (1/4 in.) below the bottom edge of the fill plug hole.
Page 909 TRANSMISSION AND TRANSFER CASE 21 - 3 DIAGNOSIS AND TESTING (Continued) A leak at the front of the transmission will be from either the front bearing retainer or retainer seal. Lubricant may be seen dripping from the clutch housing after extended operation. If the leak is severe, it may also contaminate the clutch disc caus- ing the disc to slip, grab, and/or chatter.
Page 910 21 - 4 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) adjustment or a worn/damaged pressure plate or disc (11) Disengage any wire connectors attached to trans- can cause incorrect release. If the clutch problem is mission or transfer case, if equipped, components. advanced, gear clash during shifts can result.
Page 911 TRANSMISSION AND TRANSFER CASE 21 - 5 REMOVAL AND INSTALLATION (Continued) (28) Remove clutch housing from transmission (Fig. 9). Fig. 7 Crankshaft Position Sensor —4.0L Engine (c) Reach up and around transmission case and press shift lever retainer downward with finger pres- sure.
Page 912 21 - 6 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) ward and turn it clockwise to lock it in place. Then (30) Install skid plate, if equipped. Tighten bolts to install lever dust boot on shift tower. 42 N·m (31 ft. lbs.) torque. Tighten stud nuts to 17 (11) Install rear crossmember.
Page 913 TRANSMISSION AND TRANSFER CASE 21 - 7 REMOVAL AND INSTALLATION (Continued) (6) Tighten the bolts to 17 N·m (12 ft. lbs.). (5) Lower vehicle. (7) Install release bearing and lever onto the ADAPTER HOUSING SEAL transmission. EXTENSION HOUSING SEAL REMOVAL (1) Hoist and support vehicle.
Page 914 21 - 8 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) (3) Install transfer case. (8) Remove detent ball plug (Fig. 19). (4) Check and add fluid to transmission as neces- (9) Remove detent spring and ball with pencil sary. Refer to the Recommended Lubricant section for magnet (Fig.
Page 915 TRANSMISSION AND TRANSFER CASE 21 - 9 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 23 Shift Arm Rstrictor Pins Fig. 20 Remove Detent Spring Fig. 21 Remove Detent Ball Fig. 24 Removing Shift Lever Shaft Plug Fig. 25 Remove Shifter Shaft Fig. 22 Shift Arm Retainer Bolt Removal...
Page 916 21 - 10 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (15) Remove adapter/extension housing bolts. (16) Loosen adapter/extension housing by tapping it loose with plastic mallet (Fig. 26). (17) Remove adapter/extension housing (Fig. 27). Fig. 28 Speedometer Drive Gear Assembly Fig.
Page 917 TRANSMISSION AND TRANSFER CASE 21 - 11 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 31 Separate Intermediate Plate and Fig. 34 Install Transmission Gear Case to the Transmission Case Intermediate Plate (4) Install new front bearing snap rings (Fig. 35). Fig. 32 Remove Intermediate Plate from Transmission Case (3) Align geartrain and shift rails with mating holes in transmission case and install transmission...
Page 918 21 - 12 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (5) Install front bearing retainer gasket to front bearing retainer. (6) Install the front bearing retainer (Fig. 36) and tighten bolts to 17 N·m (12 ft. lbs.). Fig. 38 Install Adapter/Extension Housing–Typical Fig.
Page 919 TRANSMISSION AND TRANSFER CASE 21 - 13 DISASSEMBLY AND ASSEMBLY (Continued) (14) Install and tighten shifter arm shaft plug to 18 N·m (13 ft. lbs.) torque (Fig. 42). Fig. 42 Shifter Arm Shaft Plug Installation Fig. 40 Install Shifter Arm Shaft (15) Install shift restrictor pins in shift tower and tighten to 27 N·m (20 ft.
Page 920 21 - 14 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (18) Install detent plug and tighten to 19 N·m (14 ft. lbs.) (Fig. 46). Fig. 46 Install Detent Ball Plug Fig. 44 Install Detent Ball Fig. 47 Install Shift Tower Fig.
Page 921 TRANSMISSION AND TRANSFER CASE 21 - 15 DISASSEMBLY AND ASSEMBLY (Continued) SHIFT MECHANISM AND GEARTRAIN (3) Remove bolt holding fifth gear shift fork to shift rail (Fig. 51). DISASSEMBLY (1) Install suitable bolts and washers in intermedi- ate plate (Fig. 49). Then clamp plate and gear assem- bly in vise.
Page 922 21 - 16 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (5) Remove fifth gear synchro ring (Fig. 53). (6) Remove the countershaft fifth gear assembly from countershaft (Fig. 54). Fig. 55 Remove Fifth Gear Thrust Ring Fig. 53 Remove Fifth Gear Synchro Ring Fig.
Page 923 TRANSMISSION AND TRANSFER CASE 21 - 17 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 58 Remove Output Shaft Rear Bearing Retainer (12) Remove bolts holding 1–2 and 3–4 shift forks to the shift rails (Fig. 59) and discard bolts. (13) Remove bolts holding reverse shift arm bracket to intermediate plate (Fig.
Page 924 21 - 18 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (17) Remove the mainshaft by moving the main- shaft forward until the mainshaft rear bearing is clear of the intermediate plate and then rotating the mainshaft downward out of the shift forks (Fig. 63). Fig.
Page 925 TRANSMISSION AND TRANSFER CASE 21 - 19 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 68 Remove Fifth Gear Check Ball Fig. 66 Remove Lock Ball And Spring CAUTION: The interlock balls and pins are different sizes and shapes. Be sure to correctly identify which position an item is removed from to ensure that it is reinstalled in the same location.
Page 926 21 - 20 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (28) Remove interlock pin from reverse shift rail (30) Remove snap-ring on 3–4 shift rail. (Fig. 71). (31) Remove 1–2 shift rail from intermediate plate. (32) Remove interlock pin from 1–2 shift rail (Fig. 73).
Page 927 TRANSMISSION AND TRANSFER CASE 21 - 21 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 75 Shift Rail Components ASSEMBLY (3) Install the interlock pin into the 1–2 shift rail Refer to (Fig. 75) while assembling and installing (Fig. 77). the shift rail components. Also, verify that all shift (4) Install the 1–2 shift rail into the intermediate plate.
Page 928 21 - 22 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (5) Install snap-ring onto 3–4 shift rail. (6) Install the reverse check ball into the interme- diate plate (Fig. 78). Fig. 80 Install Reverse Arm Bracket to Fork (9) Install reverse shift rail into intermediate plate and position reverse arm bracket to intermediate plate (Fig.
Page 929 TRANSMISSION AND TRANSFER CASE 21 - 23 DISASSEMBLY AND ASSEMBLY (Continued) (11) Install reverse shift head and rail assembly into the intermediate plate. (12) Install the fifth gear interlock ball and check ball (Fig. 83). Fig. 85 Install 1–2 Shift Fork Fig.
Page 930 21 - 24 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (25) Install snap-rings onto the rear mainshaft and countershaft bearings. (26) Install the bolts to hold the reverse shift arm bracket to the intermediate plate. (27) Install new bolts to hold the shift forks to the shift rails (Fig.
Page 931 TRANSMISSION AND TRANSFER CASE 21 - 25 DISASSEMBLY AND ASSEMBLY (Continued) (35) Depress compression spring (40) Install the fifth gear thrust ring onto the reverse idler gear shaft (Fig. 92). countershaft and over the lock ball (Fig. 94). Fig. 91 Align Idler Shaft Pin Fig.
Page 932 21 - 26 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (45) Position the fifth gear blocker ring onto the countershaft. (46) Using a suitable mallet and spacer, tap the fifth gear blocker ring onto the countershaft. (47) Install new bolt to hold fifth gear shift fork to the fifth gear shift rail (Fig.
Page 933 TRANSMISSION AND TRANSFER CASE 21 - 27 DISASSEMBLY AND ASSEMBLY (Continued) (3) Remove the output shaft pilot bearing rollers from the input shaft and the output shaft. (4) Remove the fourth gear synchronizer ring from the input shaft (Fig. 98). Fig.
Page 934 21 - 28 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (5) Install output shaft pilot bearing rollers in (3) Remove output shaft fifth gear snap ring with input shaft bore (Fig. 100). Ensure to use sufficient two screwdrivers (Fig. 102). petroleum jelly to hold rollers in position.
Page 935 TRANSMISSION AND TRANSFER CASE 21 - 29 DISASSEMBLY AND ASSEMBLY (Continued) (6) Remove first gear bearing inner race lock ball (10) Remove select fit snap-ring holding the 3–4 with pencil magnet (Fig. 104). synchronizer onto the output shaft (Fig. 106). Fig.
Page 936 21 - 30 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (2) If necessary, assemble 1–2 and 3–4 synchro- nizer hubs, sleeves, springs and key inserts (Fig. 108). Fig. 109 Select 3–4 Synchronizer Snap-ring Fig. 108 Synchronizer Identification (3) Install third gear needle bearing onto the out- put shaft.
Page 937 TRANSMISSION AND TRANSFER CASE 21 - 31 DISASSEMBLY AND ASSEMBLY (Continued) (15) Using Driver MD-998805, Adapter 6747-1A, and a shop press, press the 1–2 synchronizer onto the output shaft. (16) Install first gear synchronizer ring into 1–2 synchronizer. (17) Install first gear bearing inner race lock ball in output shaft (Fig.
Page 938 21 - 32 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) SEMI-SYNCHRONIZED REVERSE IDLER GEAR DISASSEMBLY (1) Remove snap-ring holding the reverse idler gear onto the reverse idler gear hub/race (Fig. 115). (2) Remove the plate washer from the reverse idler gear hub/race (Fig.
Page 939 TRANSMISSION AND TRANSFER CASE 21 - 33 DISASSEMBLY AND ASSEMBLY (Continued) GEAR CASE, ADAPTER/EXTENSION HOUSING, INTERMEDIATE PLATE Clean the case, housing, and intermediate plate with solvent and dry with compressed air. Replace the case if cracked, porous, or if any of the bearing and gear bores are damaged.
Page 940 21 - 34 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION (Continued) Measure output shaft runout with a dial indicator (Fig. 120). Runout should not exceed 0.05 mm (0.002 in.). Fig. 120 Check Output Shaft Runout Fig. 121 Check Gear–To–Race Clearance Replace output shaft or first gear inner bearing race if measurement of any surface is out of specifi- cation.
Page 941 TRANSMISSION AND TRANSFER CASE 21 - 35 CLEANING AND INSPECTION (Continued) SPECIFICATIONS TORQUE DESCRIPTION TORQUE Plugs, Access ....19 N·m (14 ft.lbs.) Bolts, Adapter Housing ..34 N·m (25 ft.lbs.) Switch, Back-up Light.
Page 942 21 - 36 TRANSMISSION AND TRANSFER CASE SPECIAL TOOLS 8211 Installer, Seal C-3339 Dial Indicator Set 8212 Installer, Seal C-3995-A Installer, Extension Housing Seal 8208 Installer, Seal C-4171 Handle, Universal Tool P-334 Splitter, Bearing...
Page 943 TRANSMISSION AND TRANSFER CASE 21 - 37 SPECIAL TOOLS (Continued) 8109 Cup, Installer L-4507 Tube, Driver 6747–1A Adapter, Fixture MD-998805 Installer, Seal...
Page 944 21 - 38 TRANSMISSION AND TRANSFER CASE AX15 MANUAL TRANSMISSION INDEX page page GENERAL INFORMATION DISASSEMBLY AND ASSEMBLY AX15 MANUAL TRANSMISSION ... . . 38 ADAPTER/EXTENSION HOUSING AND RECOMMENDED LUBRICANT ....38 FRONT BEARING RETAINER .
Page 945 TRANSMISSION AND TRANSFER CASE 21 - 39 DIAGNOSIS AND TESTING (Continued) Fig. 1 AX15 Manual Transmission Fig. 3 Fill Plug Location Fig. 2 Identification Code Number Location A correct lubricant level check can only be made Leaks can occur at the mating surfaces of the gear when the vehicle is level.
Page 946 21 - 40 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) rebuilt transmissions, new synchro rings may tend to stick slightly causing hard or noisy shifts. In most cases, this condition will decline as the rings wear–in. TRANSMISSION NOISE Most manual transmissions make some noise dur- ing normal operation.
Page 947 TRANSMISSION AND TRANSFER CASE 21 - 41 REMOVAL AND INSTALLATION (Continued) (4) Remove skid plate, if equipped. (5) Remove slave cylinder from clutch housing. (6) Mark rear propeller shaft and rear axle yokes for installation alignment (Fig. 6). Fig. 6 Marking Propeller Shaft And Axle Yokes (7) Mark front propeller shaft, axle, and transfer Fig.
Page 948 21 - 42 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) (b) Reach up and around transmission case and unseat shift lever dust boot from transmission shift tower (Fig. 9). Move boot upward on shift lever for access to retainer that secures lever in shift tower. (c) Reach up and around transmission case and press shift lever retainer downward with finger pressure.
Page 949 TRANSMISSION AND TRANSFER CASE 21 - 43 REMOVAL AND INSTALLATION (Continued) (18) Slide transfer case forward until case is FRONT BEARING RETAINER SEAL seated on transmission, if necessary. (19) Install nuts to attach transfer case to trans- REMOVAL mission, if equipped. Tighten transfer case-to-trans- (1) Remove release bearing and lever from the mission nuts to 35 N·m (26 ft.
Page 950 21 - 44 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) EXTENSION HOUSING SEAL ADAPTER HOUSING SEAL REMOVAL REMOVAL (1) Raise and support vehicle. (1) Hoist and support vehicle. (2) Remove propeller shaft. Refer to Group 3, Dif- (2) Remove transfer case. ferential and Driveline, for proper procedures.
Page 951 TRANSMISSION AND TRANSFER CASE 21 - 45 REMOVAL AND INSTALLATION (Continued) (3) Install transfer case. (4) Check and add fluid to transmission as neces- sary. Refer to the Recommended Lubricant section for proper fluid requirements. (5) Lower vehicle. DISASSEMBLY AND ASSEMBLY ADAPTER/EXTENSION HOUSING AND FRONT BEARING RETAINER DISASSEMBLY...
Page 952 21 - 46 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (8) Remove reverse shift head detent ball plug (Fig. 20). (9) Remove detent ball spring and ball with pencil magnet (Fig. 21), (Fig. 22). Fig. 22 Remove Detent Ball Fig.
Page 953 TRANSMISSION AND TRANSFER CASE 21 - 47 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 25 Removing Shift Lever Shaft Plug Fig. 26 Remove Shifter Shaft (14) Remove the shift arm from the adapter hous- ing. (15) Remove adapter/extension housing bolts (Fig. 27). Fig.
Page 954 21 - 48 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (16) Loosen adapter/extension housing by tapping it loose with plastic mallet (Fig. 28). (17) Remove adapter/extension housing (Fig. 29). Fig. 30 Speedometer Drive Gear Assembly Fig. 28 Loosen Adapter/Extension Housing Fig.
Page 955 TRANSMISSION AND TRANSFER CASE 21 - 49 DISASSEMBLY AND ASSEMBLY (Continued) (22) Remove cluster gear bearing snap-ring (Fig. 33). Fig. 35 Remove Intermediate Plate from Transmission Case Fig. 33 Remove Cluster Gear Snap-ring (23) Separate intermediate plate and transfer case by tapping them loose with plastic mallet (Fig.
Page 956 21 - 50 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (c) Install speedometer gear retaining snap-ring onto output shaft. (8) Apply a 1/8 to 3/16 inch wide bead of Threeb- ond Liquid Gasket TB1281, P/N 83504038, to seal- ing surface of adapter/extension housing, making sure to keep sealer bead to inside of bolt holes.
Page 957 TRANSMISSION AND TRANSFER CASE 21 - 51 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 42 Position Shift Arm in Transmission Case Fig. 44 Install Shift Arm Retainer Bolt (11) Start shifter arm shaft in hole in back of adapter\extension housing. Align shift arm and shifter arm shaft and insert shifter arm shaft through the shifter arm and into the forward portion of the adapter\extension housing (Fig.
Page 958 21 - 52 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 49 Install Detent Ball Plug Fig. 46 Install Shifter Restrictor Pins (20) Install new metal o-ring to the backup lamp switch. (21) Install backup lamp switch (Fig. 50). Tighten switch to 37 N·m (27 ft.
Page 959 TRANSMISSION AND TRANSFER CASE 21 - 53 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 51 Positioning Intermediate Plate In Vise SHIFT MECHANISM AND GEARTRAIN (4) Remove bolt holding fifth gear shift fork to shift rail (Fig. 53). DISASSEMBLY (1) Install suitable bolts and washers in intermedi- ate plate (Fig.
Page 960 21 - 54 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 54 Remove Fifth Gear Shift Fork (8) Remove fifth gear blocker ring from counter- shaft assembly with Puller L-4407 (Fig. 56). Fig. 56 Remove Fifth Gear Blocker Ring Fig.
Page 961 TRANSMISSION AND TRANSFER CASE 21 - 55 DISASSEMBLY AND ASSEMBLY (Continued) (11) Remove fifth gear thrust ring from counter- shaft (Fig. 59). Fig. 61 Remove Output Shaft Rear Bearing Retainer Bolts Fig. 59 Remove Fifth Gear Thrust Ring (12) Remove fifth gear thrust ring lock ball from countershaft (Fig.
Page 962 21 - 56 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (18) Then remove lock ball and spring from plug holes with pencil magnet (Fig. 66). (19) Remove the fifth gear shift rail (Fig. 67). Fig. 64 Reverse Shift Arm Components Fig.
Page 963 TRANSMISSION AND TRANSFER CASE 21 - 57 DISASSEMBLY AND ASSEMBLY (Continued) (20) Retrieve the fifth gear shift rail lock ball from the intermediate plate using a magnet (Fig. 68). Fig. 70 Remove Shift Fork To Shift Rail Bolts Fig. 68 Remove Fifth Gear Shift Rail Lock Ball (21) Remove the 1–2 and 3–4 shift rail c-rings using two equally sized screwdrivers (Fig.
Page 964 21 - 58 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 75 Remove 1–2 Shift Rail Interlock Pin Fig. 73 Remove Shift Forks (26) Remove the 1–2 shift rail from the 1–2 shift fork and the intermediate plate (Fig. 74). (27) Remove the 1–2 shift rail interlock pin from the 1–2 shift rail (Fig.
Page 965 TRANSMISSION AND TRANSFER CASE 21 - 59 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 79 Remove Reverse Shift Rail Interlock Pin Fig. 77 Remove Reverse Shift Rail C-ring Fig. 80 Remove Output Shaft Rear Bearing Snap-ring Fig. 78 Remove Reverse Shift Rail (36) Remove the countershaft by moving the coun- tershaft rearward until the countershaft is clear of the intermediate plate.
Page 966 21 - 60 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLY (1) Lubricate countershaft journal and rear bear- ing with petroleum jelly or gear lubricant. (2) Position the mainshaft into the intermediate plate. (3) Tap the mainshaft assembly rear bearing into the intermediate plate with a suitable rubber mallet.
Page 967 TRANSMISSION AND TRANSFER CASE 21 - 61 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 87 Install 1–2 Shift Rail Fig. 85 Install 1–2 Shift Rail Interlock Plug Fig. 86 Install 1–2 Shift Rail Interlock Pin Fig. 88 Install 3–4 Shift Rail Interlock Plug (16) Install 1–2 shift rail through intermediate plate and 1–2 shift fork (Fig.
Page 968 21 - 62 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (19) Install new bolts to hold the shift forks to the shift rails (Fig. 90). (20) Install c-rings to 1–2 and 3–4 shift rails (Fig. 91). Fig. 92 Install Reverse Idler Gear And Shaft Fig.
Page 969 TRANSMISSION AND TRANSFER CASE 21 - 63 DISASSEMBLY AND ASSEMBLY (Continued) (29) Install countershaft fifth gear assembly onto countershaft (Fig. 98). (30) Install fifth gear synchronizer ring (Fig. 99). Fig. 95 Install Fifth Gear Thrust Ring Lock Ball (27) Install fifth gear thrust ring onto countershaft and over lock ball (Fig.
Page 970 21 - 64 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (34) Install snap-ring to hold the countershaft fifth gear assembly onto the countershaft (Fig. 100). (35) Install the reverse shift head and rail assem- bly (Fig. 101). Fig. 101 Install Reverse Shift Head And Rail Assembly Fig.
Page 971 TRANSMISSION AND TRANSFER CASE 21 - 65 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 105 Countershaft Front Bearing Snap-ring INPUT SHAFT DISASSEMBLY (1) Verify that the 3–4 synchronizer is in the neu- tral position. Fig. 104 Install Detent Balls And Springs (2) Separate input shaft from output shaft (Fig. COUNTERSHAFT 106).
Page 972 21 - 66 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (3) Remove the output shaft pilot bearing from the ASSEMBLY input shaft or output shaft (Fig. 107). (1) Position input shaft bearing onto input shaft. (4) Remove the fourth gear synchronizer ring from Be sure that the snap-ring groove in the bearing is the input shaft (Fig.
Page 973 TRANSMISSION AND TRANSFER CASE 21 - 67 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 110 Output Shaft And Gears DISASSEMBLY (1) Remove input shaft and output shaft pilot bearing from output shaft (Fig. 111), if necessary. (2) Measure and note thrust clearance of output shaft gears (Fig.
Page 974 21 - 68 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (3) Remove output shaft fifth gear snap ring with (6) Remove first gear needle roller bearing from two screwdrivers (Fig. 113). output shaft. (7) Remove first gear spacer from output shaft. (8) Remove first gear synchronizer ring.
Page 975 TRANSMISSION AND TRANSFER CASE 21 - 69 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 118 Synchronizer Identification (8) Select the thickest snap-ring that will fit into the snap-ring groove of the output shaft (Fig. 119). Fig. 116 Remove 3–4 Synchronizer Snap Ring Fig.
Page 976 21 - 70 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (10) Verify third gear thrust clearance with feeler gauge (Fig. 120). Clearance should be 0.10 – 0.30 mm (0.003 – 0.0118 in.). If clearance is out of specifica- tion, refer to Cleaning and Inspection section within this group.
Page 977 TRANSMISSION AND TRANSFER CASE 21 - 71 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 123 Check First–Second Gear Thrust Clearance (28) Position fifth gear onto output shaft with the gear’s long shoulder toward the rear of shaft. Ensure that the gear and output shaft splines are aligned. (29) Using Adapter 6761, Driver L-4507, and a shop press, press fifth gear onto output shaft.
Page 978 21 - 72 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION (Continued) • First gear bearing surface is 38.86 mm (1.529 in.). • Second gear bearing surface is 46.86 mm (1.844 in.). • Third gear bearing surface is 37.86 mm (1.490 in.).
Page 979 TRANSMISSION AND TRANSFER CASE 21 - 73 CLEANING AND INSPECTION (Continued) Check the condition of the reverse idler gear bush- SPECIAL TOOLS ing (Fig. 129). Replace the gear if the bushing is damaged or worn. AX15 C-3339 Dial Indicator Set Fig.
Page 980 21 - 74 TRANSMISSION AND TRANSFER CASE SPECIAL TOOLS (Continued) 6052 Tube, Driver 8208 Installer, Seal 6761 Adapter, Installer L-4407A Puller, Gear MD-998805 Tube, Driver P-334 Splitter, Bearing 8109 Cup, Installer L-4507 Tube, Driver...
Page 981 TRANSMISSION AND TRANSFER CASE 21 - 75 AUTOMATIC TRANSMISSION—30/32RH INDEX page page GENERAL INFORMATION PARK/NEUTRAL POSITION SWITCH ..102 30/32RH AUTOMATIC TRANSMISSION ..76 SPEEDOMETER ADAPTER ....100 CAUSES OF BURNT FLUID .
Page 982 21 - 76 TRANSMISSION AND TRANSFER CASE GENERAL INFORMATION hydraulic circuit by the torque converter control (TCC) solenoid on the valve body. The torque con- 30/32RH AUTOMATIC TRANSMISSION verter clutch engages in third gear when the vehicle is cruising on a level plane after the vehicle has The 30RH automatic transmission is used with the warmed up.
Page 983 TRANSMISSION AND TRANSFER CASE 21 - 77 GENERAL INFORMATION (Continued) Fig. 1 30/32 RH Automatic Transmission...
Page 984 21 - 78 TRANSMISSION AND TRANSFER CASE GENERAL INFORMATION (Continued) TRANSMISSION IDENTIFICATION transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary Transmission identification numbers are stamped transmission fluid cooler, a heavy duty cooling sys- on the left side of the case just above the oil pan gas- tem, and the engine/axle ratio combination needed to ket surface (Fig.
Page 985 TRANSMISSION AND TRANSFER CASE 21 - 79 GENERAL INFORMATION (Continued) clutch. Torque multiplication is created when the sta- PRESSURE SUPPLY tor directs the hydraulic flow from the turbine to The oil pump develops fluid pressure for clutch/ rotate the impeller in the direction the engine crank- band application and for lubrication.
Page 986 21 - 80 TRANSMISSION AND TRANSFER CASE DESCRIPTION AND OPERATION (Continued) Clutch/Band Application DIAGNOSIS AND TESTING The front/rear clutch pistons and servo pistons are actuated by line pressure. When line pressure is AUTOMATIC TRANSMISSION DIAGNOSIS removed, the pistons are released by spring tension. Automatic transmission problems can be a result of On 2-3 upshifts, the front servo piston is released poor engine performance, incorrect fluid level, incor-...
Page 987 TRANSMISSION AND TRANSFER CASE 21 - 81 DIAGNOSIS AND TESTING (Continued) Fig. 3 Ignition Interlock Cable Routing Shift the transmission into REVERSE and test continuity at the switch outer terminals. Continuity should exist only when the transmission is in REVERSE. Continuity should not exist between the outer terminals and the case.
Page 988 21 - 82 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) (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. THROTTLE VALVE CABLE Transmission throttle valve cable adjustment is extremely important to proper operation.
Page 989 TRANSMISSION AND TRANSFER CASE 21 - 83 DIAGNOSIS AND TESTING (Continued) required, the 300 psi gauge can be used at any of the PRESSURE TEST PROCEDURE other test ports. Test One - Transmission In 1 Range Pressure Test Port Locations This test checks pump output, pressure regulation, Pressure test ports locations are provided at the and condition of the rear clutch and servo circuit.
Page 990 21 - 84 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) (5) Line pressure should be 54-60 psi (372-414 kPa) with throttle lever forward and gradually increase as lever is moved rearward. (6) Front servo is pressurized only in D range and should be same as line pressure within 3 psi (21 kPa) up to downshift point.
Page 991 TRANSMISSION AND TRANSFER CASE 21 - 85 DIAGNOSIS AND TESTING (Continued) (7) If a second stall test is required, cool down fluid before proceeding. Shift into NEUTRAL and run engine at 1000 rpm for 20-30 seconds to cool fluid. STALL TEST ANALYSIS Stall Speed Too High If the stall speed exceeds 2500 rpm, transmission clutch slippage is indicated.
Page 992 21 - 86 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) converter housing and not on the converter itself CONVERTER HOUSING AREA LEAK (Fig. 11). Pump seal or gasket leaks usually travel CORRECTION down the inside of the converter housing. Front band (1) Remove converter.
Page 993 TRANSMISSION AND TRANSFER CASE 21 - 87 DIAGNOSIS AND TESTING (Continued) DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION HARSH ENGAGEMENT 1. Fluid Level Low 1. Add Fluid FROM NEUTRAL TO DRIVE 2. Throttle Linkage Misadjusted 2. Adjust linkage - setting may be too OR REVERSE long.
Page 994 21 - 88 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) DIAGNOSIS CHART (CONTINUED) CONDITION POSSIBLE CAUSES CORRECTION 10. Governor Valve Stuck. 10. Remove and inspect governor components. Replace worn or damaged parts. 11. Regulator Valve Stuck. 11. Clean. 12. Cooler Plugged. 12.
Page 995 TRANSMISSION AND TRANSFER CASE 21 - 89 DIAGNOSIS AND TESTING (Continued) DIAGNOSIS CHART (CONTINUED) CONDITION POSSIBLE CAUSES CORRECTION 6. Valve Body Malfunctioned. 6. Check press and inspect valve body. Replace valve body (as assembly) if any valve or bore is damaged. Clean and reassemble correctly if all parts are in good condition.
Page 996 21 - 90 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) DIAGNOSIS CHART (CONTINUED) CONDITION POSSIBLE CAUSES CORRECTION 5. Rear Servo Malfunction. 5. Remove and disassemble transmission. Replace worn/damaged servo parts as necessary. 6. Front Clutch Burnt. 6. Remove and disassemble transmission.
Page 997 TRANSMISSION AND TRANSFER CASE 21 - 91 DIAGNOSIS AND TESTING (Continued) DIAGNOSIS CHART (CONTINUED) CONDITION POSSIBLE CAUSES CORRECTION 3. Governor/Valve Body, Governor Valve 3. Check line and governor pressures to Stuck Closed; Loose Output Shaft Support determine cause. Correct as required. or Governor Housing Bolts, Leaking Seal Rings or Valve Body Problem (i.e., Stuck 1- 2 Shift Valve/Gov.
Page 998 21 - 92 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) DIAGNOSIS CHART (CONTINUED) CONDITION POSSIBLE CAUSES CORRECTION 6. Low Hydraulic Pressure Due to Worn 6. Perform hydraulic and air pressure Pump, Incorrect Control Pressure tests to determine cause. Adjustments, Valve Body Warpage or Malfunction, Sticking Governor, Leaking Seal Rings, Clutch Seals Leaking, Servo Leaks, Clogged Filter or Cooler Lines...
Page 999 TRANSMISSION AND TRANSFER CASE 21 - 93 DIAGNOSIS AND TESTING (Continued) DIAGNOSIS CHART (CONTINUED) CONDITION POSSIBLE CAUSES CORRECTION TORQUE CONVERTER Lockup Solenoid, Relay or Wiring Test solenoid, relay and wiring for LOCKS UP IN SECOND Shorted/Open. continuity, shorts or grounds. Replace AND/OR THIRD GEAR solenoid and relay if faulty.
Page 1000 21 - 94 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) DIAGNOSIS CHART (CONTINUED) CONDITION POSSIBLE CAUSES CORRECTION 11. Converter Housing Area Leaks. 11. Check for leaks at seal caused by worn seal or burr on converter hub (cutting seal), worn bushing, missing oil return, oil in front pump housing or hole plugged.
Page 1001 TRANSMISSION AND TRANSFER CASE 21 - 95 SERVICE PROCEDURES (Continued) (2) Install screws to hold filter to valve body (Fig. 15). Tighten screws to 4 N·m (35 in. lbs.) torque. (3) Place new gasket in position on pan. and install pan on transmission. (4) Place pan in position on transmission.
Page 1002 21 - 96 TRANSMISSION AND TRANSFER CASE SERVICE PROCEDURES (Continued) the vehicle is parked for lengthy periods. The valve The only recommended procedure for flushing cool- check ball is spring loaded and has an opening pres- ers and lines is to use Tool 6906 Cooler Flusher. sure of approximately 2 psi.
Page 1003 TRANSMISSION AND TRANSFER CASE 21 - 97 SERVICE PROCEDURES (Continued) (11) Place CLEAR suction line into a one quart container of Mopar ATF Plus 3, 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.
Page 1004 21 - 98 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) propeller shaft. On 4 x 4 models, remove both propel- ler shafts. (14) Disconnect wires from park/neutral position switch and vehicle speed sensor. (15) Disconnect gearshift cable from transmission manual valve lever.
Page 1005 TRANSMISSION AND TRANSFER CASE 21 - 99 REMOVAL AND INSTALLATION (Continued) Fig. 19 Transmission Attachment (21) Remove engine support fixture. TORQUE CONVERTER (22) Remove transmission jack. (23) Connect vehicle speed sensor wires. REMOVAL (24) Connect wires to park/neutral position switch. (1) Remove transmission and torque converter (25) Install crankshaft position sensor.
Page 1006 21 - 100 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) (1) Lubricate converter hub and oil pump seal lip (6) Remove bolts holding extension housing to with transmission fluid. transmission case (Fig. 21). (2) Place torque converter in position on transmis- (7) Separate extension housing from transmission.
Page 1007 TRANSMISSION AND TRANSFER CASE 21 - 101 REMOVAL AND INSTALLATION (Continued) (5) Remove speed sensor retaining screw and (8) Install speedometer assembly in housing. remove sensor from adapter. (9) Rotate adapter until required range numbers (6) Remove speedometer pinion from adapter. are at 6 o’clock position.
Page 1008 21 - 102 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) PARK/NEUTRAL POSITION SWITCH (4) Place the floor shifter lever in park position. Ensure that the pawl is seated within the confines of the adjustment gauge clip. REMOVAL (1) Raise vehicle and position drain pan under (5) Snap the cable into the transmission bracket so switch.
Page 1009 TRANSMISSION AND TRANSFER CASE 21 - 103 REMOVAL AND INSTALLATION (Continued) Fig. 26 Cable and Shifter (2) Insert cable end into opening in steering col- (3) Loosen clamp bolts and remove throttle and umn hub under ignition lock. Push cable inward manual valve levers from manual lever shaft.
Page 1010 21 - 104 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) (7) Remove valve body attaching screws. (5) Position accumulator spring between accumula- (8) Lower valve body enough to remove accumula- tor piston and valve body. tor piston and piston spring (Fig. 28). (6) Position valve body on transmission and work (9) Pull valve body forward to disengage park rod.
Page 1011 TRANSMISSION AND TRANSFER CASE 21 - 105 REMOVAL AND INSTALLATION (Continued) GOVERNOR AND PARK GEAR REMOVAL (1) Hoist and support vehicle on safety stands. (2) Mark propeller shaft and axle yoke for assem- bly reference. Then disconnect and remove shaft. (3) Disconnect parking brake cable at equalizer and disconnect exhaust components as necessary.
Page 1012 21 - 106 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) PARK LOCK DISASSEMBLY AND ASSEMBLY GOVERNOR AND PARK GEAR REMOVAL (1) Raise vehicle and remove propeller shaft. (2) Remove extension housing. DISASSEMBLY (3) Slide sprag shaft out of extension housing and (1) Remove governor body from transmission.
Page 1013 TRANSMISSION AND TRANSFER CASE 21 - 107 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 38 Intermediate and Inner Governor Weights VALVE BODY DISASSEMBLY Position the valve body on a clean work surface to avoid contamination. Fig. 37 Inner Weight Snap Ring ASSEMBLY CAUTION: Do not clamp any part of the valve body assembly (Fig.
Page 1014 21 - 108 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (2) Remove adjusting screw bracket, line pressure adjusting screw (Fig. 40). (3) Remove switch valve and spring, pressure reg- ulator valve and spring, kickdown valve and spring, and throttle valve from valve body (Fig. 40). (4) Secure detent ball and spring in housing with Retainer Tool 6583 (Fig.
Page 1015 TRANSMISSION AND TRANSFER CASE 21 - 109 DISASSEMBLY AND ASSEMBLY (Continued) (14) Remove converter clutch valve, fail safe valve, and springs (Fig. 47) (15) Turn valve body over so transfer plate is fac- ing upward (Fig. 48). With valve body in this posi- tion, valve body check balls will remain in place and not fall out when transfer plate is removed.
Page 1016 21 - 110 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (19) Remove screws attaching separator plate to transfer plate (Fig. 49). (20) Note position of filter, rear clutch servo and rear servo check balls for assembly reference (Fig. 49) and (Fig. 50). (21) Remove shuttle valve end plate (Fig.
Page 1017 TRANSMISSION AND TRANSFER CASE 21 - 111 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 53 Control Valves, Shift Valves, And Governor Plugs CAUTION: Do not force valves or plugs into place (7) Install throttle pressure plug in kickdown limit during reassembly. If the valve body bores, valves, valve body (Fig.
Page 1018 21 - 112 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (19) Compress spring and install E-clip in groove on shuttle valve stem (Fig. 54). (20) Place shuttle valve end plate in position on valve body (Fig. 55). (21) Install screws to attach shuttle valve end plate to valve body (Fig.
Page 1019 TRANSMISSION AND TRANSFER CASE 21 - 113 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 60 Converter Clutch Valve Module Fig. 58 Correct Position Of Valve Body Check Balls Fig. 61 Clutch Module And Connecting Tube Fig. 59 Valve Body Transfer Plate Screws Fig.
Page 1020 21 - 114 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (39) If necessary, insert park rod end into manual lever and install E-clip (Fig. 63). Fig. 65 Manual Valve Fig. 63 Park Rod (40) Insert detent spring and ball into opening in valve body and install Retainer Tool 6583 (Fig.
Page 1021 TRANSMISSION AND TRANSFER CASE 21 - 115 DISASSEMBLY AND ASSEMBLY (Continued) NOTE: The 32RH is equipped with an additional spring under the accumulator piston. Fig. 68 Adjusting Screw Bracket, Springs, and Valves TRANSMISSION Fig. 69 Repair Stand DISASSEMBLY (1) Remove transmission from vehicle. (2) Install a suitable tail shaft housing plug to avoid contaminating internal components with clean- ing solvents.
Page 1022 21 - 116 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (12) Loosen front band adjusting screw lock nut (Fig. 72) 4-5 turns. Then tighten band adjusting screw until band is tight around front clutch. This prevents front/rear clutches from coming out with pump and possibly damaging clutch or pump compo- nents.
Page 1023 TRANSMISSION AND TRANSFER CASE 21 - 117 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 78 Front Band Fig. 76 Separating Front Clutch From Rear Clutch Fig. 79 Planetary Geartrain (27) Remove snap ring that secures low-reverse drum to rear support hub, however do not remove drum (Fig.
Page 1024 21 - 118 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 80 Rear Band Adjuster Location Fig. 83 Overrunning Clutch Cam Bolt Locations (a) Remove low-reverse drum and overrunning clutch as assembly. Slide drum and clutch through rear band and out of case (Fig. 84). Set drum and clutch assembly aside for cleaning and inspection.
Page 1025 TRANSMISSION AND TRANSFER CASE 21 - 119 DISASSEMBLY AND ASSEMBLY (Continued) REAR BAND—30RH (31) Remove rear band. The 30RH transmission is equipped with a single-wrap band with a link bar. (a) Using snap-ring plier, pull rear band anchor pin (located on the servo side of the rear support) from transmission case.
Page 1026 21 - 120 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (d) Using snap-ring plier, pull rear band lever pivot from transmission case (Fig. 90). (e) Separate rear band servo lever from trans- mission. Fig. 91 Compressing Front Servo Fig. 90 Rear Band Servo Lever Pin (33) Compress front servo rod guide about 1/8 in.
Page 1027 TRANSMISSION AND TRANSFER CASE 21 - 121 DISASSEMBLY AND ASSEMBLY (Continued) NOTE: The bolt holes in cam are slightly counter- (15) Hold low-reverse drum in position so rear sup- sunk on one side. This side of cam faces rearward port will not push it out of overrunning clutch. (16) Insert rear support into opening at rear of (toward rear support).
Page 1028 21 - 122 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (21) Install assembled output shaft and planetary geartrain in case (Fig. 96). (22) Align drive lugs on rear planetary gear with slots in low-reverse drum (Fig. 96). Then seat plane- tary assembly in drum.
Page 1029 TRANSMISSION AND TRANSFER CASE 21 - 123 DISASSEMBLY AND ASSEMBLY (Continued) (30) Insert front band into opening at front of transmission case (Fig. 103). (31) Install front and rear clutch units as assembly (Fig. 104). Align rear clutch with front annulus gear and install assembly in driving shell.
Page 1030 21 - 124 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (33) Engage front band on adjusting screw and hold band in place. (34) Install strut between band lever and front band (Fig. 105). (35) Tighten front band adjusting screw until band just grips clutch retainer.
Page 1031 TRANSMISSION AND TRANSFER CASE 21 - 125 DISASSEMBLY AND ASSEMBLY (Continued) (44) Position transmission on work surface with pan face upward. (45) Install valve body. (46) Adjust front and rear bands. (47) Install fluid filter and pan. (48) Install rear extension housing. (49) Install torque converter.
Page 1032 21 - 126 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLY (1) Assemble clutch rollers and springs in retainer if necessary (Fig. 112). (2) Install overrunning clutch roller, spring and retainer assembly in clutch cam (Fig. 113). (3) Temporarily assemble and check overrunning clutch operation as follows: (a) Assemble cam and clutch.
Page 1033 TRANSMISSION AND TRANSFER CASE 21 - 127 DISASSEMBLY AND ASSEMBLY (Continued) OIL PUMP AND REACTION SHAFT SUPPORT DISASSEMBLY (1) Remove seal ring from housing and reaction shaft support (Fig. 118). (2) Mark pump housing and support assembly for alignment reference. (3) Remove bolts attaching pump body to support (Fig.
Page 1034 21 - 128 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (4) Separate support from pump housing (Fig. OIL PUMP BUSHING REPLACEMENT 120). (1) Remove pump bushing with Tool Handle (5) Remove inner and outer gears from reaction C-4171 and Bushing Remover SP-3551 from Tool Set shaft support (Fig.
Page 1035 TRANSMISSION AND TRANSFER CASE 21 - 129 DISASSEMBLY AND ASSEMBLY (Continued) 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.
Page 1036 21 - 130 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (8) Install reaction shaft support on pump housing FRONT CLUTCH (Fig. 129). (9) Align reaction support on pump housing. Use DISASSEMBLY alignment marks made at disassembly. Or, rotate (1) Remove waved snap ring and remove pressure support until bolt holes in support and pump housing plate, clutch plates and clutch discs (Fig.
Page 1037 TRANSMISSION AND TRANSFER CASE 21 - 131 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 131 Front Clutch Components Fig. 133 Front Clutch Piston Installation Fig. 132 Compressing Front Clutch Piston Spring...
Page 1038 21 - 132 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (5) Position spring in clutch piston (Fig. 134). (c) Release the pressure plate and zero the dial (6) Position spring retainer on top of piston spring indicator. (Fig. 135). Make sure retainer is properly (d) Lift the pressure plate until it contacts the installed.
Page 1039 TRANSMISSION AND TRANSFER CASE 21 - 133 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 137 Rear Clutch Components (3) Lubricate splined end of input shaft and clutch 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.
Page 1040 21 - 134 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (9) Install piston spring in retainer and on top of piston (Fig. 142). Concave side of spring faces down- ward (toward piston). (10) Install wave spring in retainer (Fig. 142). Be sure spring is completely seated in retainer groove.
Page 1041 TRANSMISSION AND TRANSFER CASE 21 - 135 DISASSEMBLY AND ASSEMBLY (Continued) (b) Using two small screw drivers, lift the pres- PLANETARY GEARTRAIN/OUTPUT SHAFT sure plate and release it. (c) Zero the dial indicator. DISASSEMBLY (d) Lift the pressure plate until it contacts the (1) Remove planetary snap ring (Fig.
Page 1042 21 - 136 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (5) Separate front annulus and planetary gears ASSEMBLY (Fig. 147). (1) Lubricate output shaft and planetary compo- (6) Remove front planetary gear front thrust nents with transmission fluid. Use petroleum jelly to washer from annulus gear hub.
Page 1043 TRANSMISSION AND TRANSFER CASE 21 - 137 DISASSEMBLY AND ASSEMBLY (Continued) (6) Install front thrust washer on rear planetary gear (Fig. 151). 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.
Page 1044 21 - 138 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (11) Align rear thrust plate on driving shell and install sun gear lock ring. Be sure ring is fully seated in sun gear ring groove (Fig. 156). (12) Install assembled driving shell and sun gear on output shaft (Fig.
Page 1045 TRANSMISSION AND TRANSFER CASE 21 - 139 DISASSEMBLY AND ASSEMBLY (Continued) (19) Install thrust washer in front annulus (Fig. 161). Align flat on washer with flat on planetary hub. Also be sure washer tab is facing up. (20) Install front annulus snap ring (Fig. 162). Use snap ring pliers to avoid distorting ring during installation.
Page 1046 21 - 140 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION (Continued) Inspect the governor weight spring for distortion. Clean the filter in solvent and dry it with compressed Replace the spring, if distorted, collapsed, or broken. air. Replace the filter, if damaged. Inspect the park Fig.
Page 1047 TRANSMISSION AND TRANSFER CASE 21 - 141 CLEANING AND INSPECTION (Continued) gear for chipped or worn gear teeth or damaged ring grooves. Replace the gear, if damaged. Check the teeth on the park gear for wear or dam- age. Replace the gear if necessary. Inspect the metal seal rings on the park gear hub.
Page 1048 21 - 142 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION (Continued) NOTE: Do not use rags or shop towels to wipe off age the special coating and cause the valves and valve body components. Lint from these materials plugs to stick and bind. will adhere to the valve body components.
Page 1049 TRANSMISSION AND TRANSFER CASE 21 - 143 CLEANING AND INSPECTION (Continued) TRANSMISSION thrust washers and to hold parts in place during reassembly. Clean the case in a solvent tank. Flush the case bores and fluid passages thoroughly with solvent. OVERRUNNING CLUTCH/LOW-REVERSE Dry the case and all fluid passages with compressed DRUM/OVERDRIVE PISTON RETAINER air.
Page 1050 21 - 144 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION (Continued) REAR SERVO (b) Clearance between inner gear tooth and outer gear should be 0.08 to 0.19 mm (0.0035 to Remove and discard the servo piston seal ring (Fig. 0.0075 in.). Measure clearance with an appropriate 172).
Page 1051 TRANSMISSION AND TRANSFER CASE 21 - 145 CLEANING AND INSPECTION (Continued) PLANETARY GEARTRAIN/OUTPUT SHAFT Clean the intermediate shaft and planetary compo- nents in solvent and dry them with compressed air. Do not spin the planetary pinion gears with com- pressed air. Inspect the planetary gear sets and annulus gears.
Page 1052 21 - 146 TRANSMISSION AND TRANSFER CASE ADJUSTMENTS (Continued) (4) Unsnap cable from cable mounting bracket on transmission (Fig. 175). (5) Slide cable eyelet off transmission shift lever. (6) Verify transmission shift lever is in Park detent by moving lever fully rearward. Last rearward detent is Park position.
Page 1053 TRANSMISSION AND TRANSFER CASE 21 - 147 ADJUSTMENTS (Continued) be necessary. Or, if throttle body lever prevents transmission lever from returning to closed position, cable adjustment will be necessary. Throttle Valve Cable Adjustment Procedure (1) Turn ignition switch to OFF position. (2) Remove air cleaner if necessary.
Page 1054 21 - 148 TRANSMISSION AND TRANSFER CASE ADJUSTMENTS (Continued) (4) Back off front band adjusting screw 2-1/2 turns for the 30RH and 2-1/4 turns for the 32RH. (5) Hold adjuster screw in position and tighten locknut to 41 N·m (30 ft. lbs.) torque. (6) Lower vehicle.
Page 1055 TRANSMISSION AND TRANSFER CASE 21 - 149 ADJUSTMENTS (Continued) Fig. 182 Line Pressure Adjustment Fig. 183 Throttle Pressure Adjustment...
Page 1056 21 - 150 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS...
Page 1057 TRANSMISSION AND TRANSFER CASE 21 - 151 SCHEMATICS AND DIAGRAMS (Continued)
Page 1058 21 - 152 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS (Continued)
Page 1059 TRANSMISSION AND TRANSFER CASE 21 - 153 SCHEMATICS AND DIAGRAMS (Continued)
Page 1060 21 - 154 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS (Continued)
Page 1061 TRANSMISSION AND TRANSFER CASE 21 - 155 SCHEMATICS AND DIAGRAMS (Continued)
Page 1062 21 - 156 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS (Continued)
Page 1063 TRANSMISSION AND TRANSFER CASE 21 - 157 SCHEMATICS AND DIAGRAMS (Continued)
Page 1064 21 - 158 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS (Continued)
Page 1065 TRANSMISSION AND TRANSFER CASE 21 - 159 SCHEMATICS AND DIAGRAMS (Continued)
Page 1066 21 - 160 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS (Continued)
Page 1067 TRANSMISSION AND TRANSFER CASE 21 - 161 SCHEMATICS AND DIAGRAMS (Continued)
Page 1068 21 - 162 TRANSMISSION AND TRANSFER CASE SPECIFICATIONS 30/32RH AUTOMATIC TRANSMISSION GENERAL COMPONENT METRIC INCH Oil pump gear tip clearance 0.089-0.190 mm 0.0035-0.0075 in. Planetary end play 0.125-1.19 mm 0.001-0.047 in. Input shaft end play 0.56-2.31 mm 0.022-0.091 in. Clutch pack clearance/Front 4-disc. 1.70-3.40 mm 0.067-0.134 in.
Page 1069 TRANSMISSION AND TRANSFER CASE 21 - 163 SPECIFICATIONS (Continued) PRESSURE TEST—ALL ITEM RANGE PRESSURE Line pressure (at Closed throttle 372-414 kPa (54-60 psi). accumulator) Front servo Third gear only No more than 21 kPa (3 psi) lower than line pressure. Rear servo 1 range No more than 21 kPa (3 psi) lower than line pressure.
Page 1070 21 - 164 TRANSMISSION AND TRANSFER CASE SPECIAL TOOLS (Continued) Pilot Stud—C-3288-B Spring Compressor—C-3422-B Pressure Gauge—C-3292 Fixture, Engine Support—C-3487-A Pressure Gauge—C-3293SP Spring Compressor—C-3575-A Dial Indicator—C-3339 Spring Compressor—C-3863-A...
Page 1071 TRANSMISSION AND TRANSFER CASE 21 - 165 SPECIAL TOOLS (Continued) Adapter, Band Adjuster—C-3705 Seal Installer—C-3860-A Transmission Repair Stand—C-3750-B Bushing Remover/Installer—C-3887-J Puller, Slide Hammer—C-3752 Cup, Remover—SP-3633 Gauge, Throttle Setting—C-3763 Remover, Bushing—SP-5301...
Page 1072 21 - 166 TRANSMISSION AND TRANSFER CASE SPECIAL TOOLS (Continued) Installer, Bushing—SP-5118 Installer, Bushing—SP-5511 Installer, Bushing—SP-5302 Snap-ring Plier—C-3915 Remover, Bushing—SP-3550 Seal Remover—C-3985-B Remover, Bushing—SP-3629 Bushing, Remover—6957...
Page 1073 TRANSMISSION AND TRANSFER CASE 21 - 167 SPECIAL TOOLS (Continued) Flusher, Oil Cooler—6906 Nut, Bushing Remover—SP-1191 Installer—C-3995-A Universal Handle—C-4171 Remover/Installer—C-4470...
Page 1074 21 - 168 TRANSMISSION AND TRANSFER CASE NV231 TRANSFER CASE INDEX page page GENERAL INFORMATION TRANSFER CASE ..... . 170 NV231 TRANSFER CASE .
Page 1075 TRANSMISSION AND TRANSFER CASE 21 - 169 DIAGNOSIS AND TESTING NV231 DIAGNOSIS...
Page 1076 21 - 170 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (8) Align and connect propeller shafts. Refer to Group 3, Differential and Driveline, for proper proce- TRANSFER CASE dures and specifications. (9) Fill transfer case with correct fluid. Check REMOVAL transmission fluid level.
Page 1077 TRANSMISSION AND TRANSFER CASE 21 - 171 REMOVAL AND INSTALLATION (Continued) Fig. 3 Shift Linkage (6) Remove speedometer pinion from adapter. (8) Inspect terminal pins in speed sensor. Clean Replace pinion if chipped, cracked, or worn. pins with Mopar electrical spray cleaner if dirty or (7) Inspect sensor and adapter O-rings (Fig.
Page 1078 21 - 172 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) INSTALLATION AND INDEXING (4) Remove seal from front case with pry tool (Fig. (1) Thoroughly clean adapter flange and adapter mounting surface in housing. Surfaces must be clean for proper adapter alignment and speedometer oper- ation.
Page 1079 TRANSMISSION AND TRANSFER CASE 21 - 173 DISASSEMBLY AND ASSEMBLY (Continued) (2) Spread band clamp which holds output shaft boot to slinger with a suitable awl, or equivalent. (3) Remove output shaft boot from slinger and out- put shaft. (4) Using Puller MD-998056-A, remove...
Page 1080 21 - 174 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (12) Disengage oil pickup tube from oil pump and remove oil pump assembly. Remove oil pump by tilt- ing the edge of the oil pump from under the edge of the rear case half and sliding the pump (Fig.
Page 1081 TRANSMISSION AND TRANSFER CASE 21 - 175 DISASSEMBLY AND ASSEMBLY (Continued) (3) Loosen rear case with flat blade screwdriver to break sealer bead. Insert pry tool blade only into notches provided at each end of case (Fig. 19). (4) Remove rear case from front case. Fig.
Page 1082 21 - 176 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 24 Mode Fork And Sleeve Removal Fig. 22 Remove Front Output Shaft And Chain SHIFT FORKS AND MAINSHAFT REMOVAL (1) Remove detent plug, O-ring, detent spring and detent plunger (Fig. 23). (2) Remove mainshaft from mode sleeve and input gear pilot bearing.
Page 1083 TRANSMISSION AND TRANSFER CASE 21 - 177 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 27 Sector Bushing And O-Ring Removal Fig. 29 Mode Hub Removal MAINSHAFT DISASSEMBLY (1) Remove mode hub retaining ring with heavy duty snap-ring pliers (Fig. 28). (2) Slide mode hub off mainshaft (Fig. 29). (3) Slide drive sprocket off mainshaft (Fig.
Page 1084 21 - 178 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 34 Input Gear And Planetary Carrier Removal Fig. 32 Front Bearing Retainer Removal Fig. 35 Input Gear Snap-Ring Removal Fig. 33 Removing Input Gear Retaining Ring (5) Place front case in horizontal position. Then remove input gear and low range gear as an assem- bly (Fig.
Page 1085 TRANSMISSION AND TRANSFER CASE 21 - 179 DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLY Lubricate transfer case components with Mopar Dexron II automatic transmission fluid or petroleum jelly (where indicated) during assembly. BEARING AND SEAL INSTALLATION CAUTION: The bearing bores in various transfer case components contain oil feed holes.
Page 1086 21 - 180 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (6) Install new front output seal in front case with Installer Tool 8143 as follows: (a) Place new seal on tool. Garter spring on seal goes toward interior of case. (b) Start seal in bore with light taps from ham- mer (Fig.
Page 1087 TRANSMISSION AND TRANSFER CASE 21 - 181 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 49 Input Shaft Bearing Removal Fig. 47 Output Shaft Rear Bearing Installation Fig. 50 Seating Input Shaft Bearing Fig. 48 Output Shaft Rear Bearing Installation Depth (13) Remove input gear pilot bearing by inserting a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a (9) Using Remover C-4210 and Handle C-4171,...
Page 1088 21 - 182 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 51 Remove Input Gear Pilot Bearing Fig. 53 Install Front Bearing Retainer Seal Fig. 54 Oil Pump Seal Installation (19) Remove rear retainer bearing with Installer 8128 and Handle C-4171. (20) Install rear bearing in retainer with Handle C-4171 and Installer 5064 (Fig.
Page 1089 TRANSMISSION AND TRANSFER CASE 21 - 183 DISASSEMBLY AND ASSEMBLY (Continued) INPUT GEAR AND LOW RANGE GEAR INSTALLATION (1) Align and install low range/input gear assem- bly in front case (Fig. 57). Be sure low range gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing.
Page 1090 21 - 184 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) CAUTION: Do not block fluid return cavity on seal- ing surface of retainer when applying Mopar gas- ket maker or silicone adhesive sealer. Seal failure and fluid leak can result. (6) Install bolts to hold retainer to transfer case (Fig.
Page 1091 TRANSMISSION AND TRANSFER CASE 21 - 185 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 63 Install Range Fork And Hub Assembly Fig. 66 Mode Fork And Sleeve Installation (11) Install new O-ring on detent plug (Fig. 67). (12) Lubricate detent plunger with transmission fluid or light coat of petroleum jelly.
Page 1092 21 - 186 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 70 Installing Case Magnet Fig. 68 Installing Drive Chain And Front Output Shaft Fig. 71 Pickup Tube O-Ring Position Fig. 69 Install Mode Fork Spring OIL PUMP AND REAR CASE ASSEMBLY/INSTALLATION (1) Install magnet in front case pocket (Fig.
Page 1093 TRANSMISSION AND TRANSFER CASE 21 - 187 DISASSEMBLY AND ASSEMBLY (Continued) aligned and that mode fork rail extends through rear case before seating rear case on front case. (8) Install case attaching bolts. Alignment bolts at each end of case are only ones requiring washers (Fig.
Page 1094 21 - 188 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) CLEANING AND INSPECTION NV231 TRANSFER CASE Clean the transfer case parts with a standard parts cleaning solvent. Remove all traces of sealer from the cases and retainers with a scraper and 3M all purpose cleaner.
Page 1095 TRANSMISSION AND TRANSFER CASE 21 - 189 CLEANING AND INSPECTION (Continued) Fig. 80 Mainshaft, Mode Hub, And Drive Sprocket Fig. 81 Input Gear And Carrier Components Replace the slinger and seal outright; do not reuse REAR RETAINER/BEARING/ SEAL/SLINGER/ BOOT either part. Inspect the retainer components (Fig.
Page 1096 21 - 190 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION (Continued) Examine the drive chain and shaft bearings. Replace the chain and both sprockets if the chain is stretched, distorted, or if any of the links bind. Replace the bearings if rough, or noisy. LOW RANGE ANNULUS GEAR Inspect annulus gear condition carefully.
Page 1097 TRANSMISSION AND TRANSFER CASE 21 - 191 ADJUSTMENTS (Continued) Fig. 84 Rear Retainer Components Fig. 85 Seal Contact Surface Of Yoke Slinger Fig. 86 Low Range Annulus Gear...
Page 1098 21 - 192 TRANSMISSION AND TRANSFER CASE ADJUSTMENTS (Continued) SPECIAL TOOLS SPECIAL TOOLS—NV231 Installer—C-4076-B Puller, Slinger—MD-998056–A Fig. 87 Shift Linkage SPECIFICATIONS TORQUE DESCRIPTION TORQUE Plug, Detent ...16–24 N·m (12–18 ft. lbs.) Plug, Drain/Fill .
Page 1099 TRANSMISSION AND TRANSFER CASE 21 - 193 SPECIAL TOOLS (Continued) Installer, Boot Clamp—C-4975-A Installer, Bearing—5064 Installer, Seal—8143 Installer, Bearing—5065 Installer, Bushing—5066 Handle, Universal—C-4171 Installer, Bearing—8128 Installer, Seal—C-4210...
Page 1100 21 - 194 TRANSMISSION AND TRANSFER CASE SPECIAL TOOLS (Continued) Installer, Seal—7884 Remover—L-4454 Installer, Pump Housing Seal—7888 Cup—8148...

Jeep Wrangler 1997 Manual

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Page 847: General Service Information

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