Standard Procedure - Aluminum Thread Repair; Removal - Jeep 2002 WJ Service Manual

21a - 28 TRANSMISSION AND TRANSFER CASE
AUTOMATIC TRANSMISSION - W5J400 (Continued)
CONDITION
LEAKAGE AT THE AREA
OF THE ELECTRICAL
PLUG TO THE
CONDUCTOR PLATE
LEAKAGE AT THE AREA
OF BELL HOUSING/
TORQUE CONVERTER
OIL LEAKS
STANDARD PROCEDURE - 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 con-
sists of drilling out the worn-out damaged threads.
Then tap the hole with a special Heli-Coil™ tap, or
equivalent, and installing a Heli-Coil™ insert, or
equivalent, into the hole. This brings the hole back to
its original thread size.
Heli-Coil™, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.

REMOVAL

(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle.
(3) Remove any necessary skid plates (Refer to 13
- FRAME & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - REMOVAL).
(4) Mark propeller shaft and axle yokes for assem-
bly alignment.
(5) Remove the rear propeller shaft.
POSSIBLE CAUSES
1. Deformation O-Rings.
2. Deformation Adapter.
3. The Conductor Plate Is Not Fitted
Surface To Surface On The Valve
Body In One Corner, The Plug Is Not
Centered In The Socket And The
O-ring Will Not Seal.
4. Contacting At The Conductor Plate
Leaky. Oil In Harness, Sometimes In
The Control Module.
1. Bolts (Torx M6) Outer Disc Carrier
B1.
1. 6 Lower Bolts (TorxM8) Converter
Housing.
2. Oil Drain Plug Converter Loose
Resp. No Seal Ring Installed.
3. Weld Seam Of Torque Converter
Leaky.
4. Radial Sealing Ring Oil Pump
Defective.
5. O-Ring Oil Pump Defective Or Not
Installed.
6. Bushing Of Oil Pump Loose,
caused By Missing Fit Bolt At
Transmission/Engine Flange.
exhaust components.
the diesel engine adapter.
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.
manual valve lever.
ing the heat shield (2) to the transmission.
Turn bayonet lock of guide bushing (2) anti-clock-
wise.
drain plug (8).
transfer case shift lever.
shift cable into the cable support bracket.
1. Replace O-Rings.
2.Replace Adaptor.
3. Remove Nose Of Conductor
Plate.
4. Replace Conductor Plate.
1. Clean Thread and Install the
Bolts Using Sealer.
1. Clean Thread and Install the
Bolts Using Sealer.
2. Install Drain Plug Correctly.
3. Replace Torque Converter.
4. Replace Sealing Ring.
5. Install O-Ring.
6. Install Fit Bolt If Necessary.
(6) Remove the front propeller shaft.
(7) Disconnect and lower or remove any necessary
(8) Remove the starter motor.
(9) Remove the torque converter access plug from
(10) Rotate crankshaft in clockwise direction until
(11) Disconnect gearshift cable from transmission
(12) Remove bolt (3) (Fig. 22) and screw (1) hold-
(13) Disconnect 13-pin plug connector (1) (Fig. 23).
(14) Drain transmission oil by unscrewing oil
(15) Disconnect transfer case shift cable from the
(16) Remove the clip securing the transfer case
WG
CORRECTION