INTRODUCTION JEEP AW-4 ‘The AW-4 is a four speed, electronically controlled automatic transmission. Running gear consists of a lock-up converteroll pump:three planetary gear sets:clutch and brake units:hydraulle accumulators:a valve body with electric ‘Solenoids and a transmission computer unit (TCU). Cables are used for shifting ‘and throttle presaure control. A neutral safety switch permits engine starting in Park and Neutral range only. The valve body solenoids are controled by signal from the TCU. Signal sequence is determined by volicle speed and throttle position. Fourth gear is an 70:1 ratio overdrive range. First second,third and Feverse gear are conventional ranges. Third geer ratio is 1:1. A separate planetary ‘gear set provides overdrive operation in fourth gear. We thank the Chrysler Corporation for the illustrations and information that have ‘made this booklet possible ROBERT D. CHERRNAY DALE ENGLAND “TECHNICAL DIRECTOR FIELD SERVICE CONSULTANT WAYNE COLONNA ED KRUSE ‘TECHNICAL SUPERVISOR ‘TECHNICAL CONSULTANT PETER LUBAN JIM DIAL, ‘TECHNICAL CONSULTANT ‘TECHNICAL CONSULTANT GREGORY LIPNICK. JERRY GOTT | TECHNICAL CONSULTANT ‘TECHNICAL CONSULTANT DAVID CHALKER, ARSENIO RIVERA ‘TECHNICAL CONSULTANT “TECHNICAL CONSULTANT AUTOMATIC TRANSMISSION SERVICE GROUP 9200S, DADELAND BLVD. SUITE 720, ‘MIAMI, FLORIDA 33156 (605) 670-4161 LSJEEP AW-4 INDEX ‘Transmission System. 3 Diagnosis. 1 ‘Trouble Shooting... 10 ‘Transmission Service. 13 “Transmission & Torque Converter Removal 6 Transmission Overhaul... 2 ‘Sub-Assembly Overhaul “ Valve Body Teardown. nm ‘Transmission Assembly. AUTOMATIC TRANSMISSION SERVICE GROUP 19200 8, Dadeland Biv. ‘Suite 720 (MIAMI FLORIDA 33186 (205) 670-4161SERVICE INFORMATION JEEP AW-4 GEAR SHIFT POSITIONS "The AW-{tanumision has ix gor silver po- sition. Park, Reverse end Neural pontine are co ‘entonl and mechanically operated Te 12,8 nD ‘anges provide acral cnlled cing "The 12 potion proves firs aad sna get eal. ‘Tha parti provides Bt ean and third par The Drange provides Set tough forts gear Overdrive ford gar rangeisevalabe onl when the cif lever {iD postion Fig ‘TRANSMISSION IDENTIFICATION ‘The tranuieion LD. plate i tached to te came (Fig 9 The plate contain the tension serial and ‘Sedal numbers. Refer othe formation 0 this plata hen erderiog weve pars, ‘COMPONENTS AND OPERATION ectronle Controls ‘Tae AW4 is eectronialy contralld in th forward gvorrangea To contol cot the TCU, vabvbndy ‘Sleold nd sensors that moat voice ped hot {Te opening sift lever poton and bake eal pi rev ‘The TCU detrei shit nd converter lockup ta ing aed ensigns en the sensor. The val Day ‘elect are atvetadnatvred scoring. "Tae TOU bara self diagnose program. Component sod cacy malfunctions canbe dagaosed wih the o0Z2D 0 ‘ig. 2 Goar Sit Postions ‘DRE Teter. Once» malfnction i need and stared {R'TCU wonmory iis retained even after the prblen. acbeen cased Te cancels stored malencton sn Sy Saconect and reconnect the “Trans” fase m he ade provides normal sit sponds {hd pint. The Power mede provides higher engi ‘oods and shift pointe shen extra aecleration snd tong are ned The ft dasa activated bya ‘eh in te instrament pase "Teese incudethe tht position str TPS, he sped tener thn nie sity so tad he rake pil application sith "Tae tretlepston sensors mounted the hate ‘ay eslactroncly determine rote pecs and ‘laa thi nlrmation tothe TCU tocol ahi ‘ints aod eenvertar ac. "These senor consis of oto and magneton the teananiaien ott shaft and watchin een owing aaptr Tho cna switchs activated each tine the rtrd magnet complete one revslton ‘Sensor sgeals retransmit tothe TCU. ate The wth signal inkage and ‘anual valve pion tothe TCU through an ater- onneting hareeae Te switch prevents engine sar igi al pecs ther than Pak or Nesta Fg. 3 Tanemission tontiicationService Information AW-4 ‘The brake pplication evtch releases the ack-up ‘latch nthe torque coaertar whenever the brakes re Sspplied. The switch is mounted n the brake pedal ‘racket nd lgele the TCU when the pedal i presed or rele, TORQUE CONVERTER Alackup torque convert ated oral application ‘The lockup mechoniam conse of aad cute ton, chatch springs and the clutch ise material Pig) ‘The disc ir attached to the converter font ever The latch piston and clutch springs ay tached tothe turbine hub. The springs dampen engine ring t= ules and lade during te inital phase of converter Tock Lockop is controled by valve bay solenoid number thre and bythe lockup relay valve. At lek men, ‘he solenoid channel line presare tthe lockup teh {rough the relay valve "Torgs converter ockp occurs in tend per in 1-2 ition; third gear in 3 position and third ond fourth (ear inD poston. FOURTH GEAR OVERDRIVE COMPONENTS “Theoverdrive sytem consist ofthe np ba one- way elueh planetary sun gear, rng ear plentary {arte dret clutch and overdrive brake (Fig 6). The dive nan gear from turnng. During operation, the terre elements operete at flows: "The overdrive input haf and planetary carier ro tats ae nit The aun gear and overdrive direct teh rum are in mech and oprate as sngle unt. Te Airect clutch splines function othe hu for the over Arve brake. The one-way’ ctch outer rein in mech ‘wih de planetary carrier Thetenr races ad othe un gar sha, FIRST-THIRD-REVERSE GEAR COMPONENTS Frsc-thid and rereee gear eompovents er outlined ‘in Figure 6 "Th inpat shaft a med with the direct clutch bub td the forward latch drum, The elements rotate x ‘Gait The forward clutch ab rotates at uni with the front planetary tng gear. The dive dutch drum toService Information AW-4 ee ne cemetery SEANSORSDE MS chemeencucos Gren abt oe te SSE satire se planetary cartier. "Tuc Cnponent Function Chart (Pig 7 deserbes be re Ae aceeeindtotenant Pactra Tet ‘shaft. The front planetary carrier and rear carrier FINE Gonent Application Chart (Fig, 8) indicates which ‘gear are meshed and rotate as 8 unit with the output Siemens (including valve body solenoids), are applied ike varios gear MommncLaTueE FuNcnon ‘Crvaine Ome Cach vernon tne by gee corns nwa gr ond ocr Fomod Gus Conese ed ton Fate Sake ve lar cri ban ig oe cen oro Soc ‘When con rae part od ott om om ong ome re tay Cane SS ‘ig. 7 Component Function ChartService Information AW-4 comer | om fossa ||] 8 fe] ta] | a SSE tee > GSxtbeche te . Se ee Chart ee ee Ser sta ohn x ne ‘The bac hydraulic ystem consists ofthe ol pump, 8 the upper body section Fig 1 dy and solenoil and four hydraulic actu Inte Theol pump provides the necessary sytem 1. Maal Vare ‘reation and operating pressure “The manual valve is operated bythe gears link "The valve body contole application ofthe clutches, 86. The valve diverts fad co the apply ccutsae- brakes, second coast band and the toryue converter coding to shift lever positon Teekap clutch. The valve body solenoid conrel se henngoftbe 2 23und34 shaves thine Pa Rove Seen ei Schima ose wees with the Tye primary regulator valve (Fig. 1) modulates ine the TOU. "Tee accumulators are asd in the ctch and brake feed iets to contel intel apply pressure. Spring leaded acamuletor pistons modulate the inital sage at apply preaure for mocth engagement 1 Pum A geareype oll pump is usd in all AW-4 transmis: tons The punp years ere maunted inthe ol pump bd The drive gears operatedby the trque converter ‘ha. Drvetangson the hubengogeis drive slain the rive gear. Valve Body Components “Transmission operating presare i supplied tothe ‘utch end brake apply crate trough te valve body ‘The valve body consists of en upper bd lower body separa pate and upper and ler gait Pig. 8 ‘Thevaricupecl valves elsver lupe and opringe are leeaad within the to ty sneens "Tee mana vlve 1-2 sh valve pray regulator valve, accumulator coszel valve chock balls solenoids ‘and oll strainere ae lneted into lower bry section (ig. 10) The remaining contol and sit valves plus Fig. 9 Two-Section Vaive BodyService Information AW-4 DIAGNOSIS INFORMATION GENERAL DIAGNOSIS INFORMATION "The TCU vsed with the AW-4 tranimison has © sclediognetic progam. The program i compatible ‘ith the DEB I vster. "Tha AWt ie an elecronclly controlled tana: sion" Shift punts and sequence nthe forward geet ‘anges are controled by the TCU. Before attempting Fepeir willbe necessary todeterminesfamalfuneues (Secirieal or chanical ‘The DRB I tetr wl identify faults inthe leerieat contrlsysom. The raed test, presare tet, all test nd tre lg test plus the general diagnosis chars wil bap oat outs the mechanical sunning ge "Al AW-t diagnais shoud bein withthe Preimi- tary Chook Procedure. The procedure is designed to bei identify the typeof problem (nechanicaliect- ‘eal that has occurred. Th rst step ofthe procedure Tail Inpectin and Adjustment which ideale this socion INITIAL INSPECTION AND ADJUSTMENT (Q) Check and sdjust shift linkage (@) Verify line pressare cable operation. Repair or replace able binds o damaged (a! Check engine thotle operation. Have helper pres accelrato® to lor and observe injector throttle Plate movement Adj linkage if tarot pate doce {i Chest and adja ine proscure eae ifmaceeary. (G1 Check tranamiaion fd level when fd ie a normal operating temperature, Sart engine. Shit ‘Eanumiaion rough all gar range then back to New {tal Correct leva set Fl or Aa mark on dipetick With engine at curb ile peed (6) Chek and adjust neutral switch if cesar. (7).Ghesk TPS ajustaeat and operation. Adjust he sensor ifnecssery MANUAL SHIFTING TEST ‘mechanical or electrical component. {2 Stop engine and dasonect TCU or TCU fose (3) Rend tet vehicle, Sf teanesoion into stch not move in Neutral {provide irs gar ony with shit lever in 1-2 position Sports in hed gear only wilh Shi ver a pos 1 cperte in overdrive fourth gsr in D potion (2 etransmision operates as described, proved neat sep. However if frward gear ranges were i alto dheingua al fet sat), vehicle would ot hack up eer to dlagnote arta Do ot perform allo re ag test CAUTION: Do not overspeed the engine during the ‘ext test step. Ease of the vote ac sli the ve Fel slow belore downehiting (8) Cootinue road test Marallydownehif tranami sion fom D ta 3, nd fom 3% 1 poston, Then man ‘aly upahit tranamision through forward ranges “@) If tansmisson operation is OK, perform stall, ‘me lag and presse tents If ranemisnion shang ‘problem is enotuntered eer diagnosis hares. (fa probemsil exist comtnue otng with DRE teder HYDRAULIC PRESSURE TEST Pressure Tost Procedure Connet pressure test gauge to test port on pes soger side of anamision Use adaptor $654 to en ‘ect gauge. Be sure tne gauge capac tina 1 90 pt (2100 KPa, (@) Bring tranamisson Si to ormal operating em (3) Apply parking brakes and block wheels. WARNING: BO NOT ALLOW ANYONE TO STAND AT ‘THE FRONT OR REAA OF THE VEHICLE WHILE PER- FORMING THE FOLLOWING STEPS IN THE PRES. SURE TEST. (4) Cheak and adja engine car ile peed, (5) Apply serie brakes (6)Shtrnamiason into D range and aot line pee sure with engine ecu dle speed. Pressure shold be ote pal (35-4042? LPs (7) Prat acelertar t wide open throttle postion nd note line preur, Pressure should be 16h co 196 ei 0108-071505 EP‘CAUTION: Do not mainsin wide open throttle formore {hon tree o four seconde atte "2)Shiftreneianon nto Reverse and nleline pres. sure with engine at cob le peed Presure shoul be host pa (60040998 kPa (0) Presa aceleratr 1 wide open trot postion and pte line pressure in Reverse Pressure shouldbe ese 273 pat 540-0 1880 KPa EAUTION: Do notmeitsin wide open thot for more ‘hon tee or four seconds at tine. THolirinepresure snot within apeictions, aust tine peesture cable and repeat pressure tet Pressure Test Analysi Tt promures in D and Reverse are higher than spc se, chek fr the following ‘ine pressure cable lee, worn, binding or out of juste Service Information AW-4 «theta vane, downshit l Srorn or damaged ‘primary regulator valve ticking, worn, or damaged [Mprensaresin Dand Revers arelowerthan specie ches forthe flowing ne preeure cable lore, wor, binding or out of Sajustment throttle valve, dowashit pl, throttle am ticking, form or damaged (Trimory regulator vlog ticking, orm, or damaged it pump gers or boarng worn or daraged 1 Srerdeve latch worm or damaged {pressures are lw in D range only, check fr the 1 forward catch worn o dranged ‘Sha Teakage in Drange crt component ces and Oring hot cam sticking, i So ~e ig 28 Protiminary * ack Procedure aService Information AW-4 1 peeaures are le in Reverse only, check forthe flowing shift lnkage (and manual valve) out of adjstnent 1 fan leakage n Reverse cic component anal sid ‘Oring direct clutch worn or damaged 1 reverse brake svorm a damaged STALL TEST (The stl tet checks balding ability f the trane- rluson clutches and brakes and the torque converter ator ete {2 Bring transmission Mid to normal ht parting 1G) Connect tachometer to engine Poston tachome- tera tea be viewed fom Sere (4) Apply parking brakes and block whecle. (5) Apply nd had service brakes. (6)0n WD model, obiftranfercaseinto two-wheel high pation. 1) art engine. WARING: D6 NOT ALLOW ANYONE TO STAND AT [MEPRONT OR REAR OF THE VERICLE DURING THE Test. (8) Shift transmission into D range (G) Pees aceleratr to wid ope throttle position ‘and note maximum engine rpm. Sal ped should be 200.2400 rpm in Drange, CAUTION: Oo not mamta wide open trot for more {han four or ve seconde t= ie. "70) Relea thettle nn af tapamiaon into New tea. Allow transmission fd to nel for 1520 second i) Shih teenuaason ite Revers, (2d) Pree acvleratr downto wide open throttle po. sition and note masimam engine rpm Stall speed ‘Fig. 27 Pressure Test Gauge Hookup ‘Stall Speed Test Anaiysie Tenginerpmlslower than ecified in Dand Revers, hac forth allowing 1 cagineoutpuuperfrmance neuiient 1 ator elatch in orgueconverter not halding fe ‘peed we 1500 rpm oe tal sped Drange ia higher han specified, check forthe flowing fine preseare low 1 forward este sipping { overdrive one-way elute no holding I atal peed in Reverse waa higher than specified, beck for the following: line prssare ow ret uta lipping 1 Sra reverse rake siping © vorrive one-way clutch ot heling Ital epeds were higher than weed i both D ad Revert, check forthe allowing ine pressure low 1 ererive one-way cutch not hong TIME LAG TEST "Thi tat checks general condition of the overdrive clutch, forward clutch rear sitch and fne/reverne rae” Condition indented bythe amount of tie ‘require fr clutchrae engagement withthe engine ‘tear ile mond. Engagement time i mensired for D SndReversepstions Asiop watch srecommended or Tost Procedure 1 Chock nnd sur trasmisian Aid love if ac: sean. {a)rng tranamison to nora ht operating ten peru (a) Apply packing brakes (4) Tarn off ai eneditonng unit (5}On WD models eit rastr case int two-wheel ih (8) Start engine and check cub ile sped. Adjust speed fnecesary. Cur de mst be corel to ensure (i) Shift trememioion ‘nto Neutral end sat stop watch (8) During lowing test tee, start stop watcha soon a til lever resthen D and Reverse detent, "9) Shit trasumiaron nto range end rece ime it tas for engngement. Hepat test to more times, 00) Reset wep watch an shift ranamaron back to Neutral (11) Sf transition ito Reverse and record ine ‘takes fr engagement. Repeat tet two more times,Service Information AW-4 (02) Bogngement time in D range shouldbe a max- —¢ forward ltch worn ie eaten Bacugemens time for Reverse © oversive clutch worm or damaged ‘Should bea maximum of 8 se FTengagerent time fe longer tan specie fr Ro sere Et fr the flowing: ied Time Lag Test Anatysie TR Usage ms Te ee ter nge tan mie r D + fine prnare low sang nck fr the loin 2 Gretna wore TR nkage mies tratowrs brake worm ‘ine eesure lw 2 Strive cach erm or damaged corarion roam couse connicron Tappecoounormeis | fader me Ee i ists. =r Sree venacogenoruomm | sitipeesctotmmers seeing wermcomucuss | attepceseteetmm | Scorn Re cect Senet Eerie, Eenso~ Sencar EET centri pug romon sina st meomcct Rashtwadioering, Stoo wunmagoncevem nr | Rretpahinatel atone tie ees Detaiptete en | Se meer = ‘fommeantooy SEE rp rome cermrazsaisce, | tees Feta Tse * BURSE:, | En? red arsourga0nz00 | sitemeter acee BODOG On ane ore Kine Seater Fina SSA oor nomena BBw Se nee Seay rigrensore | pemergte wearer * ae edService Information AW-4 ‘SERVICE DIAGNOSIS (CONT.) “erowen Eee a =e eet epupyere: vitor eee oats ae ET er tae « peeeee renee eae ot ae Eco. a RRS Rar Ste tumATSG JEEP ‘CHECKING TRANSMISSION FLUID LEVEL AND ‘CONDITION Recommended Fluid Recommended ii for AW 4 ranemiasionsinJeepor Mopar Mere sutomati ranemision Oui, Mopar Dezron II™ may alr be ed if Mereon Maid i not svalabe, Checking Fluid Lovet (0) Be sure traneision iis at normal operting temperature, Normal operating temperature irached Mir apresisatey 15 ales (25 km of operation (Q) Postion the vehicle on a level surfs, This is important for an accarate Maid level check (@)Shif she tanamasonthroogh ll gear rangesand back to Neural. (Apply the pring brake. (6) erly that the tranemisin en Neate (6) Wipe of te dipatick handle o prevent dit fom entering the fl tae. Then remove the dpc ad ‘eck ld level end codon 1) Correct id lve i othe FULL mark on the Alpeick when the sid is at normal operating tm perature Fi. 1a) If Bid level i Tow, tp off te level with Joop Mereon™, tranamisin Meld Mopar Dexro IT” may Alas be usd if Meron ist availabe: Do not overfill {he transmission. Add only enough Muld to bring {he level to the FULL mark ‘Fig. Transmission Fi Level SERVICE INFORMATION AW-4 Checking Fluid Condition Tnvpec the eppearanceof the Bid during the Mid level eheck The fd sald be ler sn fe foreign ‘atrial or particles ithe Mids dark brown lack {color and eels burnt, the ai hasbeen overheat fd sould be replaced “Transmission operation shold ais be checked ifthe ‘ids severly sisaoved snd contains quantities oF foreign material, meal particles, o este die fein rmataril ‘A small quantity of friction material or metal particles in the oll pan normal. The particles are ‘unually generated during the breakin period and Indicate normal mating of the various transi sion components, ‘TCU SERVICE ‘Use the DRBII tener to diagnose TCU funtion when: ver a fault is suspected. Replace the TCU only when {heater Iniceteee TCU fault TCU Replacement ‘The TCU located under the instrument panelon the atsnger se the vehicle Fig. Turn te nition {Remove the TCU by unsnapping the wire harness fonnecor and removing dhe TCU from under the i ftrament panel To install te replaement par, sp {he wire harness connector luo the new TCU aod po. NEUTRAL SWITCH Switch Testing "Test owiten continuity wih an ohmmeterDiscnneet, the swish ane heck entinaity a the sonnectr tor ‘minal potion and inthe gear ranges Indiated in Figure Switch contincity should teas fellows "Continuity should ent between terminals B and © ‘vith he transmission Park and Nevtral only ig 2) 1 Continuity shoul exist between terminels A and E ‘vith the traemiaon fn Reverse Pig)Service Information AW-4 * contimity shold exist between terminals A and O ith tbe te transmsaion i thied gear Fig 3 1 Continaty shoud exit between terminals A a {tht tranamission in rt andor second gear (Fig. >. *#"continity should nt exit in D position. Nowtra! Switch Removal ‘Rain vehicle (2) Dieomnact witch wire arnss connector. (@) Pry washer lock tabs apwar and remove switeh "bat and tabbed wacer ig (4) Remove witch ajusting tlt Fig. 4 Fig. 2 TOU Removalinstalotion (6) Side site off manual rlee sal. outa Suiteh Installation And Adjustment "C)Dscoanet shitinkagerol rom shift ever one side of transaisson 2) Rotate manual shit lover all he way rearward “Then rotate lever forward two detent potions Ne 3) Ista witch on anal valve shaft and inal selehejuting bol inger ight Dont tighten bata iene (Gnu abbed washer on mana! vlve shaft and {nctallewitchsaching nat Tighten aatto6 9Nm 61 inte! torque but do not bend washer ek tabsover nut st hia tine (5) Verify that tranerason isin Neutral (6) Rotate etch to align neutral standard line with ert groove on esansl vel sat (Pg) “align switch standard ine with grove of Maton ‘mana valve sha {21 Tighten with adjusting bot to 18 Non (9 be) tora, (@) Bend atleast two washer lek tabs ore switch sttnching mt to seare i {dO) Connect nif inkagerodto shit leveroa eft side "12 Check ewiteh operation. Engine should star in Park nd Netra ls.‘Service Information AW-4 VALVE BODY SOLENOIDS ‘Solenoid Removal And Testing {ly Remove treneissoncitpas drain plug end drain ia (2) Remove yan bolts and remove il pan {Gi Remove ileereon belts end rmove seen Fig 1 sad gasket Discrd the gasket, (4) Disses solenoid wie connector (Fi (Ball snencde are being removed, mark or tag sires for aseyrelerenc bre connecting them (6) Removetolt aching slencde ta valve body bd remove solenoids Fig. 6. Do ot allow ay valve body ‘ponents ta fal eat when sleneide are removed (7) Clam el iter and pan with solvent and ry with compres at ‘@) Remar old sealer ateril rom ol pa andtrans- slain cae. Salen Testing “es scene resetance with an obmmeter Conse! the obmmetar asd tthe ened mounting ‘racket and tothe slenodwite terminal (Fig. 9. Golo resistance auld be 21-16 ce Replace sland ifresintncseaboveorbelow he petied range Solonetd installation 1) Postion selenide om valve body and itll se sd bots Tipton bls to 10 Nem (7 fb tore. (2) Connect feed wire ts slenoit Fig. 6 01 Screen Removatinstalation ‘Fig. 8 Valve Body Solenoids odService Information AW-4 (@) Insall ew gaskets oil screen and install sere, Tighten eeeor bite 19 Nem (7 be) argu. 1a) Apply bend of Three Band TB 1281 or equivalent sealer Sep sealing surface. Sealer bad should be ent 1.0 tn (040 0 da (@ lata ol pon oo transmission. Tighten pan bolts 1074 Nom (5 i! trae \Gvtwtall andtighton oi andra plug to 20 Nm(18 ‘ee traue Pil rensvssion wth Mopar Mercon” or Detron 1” trasaiasion fd ‘Solenoid Harness Adapter Seal Replacement ti) Remove ol pan ad all screen. Refer to Salen ‘Removal procedure (2) Disonnet esas wie connector (Fig. 7) (S)Remore racketeering tlenid haress adeptor (Fig 10 ta came (Pal haroess adapter and wies out of cae. (8) Remove and Gerd sdaper O-ring (6) Labecae newt O-ring ard nota! ion adaptor. (tanta nteold wie harness and adapter iene (8) awa adaptor bracket ané bracket bat (8) Connect wires to wlenois (00) Install of serena pan. VALVE BODY Removal and installation are the only valve body service precedes cored im hs ention Rafe othe {Ganamiion verbal vectin for vee bry danse Uy anning,iapection and reassembly Valve Body Removat {i} Remove ol pom pog sh enn transmision (2) Remove ol pen and of seren. Clean pan and cren in slvent sod ry them with compressed at Fig. 9 Testing Vole Boay Solenoid (@) Disconnect solenoid wire connectors Pig 7 Mark wires for asemly referee {Gb Remove valv body a tabee Fig. 12). Carflly ry te tof tle bay with prewerier, fo) Disconnect tvs eble ros tote cam (Pg. 2», {G) Remove valve body ota, Laatons fer sevenens tte are ottned in Fige 14. "7 Lower valve bady and remove overdrive catch accumulator springy: sre utch accumulator spring Sod. epacer, aweond brake sccumulator spring and pacer Fi. 15) 8) Remove valvebods and check ball and spring Fe 3, 15 Fig. 11 Diconneet Solenoid WiresValve Body Installation {B) Connect cable to thre cam Fig. 13 (2) natal cheek ball end spring Fig. 18 (@)Postion accumlatarprings and pacers. valve tea. "A Align valve bay manual vee with shit sector (Gig 7) and eareflly position valve body on case. 18) inal valve boy bolts ig, 1). Tighten bots vento 10 Nm 7 fel) ergo "6 Yoetall valve body i see. Beare tube ends.) zc (are fale shown in igure 18 "Gy Remove li eer material fer pan and trans Clan oil ereen and oll pan with solvent nat eon previany) Dry Beth components with cox ‘reed aren. Do mit ue shop towel. ‘ig, 19 Removlnginstaling Throttle Cable Service Information AWA (o)ltall ew gaskets onolaroen and install screen on ease. Tighten tereen attaching buts to 10 Nem (7 ike targa GO) Apply bead of Thre Bond TB 1281 sealer to sealingeurite oo pan Sealer bead should beat east {om OU0 in) wide Then aca pan and ighten pan bale to 7.4 Nem (65 lbs argue “G1 fatal! new gasket oa oll pan dain plo and nual plug in pon Tighten plug to 20 Nem (15 feb) terwue ‘Gay Fi traneaision with Mopar Meren" Mid (MANUAL VALVE SHAFT SEAL REPLACEMENT (Q) Remove neutral snety teh and disonnedt ig 15 Accumulator SpringsService Information AW-4 (2) Remove ol pan and valve bods (3) Remove bots attaching park od bracket to case ie. 20, 14) Remove park re es sit sector Fig. 20) (5) Cut epacer sleeve wth chisel and remove fom ‘manuel valve shaft Fig 22) ey Remove pn fen salt ad schon with pin punch (7) Remove shaft and sector fom ca, (f) Pry aha sels oat of ease (Fig 23). {ovtnapect the anal valve shaft andsctr Replace itheremponent i worn oF damaged Fig. 18 RemovingInetaling Valve Body Chock Bat “and Seng Fig. 17 Align Shit Sector And anual Yate (40 Caat replacements selewith petroleum ely nd mnt them i the ease Fi. 28) TIA) Kall new pmo slave on sector (Fig. 25) 102) tiene anal valve shal and install in 15) Labrieate sector and sleeve anita then on eat 14) Alig hole space sleeve with notch m sxtor. "Then isa shift eter ll pn ‘Tp pin no cecter and ‘haf and sake slsve to mtor and shat semrely. 15) Cocnect park rod te eet (Fig 2 (06) Intl park 70d, bracket (Fig. 261, Tighten ence bets t 10 New (7 lb trae Fig, 18 nstaing Valve Body O Tubes ‘Fig, 19 Manuel Valve Shot And SerieService Information AW-4 (17) Intl valve body, ol een, pan and neatral switch ‘THROTTLE CABLE REPLACEMENT-ADJUSTMENT ‘Throtte Cable Removal In engine compartment, disconnect cable fom ‘yote nage. Then compress cable mounting ears tnd remove cable fom kage bracket, (2) Rais vehicle, (G) Remove tranamision ol pan, (apDisengage cable rom thrtle valve cam Fig. 27), (8) Remove cable bracket bolt and remove cable and ‘racket fom san Fig. 28 (6) Remove snd discard cable ol, ‘Throttle Cablo installation (0) Lubricate nd natal new eel on cable (2) Invert cable in trnanieon ease, (G) Atach cable to thotle eam Pig 27), (@)Installesbe bracket on cane and ighte attaching alto 10 Nem 7 feb argue ig 28), "9 ig. 23 Removing Manual Valve Shat SealsService Information AW-4 (6) Remove old sealer teri rome pan and trans ‘mien case Clean l pon with alent al dy i ith “Gy Apply bewd of Tree Bond TH 128 sale toi pan sealing surface, Sealer Dead shouldbe a east 1.0 re (Cow) wide Then instal pen and tighten pn bos to A em 5 inl trae {otal sev gsi! ool pan dain pl. Install sd tighten plug 1 20 Nem 18 feb) trae "&) Connect abet engine bracket aad throttle link 2) Fil tranetisson with Mopar Mercon” ‘Fig. 26 stating Spacer Sleeve On Sector (40) Adj the cable a tind inthe Line Pressure ‘cable Adjostmeat procedure ‘Throttle Cable Adjustment TH) Torn gnition sw to Of positon. (2) Fly eraccale plunger. Press ale bton all the way down, Then path eale plunger inward Pig (2) Reta primary Chratlelovertowideopen thotie poniion Fig 30 (4) Hold piety trot lever in wie open position tant Tet cable planger extend. Relonse ever shen ‘longer fly oetended. Cable is nom aeted Fig, 26 ntaling Park Rod Bracket Fig. 27 Removinginstaing Tortie CableATSG Service Information ‘ACCUMULATOR PISTONS AND SPRINGS ‘Accumulator Platon and Spring Removal “ib Remove valve body Rafer to procure in this sce (2) Remove accumlato pitona with cmpreoed alt (Pig 80 Apply ir through eal fod hale next woch piston bore. Gach cach plston in ashoptowelesiteits ‘CAUTION: Use ony enough sr pressureto ease each piston oof the Bore nation, remove the pistons ig, 29 Retract Troe Cable Plunger Slee broken collapse ditrted pring. Replace the (oe ifthe patan bre ae damage. Fig. 21 Removing Aecumulator PistonsService Information AW-4 {Griastal new O-ring saison pistons Lubricate snd pistons and piston boro it rene “Gr Intl pltone end springs (Fg 2) (Tat Velo toy sree sd ol pao. ‘SECOND COAST BRAKE SERVO Servo Overnaul ( Remove valve boy as oxtind inthis section (2) Remove servo piston coer snap rng wile snap ing pliers Fi. 39. (3) Remove servo piston and cover with compressed sir Apply crapresd ar through ol hole in wer bas to aun patan et of bore Fg 3. (Gy Remove and dacard sal and Ovings from cover sand piston Fig 25) Tnspet Eig, piston, ping and ‘etaner,petan red and piston eprng. Replace worn or damaged pers. (6) Intl new nls on cover and ito. (6) Labricate serv components with transmission (7) Assemble and install servo components incase. Be sare servo piston rod is properly engaged inthe eeond east brake band (8) Compres cover and piston and install over snap (9) inal vale body, Fi, 32 Accumulator Piston Springs Spacers PARK ROD AND PAWL. (1) Remove valve bdy os outlined in tls sein (2) Remove bolts attaching park rod bracket to ease Og. 36, (3) Remove perk ed fom manual valve sha sectar @g.30. (@) Remove pr od. 21. Fig, 34 Removing Servo Cover And Piston(6) Remore park palpi and spring Fi. $8. (6) Examine pak rod, pr, ps and spring. Replace ny component that is wars oF Tr) Taetall pa! incase Inara and install peng. ‘Be ee spring i positioned as shown in Figure 38 1) Intl park tod and bracket (Fig. 98). Tighten barker bolts to 10 Ne 7 fb) torque. (ey Inal vale body, il seran and ol pan as ou Une in his ete. EXTENSION/ADAPTOR HOUSING SEAL REPLACEMENT (0) Rake vehicle i. 36 Removingtnetaling Park Rod Bracket Service Information AW-4 (2) On 2WD or 4WD models, disconnect or remove components necesry #0 gain aces othe wel (eg Sroeler shan eessmerber, ef lckage, transfer hoes extast component, hoes, wie “S) On BWD model, remove sel from adaptor hus lng Fi. 3. a) 4D model, remove dust shield and remove sal fam exteoion housing Fig. 28). "neal new cl with appropriate ize (2: 0n 4D modes, nd @)Rekntall components removed to gain sees 1 seal 17) Top off tranamiasion Mid if necessary. 22 Fig, 8 Removingtnstaling Park Pant-Pn-SpringService Information AW-4. ‘Speed Sensor Testing "Fem the eyo reneor with an ohmeter. Place the chimmetor ead on he terminal nthe rir cone: tor ig. 40. tate the transmission output shaft and observe the chimeter neil, The nee should deflect ndeating ‘Seewith sopeningtloning eth ror moves past the fer (Pig. 401 Replace the sear if the ohmmeter tice not play any ind of reatlog "adits ohmmeter bing ated the censor hood gnerote an inter readout each tie the Sitch ‘pene and closes. ‘Speed Sensor Replacement a) Disconnect senor wie harness conesor, (2) Remove senor reainer belt and remove sensor gan (8) Rewore and discard speed sensor Ong. (@ Tawa! new Ocring on speed Seeor a install "oy nal eer bracket end retainer tot Tighten bolt to 4 Nom (65 lt trae ‘SPEED SENSOR ROTOR-SPEEDOMETER DRIVE GEAR Rotor Drive Gear Removal Sh Raise vehicle {2} Remeve components necessry gain esse to rotor and dive goa eg propeller sha rant cae, ‘recombi nage! Fi. 99 AdpotorExtension Housing Seals (@) Disconnect speedometer eablenndfor peed sons. (@) Remove extension or neaptor using. (8) Remove epeedomeler deve gout snap ring Fi. 16) Remove the speedometer rive gear and spacer if equiped Tiflomoveotrby carefully pryingitoffoutput shat with won! dowel er hammer hale ig. 3) (8) lees sealing surface of tranamison case and cxtesioladaparboasng 23 Fig. 41 Speed Sensor RemovabinsttiationService Information AW-4 ‘Rotorbrive Gear instatiation ‘Install oto, epacer equipped) and drive gear on outpatehaf. Then neal dive gear snp ing Fie. <2) 1 Apply beed of BTV sone, to transmission case sealing sce sod nial extension adaptor housing \®) Tighten ertension/adaptr housing bolts to 9430 (25 tbe) trque (a) Tata components remove a gin acess toretor sod dive ge. TPS SERVICE ‘A separate thotle portion sensor is uted for aut mate ranunesion pplication The sensors atached {ete bee of the tht body. Refer to Croup 14 for "TPS ervice and adjustment SHIFT CABLE ADJUSTMENT (0) Shift trapmision into Park (2 Raise vehicle (@) Release abl adjuster clamp to unlock cable Fig. #, (4) Unmaap cable fom cable bracket Fig (5) Move tranaminsion shi lever all he way ren ‘ward ina Park ett Lever ion manual vale shaft ‘let id of eae (@) Verify positive engagement of park lock by a tempting a rtte propeller shat. Shaft wil not rotate ‘when por look i engegod. (2) Sap cable nto cable backs. (2) Lack shaft cable by presing cable adjuster lamp down gti i angps int place "OrCheckenginewarting Engine should start only in Park and Neutrel "20) Lower eutmabile ‘PARK LOCK CABLE ADJUSTMENT (0) Ski ranean into Parke (2) Turn igition witch to Lack position (3)Remore shit ver bezel and cose screws, aoe ‘eel and console or sens a eble ‘ay Pull enble eck button up to release able (Fig 8 (6) Pal cable forward. Then release cable and press cable lock butt down sole snape in place (6) Check ajurtment ae flows 2% Fig. 47 Sit Cable AdjustmentService Information AW4 Check movement of lease shit handle but ton ter sit or release lever (cluma eit). You ‘Should not be ale to press bution inmasd of more ‘alma lever, {@) Ta ignition switch to On pein {e) Pras for ahi leverrelese ttn o move oluma lever. Thon sil into Nesral. If cable ad Stent is correct iaiion sits can nt be atone fo Lock postion Prtrm same check with ransmie Sonn B range (Move sift lever bac to Pak and chock inition seitch operation. You shoud be abla ttarn ch to ack yostion and 2h lover release bustier staid sot move, Bg Fig 48 Pak Lock Cable‘TRANSMISSION AND TORQUE CONVERTER REMOVAL (0) Raise vehi (2) Drain tranaision Aid and renal oll pam sania og "a1 Remove uper haf of transmission fil tbe (Pig. o 4) Dicennet cover lines nt tranemieion. Cooler lines have quick disconnect ftings. Pree tng re lene abs ab pol slr line ad Biting out of ease (6) Support engine with osfety stand and supper tranaminton wit ace {@) Diecoroect or remove following: tranenision! transfer cae sift linkage neceary exhaust copo- tent; epeedmeter cable fontrear propeller shat "tonamissionwirehernene transfer cae Yacoum and tire Rarnese (7 Reeve rer rossmember. (3) Dconnettranemissonthrote cable at engine (9) Disennert ecemary vacuum ad ud hoses. Ho) Remove starter ctor 11) Remove converter se drive pat bles 112} Remove sonveter hosing--engine bolt. Fig. 49 Two-Pace Transmission Fill Tbe SERVICE INFORMATION (03) Secue transmission (and transfor cas assembly on AWD modsa) to tranemision Jock wih sally ‘ain, Then remove transmission 4) Remove torque converter converter oral pump seal are tobe serviced 5) Remove tanaer case if teneision Ie to be ovethaled ‘TORQUE CONVERTER STATOR CLUTCH INSPECTION 1) ger rotating too! BV. FM. 36 ito converter hab and wat won oneowayelich Fig. 90, (2) Taser stopper tat B Vi. FMC 7 in one converter tau notch and inte outer race of tating tol 1G) Turn rotating tool eockwiee.Conversr cloth should rotate freely and smoothly. Les than 2 Ne (22 nthe) of trgue sould be required orotate clutch I clecloissdretion ‘Gi Tur rotating tal in countercockveedretion (Converter cate sould lose (6) Replace vere if tc binds or wil nt ock OL PUMP SEAL REPLACEMENT 1) Remove converter, (2) Remove oi soa. Use Mun! punch to collapse seal, snd pry seal out of pomp housing. Do not sratch or damage seal tre. ‘Gv Eubcate ip of ae eal with petroleum ely and snstll eal i pomp Ug 5 ‘ar Align and install trgue converter. ‘TRANSMISSION AND TORQUE CONVERTER INSTALLATION 1) Mount trnsmisson on ranean ack. (2) ltl trgor converter on transmission {1 On AWD agen itll wanaercace op ean (a) Secure transi and transfer case assembly on 4¥0 snadels tac with safety can 18) Align and prion transmission and converter on Gr Iatallconverier housing ong bls (Fi aatall converter to drive plate ote (2) otal and coonet starter ator (910m 4D made, connect tanto cane shi age and vac hoo “or Connect ext componentsService Information AW-4 (a1 teeal rear exossmember {42} Connect speedometer exble and neutral sich (25) align andconnest ont ander propeller sas {18} Gonnert transi wie barneses ad tant Serene vacuum and wire baroestes. 133) Connect transmission clr line {18} Connex tranemiein throttle vale cable at en- (7 Install new O-ring colon upper half of tran ‘misionfil tobe Then sunnace upper and lower tae 18) Lower vehi. 139) i tansmlsion with Mopar Meron” actor matic tenesion MdService Information AW-4 TRANSMISSION OVERHAUL OVERHAUL SERVICE'TOOLS ‘The socal tool edad to overhaul he AW 4 trane tasson are provided into! hit 624 (BVGEM. 23) However. psoure Lest port edaprer TEGS 3 noir ‘Sdedin this kt and will bavets be ordered separately. ‘Theoverhaultnikit andes poreedaptorareavelsble ‘through the peta visas and dealer special ol pro gam ‘TRANSMISSION DISASSEMBLY 1) Remove tory converter {B) Remove dpatick ad both halves of i ler tbe [SiRemore clamp attaching Wire harness and hte pressure cable (Fig. to transmission, "arfenvore hf eve: orn nana valve shat tat side of ansciaon G1 Remove neural witch {Gi Remove spwdometer riven gear equipped and sepove oped sensor Pi 2 iv Remore converter bousing bolts and remove ous- ing Fig 31 rom cae. Ts) Remve extension housing or edapzr hosing. '8)On 2WD mde, measare nade darmeter of ex tension housing bathing with einer bre gauge oF tence micrmmster” Dunetet sould be 3809, mm Fig. 3 Removingtnstaling Converter HousingService Information (02) Remove transmis 5. {at) Remove speed senor rotor and key. Use wood del or hamier bande to lowes and remove rotor a Fe ve bay lis Fig. 1D, hve cable from hot cam (Fig Fig § Removing Speed Sensor And Speedometer ‘Drive Gear 29 Fig. Removing Ou ScreenService Information AW-4 (48) Remove valve body from cae Then remove ac- camulatar spring, spacers and choc ball and oping gs. (09) Remove second brake and clutch aecumsator pistons with compressed sr Pg. 18. Apply ar pres fare through feed prt and ease the piste out of the tore (20) Remove overdrive brake accumulator piston wth ‘compressed lr Fig 18, (G1) Remove overdrive clteh accumulator piston vith compressed alr (Fig. 1, (22) Remove thot cable Fig. 9 Solenoid Wires » (23) Remove ol pump tits and remove pomp with ‘brdge ype puller BV FB. 25 (ig. 18), (24) Remove rece fom ol pap (Fig 18) (25) Remove fourth ear versie plaetary gear tnd overdrive direct latch assembly (Pag. 17 126) Remove race from fourth gear overdrive pane. tary Pig. 18, (27) Remove thrust beeing, rae and overdrive plan sary ving gear Pig. 19. 2) ss follom (@) Mount dia indicator on case (Fig. 20) (6) Mount gouge tol BV FM. 85a it contacts ston Fig. 20. Fig, 11 Valve Body Bolt LocationsService Information AW4 (ey Apply 57-114 px air pressure through pistes (Sz) Remove overdrive support bats Fig 24 apply port en ote piston stroke on dial indcatar. (32) Remove overdrive supper’ snap ing with tol ‘Stroke length should be 140-1 70mm (055.0699 BVL FM 29 Fig 251 {nen Gcylinder models and 132-162 mm (0520 to {638 im on tinder modela 1a) I atake ie not within mis, replace brake pack retainer. Select requir retainer fom Over {Give Brake Retainer Seleston hart inSpecicasions (9) Remove overdrive brake nop ving Fig. 21 ‘hoes on lates ig ‘ig. 13 Removing Accumuletor Springs Spacers- ‘Check all, 31g. 14 Removing Accumulator PistonsTSG Servi Information AW-4 ‘941 Remove overdrive support Fig. 261 with bridge 1 eroke length i incorvet, ist new peta lope puller ool BY FAL 28 rod and fecha roe If stroke fell incoret 38tRemove race fom hub of overdtive support Fig. replace stcond cost bake band m (el Replacement paton ode are available in two 6) Measresroke length of second const brake pi: diferent length which are. 71.4 ton (281 i) and ton rod flows 12.8 2870 io, TalMakerefrencemarkenistonred(Fg.28)a8 (7) Remove seond cose ke piston stapring with shown tool BV FM, 28. Then remove pstn xver and pron 'b) Apply 57-114 pi ar presare trough piston sembly sith eomprensed ir applied through pion {sed hole and check aoe eng with pooge BV. fed hele Fig. 29 FM. a4 Gg. 28, le) Stoke length shoud be 1 $403.0 mm 0590 ig. 17 Removing Fourth Gear Planetary And Direct ‘Guten Assembly Fig. 16 Removing OU Pump Race 32 Fig, 18 Remove Fourth Gosr Planetary RaceService Information AW4 (at Dicaserbe second owt brake piston Fig. 901, _ (41) Remove the second coast brake band Eng fom {G01Removediretand forward clteh sembly Fig, bund pin and remove brake bond Fi. 9 a 4a) Remove font planetary ring oar fon bearing 40) Remove thrst bearing adage fom eatch hub race and remove ont planetary ring ea Fi. 98 Fig 32 \ Fl, 22 Removeessure Overchive Brake Dise Fig, 20 Measuring Overarive rake Piston Stoke 33,Service Information AW (48) Remove thrust bearing and rear re fom ing gear Fig 38). (ad) Remove planetary thrust ac Fi. 36 (aS Relieve lod on planetary soap rng as fellows: ‘eanumiaron being Rature Tae ans fiom over and allow output shat to suport transmis- ‘en weight. Place Wood bloks under sat o protest, ‘lines ig. 98, dG) Remove planetary snap ring end rove plane tary gear ig 3, ‘iy Remove son ger, snp drum andoneway ltch as auerbly ig 38) 4a) Measure second brake clatchpack learance Pig. 0) Clearane should be 261.981 (O24 0780 Snlon sal tanamisions and 8010215 mm (0380 10-0846) op fury. transmissions. Replace dacs if flearace is ot within specfiations (Go) Remove second brake clutch pack nap ag Pig 0) (o> Resovesacond bea latch pack (Pig 40, Ms sure dee thickness with micrometer. Minimum hk ec boul be 184 mm (0724 fa Replace desi not within spectcations (5) Remove belts attaching park rod bracket to case ‘Then daconect pk rod fot aa bat lever and remove rod and bracket (Fg. 42, (62) Remove park paw spring pin and pawl Fig 4),ATSG Service Information AW-4 099 45 30 Second Coast Brake Piston Components ‘Fig, 28 Measuring Second Coast Brake Paton RodService Information AW-4 (57 Remove scan brake um ga ashe seraper o serewrver Fig (G8) Measure inside diameter of tranemisson case CCLEANING-INSPECTION ‘Clean the transmission components with nivent and Ary them with sonpressed ir only. Do not use shop towels or ag ‘Blow compressed sir through alo feedparsages and ‘channels tobe sure they are cleer.Inpect the tran: ‘nisin compoaenis for wear and damage Replace or Dpents that are damaged or worn beyond the mis pele in the individual aver procedures, Replace all ings, gaskets and seals. Thee compo. ‘peter nt reusable. Also replace ay sap ring hat iS dasorted or damage. ‘Daring overhaul assembly operations, lbricste the ‘raniaion componente with op o Mopar Maroon” Sitomatietanemission fs or petroeam li as iate, Pesoloum lly shouldbe used to pelricate ‘thrust bearing, washer and race. Itean alo be weed tool part im postion during ete ‘Soak replacement ciAW-4 Service Information Pantsc ‘Fi, 36 Relieving Load On Planetary Sup Fing Fig. 24 Removing Front Planetary Ring Gear ‘Fo. 35 Removing Ring Gear Bearing And Rear Race 47 P37 Removing Planetary Snap Rng And GearService Information Fig. 38 Removing Sun Gear, Input Drum And ‘One-Way ny ClutchService Information AW-4 Fo, 42 Removing Pak Rod And Bracket ‘Fig, £3 Removing Park Paw Pn And SpringPAAaTSEService Information AW-4 sl |ASSEMBLY OVERHAUL AND TRANSMISSION ASSEMBLY (MANUAL VALVE SHAFT OVERHAUL ‘ay Remove shaft epocer sleeve in alfwithchiseland 1 Labrcate new mal with aso jelly ad in ie) natal ow spacer eve on shift sector Fig 9 sere i from lover and tha Fit. 2 (Fr tostal sector tnd sleeve cn shat and sata {2 Remve shift sector reinning pi with pin peneh {08 ; teees Fg 2. "Bh Align sector and sleeve and neal new retaining Pall shaft out of ate and remove manual lever. pin 14) Carfally pry shat seas trom ase, 1 rhe, To) Align nochin leeve with depresion nseetor and stakeslerveinwoplaen Besurelever and haftrotate socal ‘ia, | Manual Valve Shaft Components ‘Fig. 3 Removingtnstaing Sector Retaining Pin ‘Fig 5 Intaling Manual Shaft And SectorService information AW-4 ‘Fig. 101 Pump Components OIL PUMP OVERHAUL (0) Remove pomp body O-ring Pig 1 (2) Remove pump seal ings Fig (3) Remove tlt attaching ator shaft to pump body and separate componenss. di Hemove drive gear and driven gear ftom pap body ig. D. (B) Messare inside dametor of pump boty bushing svith bore gnoge (Fig 2) Diameter shouldbe maximum 1038 19mm (15035 im. Replace pump body i bushing Di proatr than spose (6) Meaoure inside diameter of stator shaft bushing (fig. 2) Toke easareront at font and rear of bush ing Diameter thould be maxima f 2 58mm (08496 inv et font and 2708 rm (1.801 In) a rue. Replace ‘Sato shat if bushing diameter greater than pec fed 7) Measure oll pump closrances (Fg. = Clearencebatween pump driven ger and pam body Thou be meximam af 3 ram (O12 Tn. ='Clearanes between ips of pump gear teeth should be raximm of 3 ne (O12 1 Clearance between rear surface of pump housing and ‘ose gear should be maximum of 0. mm (004 tn “Replace purnp body and gears any clearance is reste than speed. (9) Remove Sid pump sal Intl new Seal within taller tol BV FO. 88 Fig 8 {U0 Labreate and install gars in pump bods {01} Aweuble stator aba and pump body. Tighten shalt tocbody ole to 10 Nes 7 fel) torgus. "221 stall new Orring on pump body ad new seal ring on rat shalt (29) natal pumpin torque converter and check pump cartotaton, Gears mut tate noothy when tered kien eounterlockise is) brent pump O-ring and eal rings with pe: teooum ely Fig. Checking PumpyStator Shaft Bushings 2Service Information 4 aTSGService Information AW-4 ‘OVERDRIVE PLANETARY GEAR AND CLUTCH ‘OVERHAUL Goar And Clutch Disassembly i Chhack operation fanesway eet in latch drum, Hold drum and ture planetary shaft clokwie end ountercieckwise. Shaft abouldtarm clockwise rely ‘ut lock when tarned counterclockwise, Replace oe tray etch itneceasary ‘Remove ovrdrive ste rom planetary gear Pig », (9) Remove thrust bearing and race aaserbly from tate dram Fig a) Measure stoke length of teh piston as flows: (a) Mount il pump on torgoe covert, Then mount eltch ono pu (Fg 5. (@) Mount dal fndientor an eateh end poston Indlcatar stylus on clutch pat Fi. {c) Apply compressed tr hough elutch feed ble in ol pump and note pint stroke length Stoke length shou be 185 to 216 em 728 00846 8. |S) Replace clutch pack retainer i etre length Is innrec fer a cart Specifications veto or = cement retainer thicknesses 6) Remove clteh pack snap sing and remove the cluich pack (7) Comprea piston return spring wit tol VL PML 27 and shop pres and vermove piston snap ring Fi 8. (d) Remove compressor tl and piston return spring. {9) Mouot ol pump on converter. Then mount clutch enol pump (i. 9 wot ig 1 Overarve Planetary Gear And Clutch ComponentsService Information AW-4 (40) Hold ath pny band and apply compressed ‘ar through oil pomp feed holst ease piston out Fg ‘Apply nly enough ar prearure to remove piston. “dit Remora bearing andar from ring fear Fig 10, (1) Remove sap ing fuming ear and remove ring sear hub ig 10. {G3) Remove race from planetary gear Pig. 12 (Qe) Remove snap ring and remove retaining plate mig 19. Us) Remove one way cuth nd outer ac as assem lly, Then separate ace fom cuts Fg. 18) (ie) Remove thrust washer (Fg 15). (AP) Measure clutch die thicknes, Minimum allow ble thickness 1.54 rms (OTR ‘ig. 3 Removing Overdrive Clutch From Gear (a8) Meavare ree length of pnton return meine with springen satainer Pig 10), Length sold be 168m. (sat in. ‘091 Check clutch piston check all Fig. 17. Shake piston ee fal moves rely. Then deck bal seal {ngbraplsig ow pressure compressed air toballilet fuehown Air should not leak part ehesk ball 0) Check inside diameter of eaten drum bushings withtore gauge Pig 18) Masimom inside diate Is 2-11 man (1.0679 in). Replace dam s busing nse flamer is greater than specie SS. ‘ig, § Assembling Converter, Pump And Clutch ForService Information AW-4 (21 Choc aie diameter of planetary ger bushing (Pig. 19) Marimum inode dlameter fo 1127 mm (0457 i). Replace planetary gear if bushing inside Aliameter grater then specie rahe in planetary gear Fig 20) Grooved ide of washer faces up nd toward 2) Install one-way latch in ac side of shteh mort face upward as 20 a/tntall asebledoneway teh planetary ger Bese Mange side of ate i facing Gerard TZ natal cate pac retaining plate end anap ring sn planetary goa. To ERR Euten Raton Fig. Checking Overdrive Clutch Piston Stroke Fig.” Removing Clutch Pack Snap ing (©) Coat planetary race with petzoeum jelly sn in seal ion plansary gear Oat damter a ac ie {018 mm (646 nde inter e271 mm (057 Ines bab inpanetary ring gear and install snap ng. (Coat race and bearing with petroleum ally andService Information AW-4 Laeocipenditin Apia ny Garmin anes eames caer a cs facemeorceentaretas i ia maar ae - coca ome ae es 5 47 Fig 19 Removing Snap Ring And Retaining Pate‘Service Information AW-4 Osi diameter asiersbed bering andaceie502 (17) Verify ne-ay utc operation, Hold drum and ‘tl S76 in Inside diameter is 289 rm 2.198 is), turn planetary she clskwie ad counerlskvse "16 nus catch an planetary gee ‘Shatshoul tar clockwise Rely ut lock when tamed coutrseeie. Fi. 17 Testing Clteh Piston Check Bat Fig, 15 Removing Planetary Thrust WasherService Information AW-4 Fig. 19 Checking Planetary Bushing ig. 21 Assembling One-Way Clutch And Racecs ig. 22 Intl Ring Gear Bearing And RaceAATSG Service information AWA eZaaTSG Service Information AW-4 OVERDRIVE SUPPORT OVERHAULService Information AWA (9) Measure fre length of piston tur springs with syringe mount in slsier (Fig 7) Length should be Yoel mm (733 in. (00) Clean support eamponents and dry them with compressed at "AL Inspect overdrive support and brake pion, Re- lace support snd piston ier partis wor or dam Fig §Removingtnetaling Piston Snap Ring Assembling Overdrive Support i) Lubcente ne spor seal ings, Then ome rings and nal! them on support Fig. 8. {rLubricte and etal new O-ringron brake piston. ‘then coeflly soa poten in oppor. (2) nal eur springs en brake piston. 0) Compres seeuro springs with tol (ig. 81 and ‘esa piston snap ng "ar Intell apport beating race and clutch dram rat washer Fig. (Gy nwa thrust bearing 238 front and rear bearing races Thrust braving rllers should Tao upward a8 ‘Shown Fig 8 Fig. 7 Checking Piston Return Spring LengthATSG Service Information (1 Verify thrust earingocesne Fig. 9) Frontrace (882 inside dlameter i 349m (1.80) Boar Ing outer diamater e477 mm (1.8086 aside dim (hecse 827 am (1.287 i (Werf beak piston pertion. sesame procedure Aeseibed 4 beginning of diascembly. Piste shuld Sperate smoothly and not bind or sick. Fig, 9 intaling Support Thrust Bearing And RacesATSG Service Information AW-4 (9) Check catch pate roe longth ae outnad inc) Compress cutsh springs with tool BV. FM. 27. falowing stops Remove teh pack nap rng and remove retaner and [dnMount directclatchonoverériveruppercaeembly clutch pack fom drum (Fg 8) wpe. 19) Compress clutch psn rota springs with tol 18) Mount dia indicator on utc and poston Indl BVEFME27 snd rerovecuth piston snap ring Piz ator plonger on cute piston Fig. 8. Pe "Gr Apply 7-14 pt aurpreseurethroughfeedtolein (01 Remove compresoe tool and return spring overdrive soppartahd ate patometrakelength Pig $1. {111 Remave cute piston Reroute clutch oy ve heck stroke at lar ties. Arve suppor Fig. B. Apply compressed se through (CyPistonstroke length shouldbe 37mm to 607mm lst feed hae in support to remeve piston Use only 10899 @,0642 im. Itroke length enone ether eo0agh ar tease piston ot the latch pack elaine or atch disc wal have tbe ‘Fig. 6 Removing Clutch Pack Snap Ring Fig, § Checking Direct Cuich Paton Stroke Langin 38. Fi. 7 Removing Piston Return Spring Sra RingService Information AW-4 (22) Remove aa daca teh piston O-rings. 119) Measure catch dice hickneae. Minium allo ble thikneer ie 1.8 mm (O72 te. Replace diss if 14) Measure free length of piston return springs with sings nretainer Pig 9} Leng hold be 21 32a E80 inl plac ratrn springs mot within speci "USI Chock catch piston ehec ball (ig. 10). Sako picten tome fall moves realy. Then check al seat aby applying law ressurecampresed ai tall inet tesbown, Air should not leak past check bal. Fig. 8 Removing Direct Cluch Piston Fi. © checking Paton Return Spring Length (06 Measure inside diameter of teh drum bushing Inside diooeter shold be no more then 5897 mam (1048 in Replace drum if bushing inside ameter rete than specie. Direct Cuutch Assembly ( Labrcate and inal replacement Ovrngs on late psten (@) Intl ctuteh piston in dram and instal return at Compress piston return springs ad install sap ring Fg. Be sure snap rig end gop tno lignod ‘ith spring retainer ‘ab 1) atl clutch dacs and plates (Fg. 1. stall plate then dice uni all pats spd dics oe install Ue four plates and ie in Gl transminsens and {hee ples and dice ney tanasion. (8) naa catch pack retainer in drum (ig. 12) (6 nal cates pack snap ving (Fig. 12) (2) Check soap ring poston I racessary, ei snap ing anti end gap i not aligned with an matches in ‘te drum Pig 12, (8) Check clutch piston stroke length a second time. leng OK continue with ase Isto length fafncoret replace clutch duc rue diferent thick ‘es clutch peck retainer (Pig 12) See Sperifieatons ‘ston for retainer thickness Io) Lsbrceeeten drum trast washer with pate: team ally ed inal iin drum Pig 3 {U0/ Mount dret clutch assembly on forward clutch assembly and check asombled height Fig. 1) Height ‘Soul be 103 to 71.5 mn 2767 to 2818 TO assembled height encore, clutches are nat ig 10 Testing Piston Check Ball SeatingService Information AW-4 (42) Heute heights OK, remove direct elutch from forward latch nd proved to lrward dutch overt Fig. 19 Adjusting Clutch Pack Snap Ring Postion ig, 12 neta Cltoh Pack Retainer Fig. 14 Checking Direct Clutch Assembled HeightService Information AW-4 Forward Clutch Disassembly (Cheek clutch pistan stroke outlined in flowing stop (2) Position overdrive support on wend blacks and mount forward cc dram en support Fig. 2 (3) Remove bearing and race ‘om forward latch drum Fig 2 ‘Moun il indiatar on catch drum, Position dat indlestor plunger agus clutch pst ig 9 oun SSS ‘Fig. 2 Postioning Drum And Support On Wood Blocks (8) Appi ompresaed se trough ght ide fed he ‘in support and noe plson stroke length on dal nd. (6) Stroke length should be: 5.75 104.89 eam 146919 1807 ion Gayl tranumisons and 3.42 429 am (4346 te 1655 ta) on tal transmissions (2) Repaoe utc dace i stroke length eicoret (8)Removeclute pack seapring and removeretsiner apd teh pack Fg 0) Remove clutch pack cushion plate (Fig 8) (00) Compre clutch springs with ol BV. FM. 27 bd remove piston snap Png (DD) Remove priageompresor too and piston return ‘Fig. 4 Removing Retainer And Chiten Pack 6 Fig. 5 Removing Cuehion PatoService Information AW-4 (32) Remount forward hutch drum on overdrive aup- por ig. 8, Ta) Apply compressed ae though fed ol in p= porto Remove piston (Pig. 6). Use aly enough sl resure to ease piston otf drum, "Ga Remove and discard eltoh piston O-ring. (05) Remove latch drum O-ring from rae bub OO) OF te drum 16) Remove three sal rings ro cutch drum shaft 1H?) Remove thrust bearing and race assembly from clutch drum Fig 8) 6 (08) Measure clutch dite thickness (Fig 20), Min smuim allowable thickness 1.84 mm (0724 in co ‘Toy trenumiesone end 1.51 sn .089 it on Gey (Uo) Measure ie length ofpston return springs with springs mounted nrotelner Fig. 11) Length shouldbe 1847 mm (7 in) Replace springs and retainer if length incorrect. (20) Inspec teh pstan check ball (ig 121. Ball shoul move rely within piston. Check bal ating by Fig. 9 Removing Cutch rum Thrust Bearing AS- ‘samolyService Information AW-4 plying lw pressure compressed iro ball eed hale, Ball should seat Remi and et leak at (21) Messore inside diameter of bushing in clutch ram hub Mannan allowable éiameter i 24.08 mm (G0 in). Replace clutch dam boning aside dha ‘eri greater than specified. Forward Clutch Assembly Lorene baring and race asembly with petro team jelly and instal i elute drum (ig, 13). Base fide of atzcrbly feces downward and toward dru, Bearing rollers face up (ig. 19) Fig 10 Measuring Cuten Disc Thickness (2) Cost new clutch dram shaft seal rings with pe ssoleem lly Bair iestaling dru set al ring, ‘squesse (contact) each ring eo Fng ends overlap (Fi 14) This tightens ring making date netallatin as 9) Intl eal rings on sha. Keep rings cloud ax tightly ae possible during installation, Avoid ore. reading them (a) Mowat clutch drum on overdrive support (5) Labvieae and instal new Ong on ctch dram ub ig 7, Fig. 12 Testing Piston Check Ball(6) Lubricate and install ew Ong on lutch piston (3) Gompres piston satura springs with tol BY [FML2T and shepprse snd intl piston susp sing, Be sure snap ring end gap lsat aligned with any notches ‘drum Ol Inealoutbion plat rum. Concaveside slate ‘sens downward (Pig. 8 (GD) sal late des, plates and retainer (Fig 15), Ista! tabted plate followed by dice unt required ‘ube plata and dsc are natlled. Une sx plates {ind diss in a Gyl ranwmicson snd five plates find dises in pl. transmiseion (UD Tatll atch pack snap ng (G2) Recheck ute psn stroke length using same mothedoulnedat begiasingofdseaembyprocedare ateoke lent ene within specie limit, replace latch dic (03) Lubricate race ad bering with pteleum sand inal thm in clatch drum (Fg 18) Beare bot "ng rller fae up cod race peat in drum as shown ‘Fig. 14 Instaling Chtch Drum Shaft Seal Rings Service Information AW-4 (40 Verily hearing and race sing, Outer diameter of ‘earings 467 mm (690). Outer dhameter race it 43.9.7m (192540) Inner diameter of beeing ond race 1s 280 mm 1.024 in, (4) Mount forward clutch on ace leh ad check stoembled height (Fig. 1D. Height shold be 709 to ‘TS mm (2767 © 2818 i), ig. 16 inatting Thrust Bearing And Race aaug, Bat ig. 17 Checking Forward Clutch Assembled Height FRONT PLANETARY GEAR OVERHAUL Front Planetary Disassembly "ty Remove ring gear fom planetary gear Fig {2} Remove rt bearing and the two res oem rng "S) Remove tabbed thrust race from planetary gear ig 1) Remove snap ring attaching pls shat wad remove goa 15) Remove rear bearing and race from planetary i Masse inside diameter of ring gear bushing Service Information AW-4 Maximum allowable diameters 24.08 mm (910 in. Replace rng goa if bushing sido dieters greater than spect ‘Front Planetary Assembly ‘ir Lubricate planetary ting evar bearings and os with petaloum lly 2) Kot panwtary Neaings and res before in stallaion iPig 1) Bearings an race canbe identi by blowing dimensions « utar diameter of rear bearings 4.7 mm 1.78 Inner diameter 1255 sum (1.398, ‘ig 1 Front Planetary Geer Components 6