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TRANSMISSION AND TRANSFER CASE

CONTENTS

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AX 15 M ANUAL TRANSMISSION . . . . . . . . . . . . 1AW-4 AUTOMATIC TRANSM ISSION . . . . . . . . . 3446RH AUTOMATIC TRANSM ISSION . . . . . . . . 1 5 1NP231 TRANSFER CASE . . . . . . . . . . . . . . . . 2 7 1

NP242 TRANSFER CASE . . . . . . . . . . . . . . . . 2 9 2NP249 TRANSFER CASE . . . . . . . . . . . . . . . . 3 1 9SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 3 4 5

AX 15 MANUAL TRANSMISSION

INDEX

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General Information . . . . . . . . . . . . . . . . . . . . . . . . 1Transmission Assembly and Adjustment . . . . . . . . 19Transmission Diagnosis . . . . . . . . . . . . . . . . . . . . . 2Transmission Disassembly and Overhaul . . . . . . . . 5Transmission Gear Ratios . . . . . . . . . . . . . . . . . . . 2Transmission Identification . . . . . . . . . . . . . . . . . . . 1

Transmission Installation . . . . . . . . . . . . . . . . . . . . 4Transmission Lubricant . . . . . . . . . . . . . . . . . . . . . 2Transmission Removal . . . . . . . . . . . . . . . . . . . . . . 3Transmission Shift Pattern . . . . . . . . . . . . . . . . . . . 2Transmission Switch and Plug Locations . . . . . . . . 2

GENERAL INFORMATIONTh e A X 1 5 is a f ive sp ee d , syn ch rom e sh , m a n u a l

t ra n sm issio n . F i f t h g e a r is a n o ve rd rive ra n g e wit h a

ra t io o f 0 .7 9 :1 . T h e sh if t m e ch a n ism is in t e g ra l a n d

m ou n t ed i n t h e s h if t t ow e r p or t i on of t h e a d a p t e rhousing (Fig. 1).

TRANSMISSION IDENTIFICATIONThe AX 15 identificat ion code numbers are on the

bottom surface of the t ra nsmission gea r case (Fig. 2).

Th e f irst n u m b er re pre sen t s ye a r of m a n u f a ct u re .

For example, 3 would represent 1993. The second andt h ir d n um ber s in dica t e m on t h of m a n ufa ct ur e.

Fig. 1 AX 15 Manual Transmission

Z TRANSMISSION AND TRANSFER CASE 21 - 1


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For example, 11 would represent November. The last

series of numbers is the transmission serial number.

TRANSMISSI ON SHIFT PATTERNThe AX 15 shift pattern is shown in Figure 3. Firsta n d s e c o n d a n d t h i r d a n d f o u r t h g e a r r a n g e s a r e i n

a n H p a t t er n . F i f t h a n d r ev er s e g ea r r a n g es a r e a l s o

in line at the right of the H pattern (Fig. 3).

Th e AX 15 i s e q ui pp ed w i t h a r ev er s e l ock ou t

m e ch a n ism . Th e sh ift leve r m u st b e m o ved t h ro u gh

the Neutral detent before making a shift to reverse.

TRANSMISSION LUBRICANTRecommended lubricant for AX 15 transmissions is

Mopar SAE 75W-90, AP I G ra de G L-5 gear lubrican t .

Co rrect lu brica n t re fi ll or t o p-of f level is t o t h e

bottom edge of the fill plug hole.

L u br i ca n t ca p a c it y i s a p pr ox im a t e ly 3. 10 l it e r s

(3.27 qts.).

TRANSMISSION SWITCH AND PLUG LOCATIONST h e f i l l p lu g is a t t h e d rive r s id e o f t h e g e a r ca se

(Fig. 4).

T h e d ra in p lu g a n d b a ck u p l ig h t swit ch a re o n t h e

passenger side of th e gear case (Fig. 5).

TRANSMISSION GEAR RATIOSAX 15 transmission gear rat ios are:

First gear - 3.83:1

Second gear - 2.33:1

Third gear - 1.44:1

Fourth gear - 1.00:1

Fifth gear - 0.79:1

Reverse - 4.22:1

TRANSMISSION DIAGNOSIS

LOW LUBRICANT LEVELA low t ra n sm ission lu brica n t leve l is g e n era l ly t h e

result of a leak, inadequate lubricant f ill , or an incor-

rect lubricant level check.

L e a k s ca n o ccu r a t t h e m a t in g su rf a ce s o f t h e g e a r

case, intermediate plate and adapter housing, or from

th e front/rea r s eals. A suspected leak could a lso be the

result of an overfill condition.

L ea k s a t t h e r e a r of t h e a d a p t er h ou si ng w i ll b e

f rom t h e h o u sin g oi l se a ls . L e a k s a t com p on e n t m a t -

Fig. 2 Transmission Identification Code Location

Fig. 3 AX 15 Shift Pattern

Fig. 4 Fill Plug Location

Fig. 5 Drain Plug And Backup Light Switch Location

21 - 2 AX 15 MANUAL TRANSMISSION Z


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ing surfaces will probably be the result of inadequate

sealer, ga ps in the sealer, incorrect bolt t ightening, or

use of a non-recommended sealer.

A lea k a t t h e f ron t of t h e t ra n sm ission a re f rom t h e

front bearing retainer or retainer seal. Lubricant may

b e se en d ripp in g f rom t h e clu t ch h o u sin g a f t e r e x-

t e nd ed op er a t i on . I f t h e l e a k i s s ev er e, i t m a y a l s o

con t a m i n a t e t h e cl ut ch d is c c a u s in g s li p, g r a b a n dchatter.

Tra nsm issions filled from air or electrically pow ered

lubricant conta iners can be underfilled. This gener-

ally happens when the container delivery mechanism

is improperly calibrated. Always check the lubricant

level a fter f illing to a void a n un der fill condit ion.

A corre ct lu brica n t level ch eck ca n on ly b e m a d e

w h e n t h e v eh i cl e i s l ev el ; u s e a d r iv e-on h oi st t o

e n sure t h is . Also a l low t h e lu b rica n t t o se t t le f or a

minut e or s o before checking. These recommenda tions

will ensure an accurate check and avoid an under-or-

overfill condit ion.

HARD SHIFTING

H a r d s h if t in g i s u s u a l ly t h e r e s u lt of a l ow l ub r i-

cant level, improper or conta minat ed lubricant s, com-

ponent damage, incorrect clutch adjustment, or by a

dam aged clutch pressure plat e or disc.

S u b st a n t ia l lu b rica n t lea k s ca n re su lt in g ea r , sh i f t

r a i l, s y nch r o a n d b ea r i ng d a m a g e. I f a l ea k g oes

u n d et e ct e d f or a n e xt e n d ed p eriod , t h e f irst in d ica -

tions of a problem are hard shift ing and noise.

Incorrect or conta minat ed lubricant s a lso contribute

t o h a r d s h if t in g . Th e con s eq u en ce of u s in g n on -

recommended lubricants is noise, excessive wear, in-t e rn a l b in d a n d h a rd sh if t in g .

Improper clutch release is a frequent cause of hard

s h if t in g . I n cor r ect a d ju s t m en t or a w o r n, d a m a g e d

p ressu re p la t e or d isc ca n ca u se in corre ct re le a se . I f

t h e cl ut ch p r ob le m i s a d v a n ce d, g ea r cl a s h d u r in g

shifts can result .

Wor n or d a m a g e d s y n ch r o r i n g s ca n ca u s e g ea r

c l a s h w h e n s h i f t i n g i n t o a n y f o r w a r d g e a r . I n s o m e

n e w or re bu ilt t ra n sm ission s, n e w syn ch ro r in g s m a y

t e n d t o st ick sl ig h t ly ca u sin g h a rd o r n o isy sh if t s . I n

m ost ca ses, t h is con d it ion wil l d e cl in e a s t h e r in g s

wear-in.

TRANSMISSION NOISE

M o st m a n u a l t ra n sm issio n s m a k e so m e n o ise d u r-

in g n o rm a l o p e ra t io n . Ro t a t in g g e a rs ca n g e n e ra t e a

m il d w h in e t h a t m a y on ly b e a u d ib le a t ex t rem e

speeds.

Severe transmission noise is generally the result of

a lubrican t problem, or interna l component da ma ge.

Insufficient , improper, or contaminated lubricant can

p r om ot e r a p id w e a r of g ea r s , s y n ch r os , s h if t r a i l s,

f ork s a n d b ea rin g s. Th e o verh e a t in g ca u se d b y a lu -

bricant problem, can also lead to gear breakage.

TRANSMISSION REMOVAL(1) Shift transmission into Neutral.

(2) Raise vehicle on hoist.

(3) Remove skid plate.

( 4 ) M a rk f ro n t a n d re a r p ro p e lle r sh a f t s f o r in st a l-

lation alignment (Fig. 1). Then remove shafts.

(5) Disconnect tra nsfer case shift l inkage from shift

lever, or range lever.

(6) Disconnect w ire ha rness from dista nce sensor.

( 7 ) Re m o ve h a rn e ss wire s f ro m cl ip s o n t ra n sm is-

sion case.

(8) Disconnect transmission and transfer case vent

hoses.

(9) D i s con n ect w i r es a t t r a n s f er ca s e e le ct r i ca l

swit ch .

(1 0) S u p port t ra n sm ission wit h t ra n sm ission ja ck .

Secure transmission on jack with safety chains.

(11 ) S u p port e n gin e wit h ja ck p osi t ion e d u n d er

clutch h ousing or oil pan flange.

(1 2) Rem ove b olt s/n u t s a t t a ch in g re a r m ou n t t o

crossmember (Fig. 2).

(13) Remove rear crossmember.

( 1 4 ) R e m o v e t r a n s f e r c a s e a t t a c h i n g n u t s a n d r e -

move transfer case from transmission.

(15) Lower tra nsmission enough to provide a ccess

to shift lever.

(16) R e a c h u p a n d a r o un d t r a n s m i ss ion ca s e a n d

u n se a t sh if t le ve r d u st b o o t f ro m t ra n sm issio n sh if tt o we r (F ig . 3 ). M ove b o ot u p wa rd on sh ift lever f or

access to lever reta iner.

(17) Disengage t ra nsmission sh ift lever as follow s:

( a ) R e a c h u p a n d a r o u n d t r a n s m i s s i o n c a s e a n d

p re ss sh if t le ve r re t a in e r d o wn wa rd wit h yo u r f in -

gers.

(b) Turn reta iner counterclockwise to release it .

(c) Lift lever and retainer out of shift tower (Fig.

3). It is not necessary to remove shift leverfrom floorpan boot. Simply leave lever inplace for later installation.

Fig. 1 Marking Propeller Shaft And Axle Yoke

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(18) D isconnect and remove engine t iming sensor.

Re t a in se n sor a t t a ch in g screws.

(19) Remove clutch slave cylinder from clutch hous-

in g . M o ve cyl in d e r a sid e f o r wo rk in g cle a ra n ce a n d

access to other components.

(20) Remove bolts at taching clutch housing to en-

gine.

( 2 1 ) Pu ll t ra n sm issio n re a rwa rd u n t i l c lu t ch h o u s-ing is clear of engine. Then remove transmission from

under vehicle.

TRANSMISSION INSTALLATION(1) Mount transmission and clutch housing assem-

bly on transmission jack. Secure assembly with safety

chains.

(2 ) L u b rica t e p ilot b ea rin g a n d t ra n sm ission in pu t

shaft splines with Mopar high temperature grease.

(3 ) Alig n t ra n sm ission in pu t sh a f t a n d clu t ch d isc

splines a nd seat clutch housing on engine.

( 4 ) I n st a l l a n d t ig h t e n b o lt s t h a t c lu t ch h o u sin g t o

engine. Tighten bolts to 61 Nm (45 ft. lbs.) torque.

(5 ) L o we r t ra n sm ission f or a cce ss t o t ra n sm ission

shift t ower.

( 6 ) Re a ch u p a n d a ro u n d t ra n sm issio n a n d in se rt

sh if t le ve r in sh if t t o we r. Pre ss le ve r re t a in e r d o wn -

wa rd a n d t u rn i t c lo ck wise t o lo ck i t in p la ce . T h e n

insta ll lever dust boot on shift t ower.

(7 ) Alig n t ra n sf er ca se a n d t ra n sm ission sh a f t s a n d

in st a l l t ra n sf er ca se. Tig h t en t ra n sf er a t t a ch in g n u t s

to 35 Nm (26 ft. lbs.) torque.

( 8 ) M o ve a d ju st a b le su p p o rt s t a n d f ro m u n d e r e n -

g in e a n d re posit ion i t u n d er t ra n sm ission . Th e n re -

move tra nsmission jack.(9) Install rear crossmember. Tighten crossmember-

to-frame bolts to 41 Nm (30 ft. lbs.) torque. Tighten

tr a nsmiss ion-to-rea r support bolts/nut s t o 45 Nm (33

ft . lbs.) torque.

(10) I n st a l l s la v e cy li nd er i n cl ut ch h ou si ng .

Tighten cylinder a t t aching nuts securely.

(11) Connect or install engine t iming sensor, if re-

moved.

(12) Connect transfer case electrical switch wires.

(13) Connect tra nsfer case shift rod to ra nge lever.

(1 4) Co n n ect t ra n sm ission a n d t ra n sf er ca se ve n t

hoses.(15) Connect backup light swit ch wires.

(16) Connect distan ce sensor a nd sensor w ires.

(17) Align an d insta ll front/rear propeller shaft s.

Tighten shaft U-joint clamp bolts to 19 Nm (170 in.

lbs.) torque.

(18) Inst all skid plat e if removed. Tighten bolts to

42 Nm (3 1 f t . lb s.) t orqu e . Tig h t en st u d n u t s t o 1 7

Nm (150 in. lbs.) torque.

(1 9) Top of f t ra n sm ission a n d t ra n sf er lu brica n t

levels.

(20) Lower vehicle.

Fig. 2 Transmission Rear Mounting

Fig. 3 Shift Lever Attachment



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TRANSMISSI ON DISASSEM BLY AND OVERHAUL

ADAPTER HOUSING REMOVAL

(1 ) Re m ove re le a se b ea rin g , re le a se lever a n d re -

lease fork from clutch housing. Then remove clutch

housing from t ra nsmission.

(2) Remove backup light switch. Then remove drain

p lu g (F i g. 1) a n d d r a i n t r a n s m i ss ion l ub r ica n t i n t op a n .

(3) R em ov e s h if t t ow e r b ol t s a n d r e mov e t ow e r

from adapter or extension housing (Fig. 2).

(4) Remove gasket from shift tower (Fig. 3).

(5) Remove shift ar m reta iner bolt (Fig. 4).

(6) Loosen and remove restrictor pins (Fig. 5).

(7) Remove shift a rm sha ft plug (Fig. 6).

(8 ) Re m ove sh ift a rm sh a f t wit h la rg e m a g n e t (F ig .

7).

(9) Remove shift arm (Fig. 8).

(10) R emove plug for reverse shift head lock ba ll .

Plu g is a t r ig h t s id e o f a d a p t e r h o u sin g n e a r b a ck u p

light switch (Fig. 9).

(11 ) Rem ove lock b a l l sp rin g wit h p en cil m a g n e t

(Fig. 10).

Fig. 1 Drain Plug And Backup Light Switch Location

Fig. 2 Shift Tower Removal/Installation

Fig. 3 Shift Tower Gasket Removal/Installation

Fig. 4 Shift Arm Retainer Bolt Removal/Installation

Fig. 5 Removing/Installing Restrictor Pins



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( 1 2 ) Re m o ve sh if t h e a d lo ck b a l l wit h p e n cil m a g -

net (Fig. 11).

(13) Remove adapter housing bolts (Fig. 12).

(14) Loosen a da pter/extension housing w ith rubber

ma llet (Fig. 13).

(15) Remove housing after loosening it (Fig. 14)

(16) R e m ov e a d a p t er h ou s in g oi l s ea l w i t h a p r y

tool (Fig. 15).

Fig. 6 Removing/Installing Shift Lever Shaft Plug

Fig. 7 Removing/Installing Shift Lever Shaft

Fig. 8 Shift Arm Removal/Installation

Fig. 9 Removing/Installing Lock Ball Plug

Fig. 10 Removing/Installing Lock Ball Spring

Fig. 11 Removing/Installing Shift Head Lock Ball



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Fig. 13 Loosening Adapter Housing

Fig. 14 Adapter Housing Removal

Fig. 15 Removing Adapter Housing SealFig. 12 Adapter Housing Bolt Locations



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GEAR CASE REMOVAL

(1 ) Re m ove b e a rin g re t a in e r b olt s a n d re m ove re -

tainer (Fig. 16).

(2) Remove retainer oil seal with pry tool (Fig. 17).

(3) Remove input sha ft bear ing sna p ring (Fig. 18).

(4) R e m ov e cl u st e r g ea r f r on t b ea r i n g s n a p r i ng

(Fig. 19).

(5) Loosen gear case by tapping it away from inter-

mediate plat e wit h r ubber m allet (Fig. 20).

( 6 ) Re m o ve g e a r ca se f ro m g e a rt ra in a n d in t e rm e -

diate plate (Fig. 21).

Fig. 16 Front Bearing Retainer Removal

Fig. 17 Front Bearing Retainer Seal Location

Fig. 18 Removing Input Shaft Bearing Snap Ring

Fig. 19 Removing Cluster Gear Front Bearing Snap Ring

Fig. 20 Loosening Gear Case

Fig. 21 Gear Case Removal



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(7) R em ov e s pe ed om et e r g ea r s n a p r i n g a n d r e -

move speedometer gear an d spa cer from output sh aft .

FIFTH GEAR AND SYNCHRO ASSEMBLY RE-

MOVAL

(1) Remove three lock ball plugs from intermediate

plat e (Fig. 22).

(2 ) Re m ove t h re e lock b a l l sp rin g s a n d lock b a l ls

from intermediate plate w ith pencil ma gnet (Fig. 23).

(3 ) M o u n t in t e rm ed ia t e p la t e a n d g e a rt r a in a sse m -

bly in vise a s follow s:

(a) Insert two spare bolts in one bottom bolt hole

in in t erm e d ia t e p la t e . I n se rt b olt s f rom op posit e

sides of plates (Fig. 24).

(b ) I n st a l l e n ou g h f la t wa sh e rs u n d e r e a ch b olt

head to prevent bolts from touching (Fig. 24).

(c) Ta p e b o lt s a n d wa sh e rs in p la ce a n d m ou n t

intermediate plate in vise (Fig. 24).

(d ) Cla m p vise ja ws se cu re ly a g a in st b o lt h e a d s

(Fig . 24). Do not clamp vise jaws on intermedi-ate plate. Clamp only on bolt heads.

Fig. 22 Lock Ball Plug Locations

Fig. 23 Removing/Installing Lock Ball And Spring

Fig. 24 Mounting Intermediate Plate And Geartrain In Vise



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(4 ) Rem ove f i f t h g ea r sn a p rin g (F ig . 2 5 ). Re t a in

s n a p r i ng f or a s s em b ly r ef er en ce. I t i s a s el ect f it

component.

(5) Remove E-ring that secures reverse shift arm to

fork (Fig. 26).

(6) R em ov e b ol t s a t t a c hi ng r ev er s e s h if t a r m

b ra ck et t o in t e rm ed ia t e p la t e . Th e n re m ove b ra cke t

(Fig. 27).

(7) Remove reverse shift arm and shoe (Fig. 28).

(8) Remove fifth gear shift fork set screw (Fig. 29).

(9 ) M o ve f if t h g e a r sh ift ra i l f o rwa rd u n t i l i t c lea rs

shift fork.

(10) R em ov e f if t h g ea r s h if t f or k f r om s y n ch r o

sleeve (Fig. 30).

(11) R e mov e r e ve r se s h if t r a i l a n d r ev er s e s h if t

head as assembly (Fig. 31).

(12) Me a s ur e t h r u s t cl ea r a n c e b et w e en cou n t er

f i f t h g e a r a n d t h r u s t r i n g w i t h f e e l e r g a u g e . C l e a r -

a nce should be 0.10 to 0.40 mm (0.003 to 0.019 in.). If

cleara nce exceeds limits, gea r and /or ring will h ave to

be replaced.

(13) Loosen fifth spline gear with standard two-jaw

puller (Fig. 32). Position puller jaws behind fifth

counter gear as shown.

(14) Remove fifth spline gear (Fig. 33).

(15) Remove fifth gear synchro ring (Fig. 34).

Fig. 25 Fifth Gear Snap Ring Removal

Fig. 26 Removing Reverse Shift Arm E-Ring

Fig. 27 Removing Reverse Shift Arm Bracket

Fig. 28 Removing Reverse Shift Arm And Shoe

Fig. 29 Removing Fifth Gear Fork Set Screw



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(16) Remove fifth gear synchro and sleeve assembly

(Fig. 35).

(17) Remove counter fifth gear thrust ring (Fig. 36).

(18) Remove thrust ring lock ball with pencil mag-

net (Fig. 37).

(19) Remove bolts at taching output shaft rear bear-

ing reta iner to int ermediate plat e (Fig. 38).

Fig. 30 Removing Fifth Gear Shift Fork

Fig. 31 Removing Reverse Shift Head And Rail

Fig. 32 Loosening Fifth Spline Gear

Fig. 33 Removing Fifth Spline Gear

Fig. 34 Removing Fifth Gear Synchro Ring

Fig. 35 Removing Counter Fifth Gear And Synchro

Assembly



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(20) Remove rear bearing retainer (Fig. 39).

(21) Remove reverse gear and shaft (Fig. 40). SHIFT RAIL AND FORK REMOVAL

Th er e a r e a t ot a l of f iv e s h i ft r a i l s i n t h e AX 1 5

t ra n sm ission . Th e 1-2 , 3 -4 , f i f t h g ea r a n d f ron t re -

verse shift rails are shown in Figure 41.

Two shift ra ils ar e used for reverse gear ra nge. The

f ro n t re ve rse ra i l is a t t h e f o rwa rd sid e o f t h e in t e r-

m e d ia t e p la t e (F ig . 4 1). Th e sh o rt re a r re verse ra i l

a n d r ev er s e s h if t h ea d a r e a t t h e r e a r s id e o f t h e

intermediate plate.

It is not necessary to remove the shift rails if

they are in good condition. Only the shift forks

need be removed for access to the shafts and

gears.

(1) Remove fifth gea r shift r ail (Fig. 41). C at ch lock

b a l l i n y o u r h a n d a s r a i l c o m e s o u t o f i n t e r m e d i a t e

plate.

(2) Remove 1-2 and 3-4 shift rail C-rings with two

screwdrivers of equa l size a nd length (Fig. 42).

(3) Remove shift fork set screws (Fig. 43).

(4) Remove 3-4 shift rail from shift fork and inter-

mediate plate (Fig. 44).

Fig. 36 Removing Fifth Gear Thrust Ring

Fig. 37 Removing Thrust Ring Lock Ball

Fig. 38 Removing Output Shaft Rear Bearing Re-tainer Bolts

Fig. 39 Removing Output Shaft Rear Bearing Re-tainer

Fig. 40 Removing Reverse Idler Gear And Shaft



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Fig. 44 Removing 3-4 Shift Rail

Fig. 41 Shift Rail Identification

Fig. 42 Removing Shift Rail C-Rings

Fig. 43 Removing Shift Fork Set Screws



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(5) Remove 3-4 shift rail interlock plug from inter-

mediate plate with magnet (Fig. 45).

(6) Remove 1-2 shift rail from shift fork and inter-


(7 ) Re m ove 1-2 sh ift ra i l in t erlock p in f rom sh ift

ra il (Fig. 47).

(8) Remove 1-2 shift ra il int erlock plug from inter-


(9 ) L if t re verse sh if t f ork u p wa rd a n d re m ove f i ft h

gear shift rail lock ball (Fig. 49).

(10) Remove 3-4 shift fork (Fig. 50).

(11) Remove 1-2 sh ift fork (Fig. 50).

(12) R em ov e r e ve r se s h if t r a i l C -r i n g w i t h t w o

equal length a nd s ize screwdrivers (Fig. 51).

(13) Remove reverse shift rail and fork (Fig. 52).

(1 4) Re m o ve in t e rlock p in f rom re verse sh ift ra i l

(Fig. 53).

(15) Position shift rails, shift forks, lock balls, inter-

lock p lu gs a n d in t erlock p in s on t h e wo rk be n ch in

order of removal. This will help in identifying compo-

nents dur ing inspection an d a ssembly.

OUTPUT SHAFT AND CLUSTER GEAR RE-

MOVAL

(1) R em ov e ou t pu t s h a f t r e a r b ea r i n g s n a p r i n g

(Fig. 54).

Fig. 45 Removing 3-4 Shift Rail Interlock Plug

Fig. 46 Removing 1-2 Shift Rail

Fig. 47 Removing 1-2 Shift Rail Interlock Pin

Fig. 48 Removing 1-2 Shift Rail Interlock Plug

Fig. 49 Removing Fifth Gear Shift Rail Lock Ball



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(2) R em ov e cl us t er g ea r r ea r b ea r i n g s n a p r i n g

(Fig. 54).

(3 ) Ta p e n d o f o ut p u t sh a f t wit h m a lle t t o u n se a t

a n d st a rt re a r b ea rin g ou t of in t e rm ed ia t e p la t e ( F ig .

55).

(4) Remove output shaft by rocking it l ightly until

rear bearing comes out of intermediate plate (Fig. 56).

(5) Remove cluster gear by pulling it stra ight out of

rear bearing (Fig. 57).

(6) Remove cluster gear rear bearing from interme-

diate plate (Fig. 58).

(7) Remove input shaft from output shaft (Fig. 59).

(8 ) Re m ove ou t p u t sh a f t p ilot b ea rin g f rom in pu t

shaft (Fig. 60).

(9) Remove synchro ring from input shaft (Fig. 61).

( 1 0 ) Re m o ve b e a rin g sn a p rin g a n d p re ss b e a rin g

off input shaft (Fig. 61).

OUTPUT SHAFT DISASSEMBLY

( 1 ) M e a su re t h ru st c le a ra n ce o f o u t p u t sh a f t f i rst ,

second and third gears wit h feeler ga uge (Fig. 62).

Fig. 50 Shift Fork Removal

Fig. 51 Removing Reverse Shift Rail C-Ring

Fig. 52 Removing Reverse Shift Rail And Fork

Fig. 53 Removing Reverse Shift Rail Interlock Pin



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F i r st g ea r cl ea r a n ce s h ou ld b e 0. 100. 40 m m

(0.0030.0197 in).

Secondthird gear clearance should be 0.100.30

mm (0.0030.0118 in.).

(2) I f f ir s t g ea r t h r u s t cl ea r a n c e i s i n cor r ect , r e -

p la c e g ea r a n d t h r u s t w a s h er. If second or third

gear clearance is incorrect, either gear and

bearing, or output shaft flange is worn. Refer to

output shaft inspection in C leaning and Inspec-

tion section.

(3) P r e s s f if t h g ea r a n d r ea r b ea r i ng of f r ea r of

output shaft .

( 4 ) Re m o ve t h ru st wa sh e r, p in , a n d f irst g e a r a n d

bear ing (Fig. 62).

Fig. 54 Removing Bearing Snap Rings

Fig. 55 Unseating Output Shaft Rear Bearing

Fig. 56 Removing Assembled Input And OutputShaft

Fig. 57 Cluster Gear Removal

Fig. 58 Removing Cluster Gear Rear Bearing



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(5) Remove first /reverse h ub sn a p ring (Fig. 63).

(6) Remove synchro ring.

(7) P r e s s r ev er s e g ea r a n d f ir s t /r ev er s e h u b of f

sh a f t a s a sse m b ly.

(8) R em ov e r e ma i n in g s y n ch r o r i ng a n d s econ d

gear an d bear ing (Fig. 63).

(9 ) R e m ove sn a p rin g a t f ron t of o u t p ut sh a f t (F ig .

63).

(1 0) P re ss 3 -4 h u b a n d slee ve of f o u t p ut sh a f t a s

as sembly (Fig. 63).

(11) Remove synchro ring.

(1 2) Re m ove t h ird g e a r a n d n e ed le b e a rin g (F ig .

63).

TRANSMISSION CLEANING AND INSPECTION

C l ea n t h e t r a n s m i ss i on com pon en t s i n s ol ve nt .Th en d r y t h e ca s es , g ea r s , s h if t m ech a n is m a n d

sh a f t s wit h com p ressed a ir . Dry the bearings withclean, dry shop towels only. Never use com-pressed air on the bearings. This could damagethe bearing rollers.

R epl a ce com pon en t s t h a t a r e ob vi ou sl y w or n ,

cracked, chipped or damaged in any way.

I n sp e ct t h e t ra n sm issio n ca se . Re p la ce t h e ca se i f

cra ck e d o r p o ro u s o r i f a n y o f t h e b e a rin g a n d g e a r

b ore s a r e d a m a g ed .

Output Shaft Inspection

Measure thickness of the output shaft f lange with am i cr om et e r (F i g. 64). M in i m um a l l ow a b le f la n g e

th ickness is 4.70 mm (0.185 in).

If shaft flange thickness is OK but previouslymeasured second/third gear thrust clearancewas incorrect (Fig. 62), replace the necessarygear and needle bearing as an assembly.

Ch e ck d ia m e t e r o f t h e f irst , se co n d a n d t h ird g e a r

b ea rin g su rf a ce s of t h e ou t p u t sh a f t (F ig . 6 4). M in i-

m u m a l lowa b le d ia m e t e rs a re :

38.86 mm (1.529 in.) for first gear surface

46.86 mm (1.844 in.) for second gear surfa ce

Fig. 59 Input Shaft Removal

Fig. 60 Removing Input Shaft Pilot Bearing

Fig. 61 Input Shaft Components

Fig. 62 Checking Output Shaft Gear Thrust Clear-ance



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37.86 mm (1.490 in.) for third gear surface

Check output shaft runout with V-blocks and a dial

indicator (Fig. 64). Maximum allowable runout is 0.06

mm (0.0024 in .).

Re p la ce t h e o u t p u t sh a f t i f a n y su rf a ce m e a su re d

fails to meet stated tolerance.

Cluster Gear Inspection

I n sp e ct t h e clu st e r g e a r t e e t h . Re p la ce t h e g e a r i f

a n y t eet h a r e w or n or d a m a g ed or i f t h e b ea r i ng

su rf a ces a re d a m a g ed .

Ch e ck d ia m e t e r o f t h e clu st e r g e a r jo u rn a l wit h a

micrometer (Fig. 65). Minimum allowa ble diameter is

27.860 m m (1.096 in .).

Ch e ck con d it ion of t h e clu st er g ea r f ron t b ea rin g .

Replace the bear ing if w orn, n oisy, or da ma ged.

GEAR AND SYNCHRO INSPECTION

I n st a l l t h e syn chro r in g s on t h e ir re spe ct ive g e a rs.

Rotate each ring on the gear and note synchro action.

Replace any synchro ring that exhibits a lack of brak-

ing action or binds on the gear. Also replace any ring

that is worn or has chipped or broken teeth.

M ea s u r e e nd cl ea r a n c e b et w e en t h e s y n ch r o r i n g

a n d t h e g e a r wit h a f ee le r g a u g e ( F ig . 6 6). C lea ra n ce

should be 0.06 mm to 1.6 m m (0.024 to 0.063 in.).

I n st a l l t h e n e e d le b e a rin g s in t h e f irst , se co n d a n d

third gear s. Then insta ll the gears on the output shaft

a n d ch eck sh a f t -t o -g e a r clea ra n ce w it h a d ia l in d ica -

tor (Fig. 67).

Maximum allowa ble cleara nce is 0.16 mm (0.0063

in.). I f any gear exhibits excessive clearance, replace

the gear and needle bearing.

Ch e ck clea ra n ce b e t we e n t h e sh ift f ork s a n d syn -

chro sleeves with a feeler gauge (Fig. 68). Clearance

sh ou ld n ot e xce ed 1 .0 m m (0.03 9 in .). Re pla ce t h e

syn ch ro sle eve (a n d m a t ch in g h u b ) i f c le a ra n ce e x-

ceeds the stated limit .

Ch e ck con d it ion of t h e re verse id le r g ea r b u sh in g

(Fig. 69). Replace the gear if t he bushing is scored or

wo rn .

Gear Case, Housing And Intermediate PlateCle a n t h e ca se, h o u sin g a n d p la t e w it h so lve n t a n d

dry with compressed air. Replace any component that

is cra ck ed , wa rp ed o r d a m a g ed in a n y w a y.

I n sp e ct t h e t h re a d s in t h e ca se , h o u sin g a n d p la t e .

M in or t h r ea d d a m a g e ca n b e r ep a ir ed w i t h s t eel

t h re a d in sert s i f n e ce ssa ry. H owe ve r, d o n o t a t t e m pt

t o r epa i r if t h e cr a cks a r e ev id en t a r ou nd a n y

threa ded hole.

Fig. 63 Output Shaft And Gears



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I n sp ect t h e re verse p in in t h e a d a p t er/e xt e n sion

housing. Replace the pin if w orn or dama ged. Refer to

the replacement procedure in the Tra nsmission As-

sembly section.

TRANSMISSION ASSEMBLY AND ADJUSTMENTL u b rica t e t h e t ra n sm ission com p on e n t s wit h g ea r

lubricant during assembly. Use petroleum jelly to lu-b rica t e se a l l ips a n d /or h old p a rt s in p la ce d u rin g

installat ion.

FRONT BEARING/BEARING SEAL/REVERSE

SHAFT PIN INSTALLATION

(1) Press front bearing on input shaft . Then secure

b ea r i n g w i t h t h i ck es t s n a p r i n g t h a t w i l l f it i n s h a f t

groove (Fig. 70).

(2) P ress front bearing on cluster gea r. Then secure

b e a r i n g w i t h t h i c k e s t s n a p r i n g t h a t w i l l f i t i n r i n g

groove on gea r (Fig. 71).

Fig. 64 Checking Output Shaft Tolerances

Fig. 65 Checking Cluster Gear Journal Diameter

Fig. 66 Checking Synchro Ring End Clearance

Fig. 67 Checking Gear-To-Shaft Clearance



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(3 ) I n st a l l n e w oi l se a ls in f ron t b ea rin g re t a in e r

and adapter housing (Fig. 72). Installat ion depth for

b ea rin g re t a in e r se a l is 10 .5 t o 1 1.5 m m (0 .4 14 t o

0.453 in.).

( 4 ) I n st a l l re ve rse sh a f t a n d sh a f t re t a in in g p in in

a d a p t e r h o u sin g . T h e n in st a l l a cce ss h o le p lu g wit htorx bit (Fig. 73).

(5 ) L u b rica t e re verse sh a f t a n d g ea r com p on e n t s

with Mopar 75W-90 gear lubricant.

OUTPUT SHAFT ASSEMBLY

(1) L u br ica t e ou t pu t s h a ft jou r na l s, g ea r s a n d

needle bearings with recommended gear lubricant .

(2) I n s t a l l t h i r d g ea r a n d n eed l e b ea r i n g on s h a f t

(Fig. 63)

(3) Inst all sy nchro ring on third gear (Fig. 63).

(4) Assemble 1-2 and 3-4 synchro hubs and sleeves

(Fig.74).

( 5 ) I n st a l l in se rt s a n d sp rin g s in syn ch ro sle e ve s.

P o s it i on op en e nd s of s pr i n gs 180 a p a r t a s s h ow n

(Fig. 75).

(6 ) I n st a l l 3 -4 syn ch ro h u b a n d slee ve o n ou t p u t

shaft . Press hub onto shaft if necessary.

(7) Install 3-4 synchro hub snap ring (Fig. 76). Use

thickest snap ring that will f it in shaft groove.

Fig. 68 Checking Shift Fork-To-Sleeve Clearance

Fig. 69 Reverse Idler Gear Bushing

Fig. 70 Selecting Input Shaft Front Bearing Snap

Ring

Fig. 71 Selecting Cluster Gear Front Bearing SnapRing



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(8 ) Ve rif y t h ird g ea r t h ru st c le a ra n ce wit h f ee le r

gauge (Fig. 56). Cleara nce should be 0.10 to 0.25 mm

(0.004 to 0.010 in.).

(9) L u br i ca t e r em a i n in g ou t pu t s h a f t g ea r s a n d

b ea rin g s w it h g e a r lu brica n t .

Fig. 72 Oil Seal Installation

Fig. 73 Installing Reverse Shaft Pin

Fig. 74 Synchro Sleeve And Hub Identification

Fig. 75 Insert Spring Position

Fig. 76 Installing 3-4 Synchro Hub Snap Ring



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(10) I ns t a l l s econ d g ea r a n d n eed l e b ea r i n g on

shaft (Fig. 78).

(11) Install synchro ring on second gear (Fig. 78).

(12) Assemble first /reverse h ub, ins ert springs, in-

serts, reverse gear and 1-2 sleeve (Fig. 78). Be surespring ends are 180 apart. Note that splines inhub bore are chamfered on one side. Install hubso chamfered side faces front of output shaft.

(13) P r e s s a s s em b le d h u b a n d s le ev e on ou t pu t

sh a f t .

(14) Insta ll selective snap ring (Fig. 78). U se th ick-

est snap ring that will f it in output shaft groove.

(15) Insta ll synchro ring on first gea r (Fig. 79).

( 1 6 ) I n s t a l l f i r s t g e a r s p a c e r o n s h a f t a n d a g a i n s t

selective fit snap ring (Fig. 79).

( 1 7 ) I n st a l l f i rst g e a r a n d n e e d le b e a rin g ( F ig . 7 9 )

on output shaft .

(1 8) I n st a l l loca t in g p in a n d t h ru st wa sh er o n sh a f t

(Fig. 79).

( 1 9 ) Pre ss re a r b e a rin g o n sh a f t . Po si t io n b e a rin g

snap ring groove so it is closest to end of output sha ft .

( 2 0 ) Ch e ck f irst a n d se co n d g e a r t h ru st c le a ra n ce

with feeler gauge (Fig. 62).

F i r st g ea r cl ea r a n ce s h ou ld b e 0. 10 t o 0. 40 m m

(0.003 t o 0.0197 in.)

Second gear clearance should be 0.10 to 0.30 mm

(0.003 to 0.0118 in.)

(21) Press fif th gear onto output shaft . Then install

se le ct f i t sn a p r in g ( F ig . 8 0 ) . Use t h ick e st sn a p rin g

that will f it in shaft groove.

(22) Lubricate input shaft pilot bearing with petro-

leum jelly a nd inst all bea ring in sha ft (Fig. 60).

(23) Inst all input sha ft on output sha ft (Fig. 59). B e

sure output shaft hub is fully seated in pilot bearing.

OUTPUT SHAFT AND CLUSTER GEAR IN-

STALLATION

(1) Mount intermediate plate in vise (Fig. 24).

(2 ) L u b rica t e clu st e r g e a r jou rn a l a n d re a r b ea rin g

w ith petroleum jelly or gear lubrican t .

(3) Install cluster gear rear bearing in intermediateplate (Fig. 81). B e sure sna p ring groove in bear ing is

r e a r w a r d a s s h ow n .

(4) St ar t cluster gear into bearing (Fig. 57). Then

h old b e a rin g a n d p u sh g ea r in t o p la ce. U se p la st ic or

rawhide mallet to seat bearing if necessary.

( 5 ) S t a rt o u t p u t sh a f t re a r b e a rin g in in t e rm e d ia t e

pla t e. P u s h s ha f t r ea r w a r d a n d t a p in t er m ed ia t e

p la t e w it h m a llet t o sea t b ea rin g .

Fig. 77 Checking Third Gear Clearance

Fig. 78 Second Gear And Synchro Assembly

Fig. 79 First And Fifth Gear Components



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( 6 ) I n s t a l l s n a p r i n g s o n c l u s t e r a n d o u t p u t s h a f t

rear b ea r i n g s on l y (F i g. 82). D o n ot i n st a l l f r on t

b ea rin g sn a p rin g s a t t h is t im e .

(7) Install reverse idler gear and shaft (Fig. 83).

(8) Posit ion rear bearing retainer over output shaft

a n d re a r b e a rin g . Be sure bearing retainer tab is

engaged in reverse idler shaft notch (Fig. 84).

( 9 ) I n st a l l a n d t ig h t e n re a r b e a rin g re t a in e r b o lt s

to 18 Nm (13 ft-lbs).

SHIFT RAIL AND FORK INSTALLATION

T h e sh if t ra i l in t e rlo ck p in s, b a l ls a n d p lu g s m u st

be installed in the correct sequence for proper shift-

ing. Refer to the installat ion diagram (Fig. 85) during

assembly.

Fig. 80 Selecting Fifth Gear Snap Ring

Fig. 81 Installing Cluster Gear Rear Bearing

Fig. 82 Installing Rear Bearing Snap Rings

Fig. 83 Installing Reverse Idler Gear And Shaft

Fig. 84 Installing Rear Bearing Retainer



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Coat the intermediate plate shift rail bores

and the interlock balls, pins and plugs with athick covering of petroleum jelly before assem-bly. The jelly will hold the interlock componentsin place making installation easier. Use a pencilmagnet to hold and insert the interlocks. Thenuse a small screwdriver to push the interlockcomponents into place.

(1 ) C oa t re verse ra i l in t erlock p in wit h p et ro le um

jelly an d inst all pin in ra il (Fig. 86).

(2 ) I n st a l l r e ve rse sh ift ra i l in in t e rm e d ia t e p la t e

(Fig. 87).

(3) Inst all reverse shift ra il C-ring (Fig. 51).

Fig. 85 Shift Rail Ball-Plug-Pin Position

Fig. 86 Installing Reverse Shift Rail Interlock Pin Fig. 87 Installing Reverse Shift Rail And Fork



25/355

(4) P os it i on 1-2 a n d 3-4 s h if t f or k s i n s y n ch r o

sleeves (Fig. 88). (5) Coat reverse rail lock ball with

petroleum jelly. Then t ilt reverse shift fork upwa rd

an d insert ball in intermediate plat e (Fig. 89).

(6) Coat 1-2 shift rail interlock plug with petroleum

jelly a nd inst all i t in intermediate plate bore (Fig. 90).

(7) Coat 1-2 shift rail interlock pin with petroleum

jelly a nd insert it in shift ra il (Fig. 91).

( 8 ) I n st a l l 1 - 2 sh if t ra i l in in t e rm e d ia t e p la t e a n d

1-2 fork (Fig. 92).

(9) Coat 3-4 shift rail interlock plug with petroleum

jelly an d inst all plug in intermediate pla te (Fig. 93).

(1 0) I n st a l l 3 -4 sh if t ra i l in in t e rm e d ia t e p la t e a n d

in both shift forks (Fig. 94).

(11) Verify t ha t none of th e int erlock ba lls, plugs,

Fig. 88 Shift Fork Installation

Fig. 89 Installing Reverse Shift Rail Lock Ball

Fig. 90 Installing 1-2 Shift Rail Interlock Plug

Fig. 91 Installing 1-2 Shift Rail Interlock Pin

Fig. 92 Installing 1-2 Shift Rail



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or pins were displaced during shift rail installat ion.

( 1 2 ) I n st a l l a n d t ig h t e n sh if t f o rk se t scre ws t o 2 0

Nm (14 ft. lbs.) torque (Fig. 95).

(13) Install 1-2 and 3-4 shift rail C-rings (Fig. 96).

(14) Insert f if th gear shift rail through reverse shift

fork. Then slide rail into intermediate plate just

far enough to secure interlock ball. Do not fully

install shift rail at this time.

FIFTH-REVERSE GEAR AND SHIFT COMPO-

NENT INSTALLATION

(1) Install thrust ring lock ball in cluster gear jour-

nal (Fig. 97). Use petroleum jelly to hold ball in place.

( 2 ) I n st a l l f i f t h g e a r t h ru st r in g ( F ig . 9 8 ) . B e su re

thr ust ring notch fits over lock ball .(3) Assemble counter f if th gear, sy nchro sleeve, in-

serts an d insert springs (Fig. 99).

(4 ) L u b rica t e t w o-p ie ce b ea rin g wit h p et ro le u m

jelly a nd insta ll i t in counter f if th gear (Fig. 100).

(5 ) I n st a l l cou n t e r f i f t h g e a r a n d syn ch ro a ssem b ly

on cluster gear journal (Fig. 101).

(6) Install synchro ring in synchro sleeve (Fig. 102).

(7) Install f if th spline gear on cluster journal (Fig.

103). Tap spline gear into place w ith plast ic ma llet if

necessary.

Fig. 93 Installing 3-4 Shift Rail Interlock Plug

Fig. 94 Installing 3-4 Shift Rail

Fig. 95 Installing Shift Fork Set Screws

Fig. 96 Installing Shift Rail C-Rings

Fig. 97 Installing Thrust Ring Lock Ball



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(8) Install f if th gear selective snap ring (Fig. 104).

Use t h ick est sn a p rin g t h a t wil l f i t in sh a f t g roove.

(9 ) I n st a l l re verse sh ift h e a d a n d ra i l (F ig . 1 05 ).

Then insta ll lock ball in shift head.

(10) Posit ion fif th gear shift fork in synchro sleeve

(Fig. 106).

Fig. 98 Installing Fifth Gear Thrust Ring

Fig. 99 Assembling Fifth Gear And Synchro Assem-

bly

Fig. 100 Installing Counter Fifth Gear Bearing

Fig. 101 Installing Counter Fifth Gear And Sleeve

Fig. 102 Installing Fifth Gear Synchro Ring

Fig. 103 Installing Fifth Spline Gear



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(11) Insta ll f if th gear shift r ail (Fig. 107). Slide ra il

t h ro u g h f o rk , sh if t h e a d , in t e rm e d ia t e p la t e a n d re -

verse shift fork. B e sure int erlock ball is not displaced

during installat ion.

(1 2) Alig n scre w h oles in sh ift f ork a n d ra i l a n d

install set screw (Fig. 108). Tighten screw to 20 N m

(15 ft. lbs.) torque.

( 1 3 ) I n st a l l lo ck b a l ls a n d sp rin g s in in t e rm e d ia t e

p la t e (F ig . 1 09). Th e n in st a l l a n d t ig h t en lock b a l l

plugs to 19 Nm (14 ft. lbs.) torque.

(1 4) I n st a l l re verse sh ift a rm b ra ck et (F ig . 11 0).

Tighten bracket bolts to 18 Nm (13 ft. lbs.) torque.

(1 5) I n st a l l re verse sh ift a rm (F ig . 11 0). P osi t ion

a r m o n r e v e r s e f o r k p i n a n d e n g a g e i t w i t h p i n o n

sh ift a rm b ra cke t .

Fig. 104 Installing Fifth Gear Snap Ring

Fig. 105 Installing Reverse Shift Head And Rail

Fig. 106 Installing Fifth Gear Shift Fork

Fig. 107 Installing Fifth Gear Shift Rail

Fig. 108 Shift Fork Set Screw Installation



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(16) Ve r if y t h a t s h if t a r m s h oe i s e ng a g ed i n r e -

v er s e i dl er g ea r . Th en s ecu r e s h if t a r m t o p in on

reverse fork with new E-clip.

GEAR CASE AND ADAPTER INSTALLATION

(1 ) D ism ou n t in t e rm ed ia t e p la t e a n d g ea r a sse m -

blies from vise.

(2) Clean mating surfaces of intermediate plate and

t ra n sm ission g e a r ca se wit h wa x a n d g re a se re m over.

Then wipe dry with a clean cloth.

(3) Apply 3 mm (1/8 in.) wide bea d of Mopar G as ket

Maker, or Loctite 518 to mating surface of gear case.

K ee p s e a l er b ea d i n si d e b ol t h ol es a s s h ow n (F i g.

111).

(4) Inst all gea r case (Fig. 112). Align shift r ails a nd

bearings in case and tap case into posit ion.

( 5 ) V e ri f y t h a t g e a r ca se is se a t e d o n in t e rm e d ia t e

plate dowel pins.

(6) Inst all front bearing sna p rings (Fig. 113).

(7 ) Cle a n g e a r ca se a n d f ro n t b e a rin g re t a in e r se a l-

ing surfaces with wax and grease remover. Then wipe

dry with a clean cloth.(8) Install new seal in front bearing retainer. Then

lubricat e sea l lip wit h petroleum jelly. Installation

depth for seal is 10.5 to 11.5 mm (0.413 to 0.453

in.).

(9 ) Ap ply a 3 m m (1 /8 in .) wid e b ea d of M op a r

G asket Maker, or L octite 518 to front bearing reta iner

sealing surfa ce.

(1 0) A lig n a n d in st a l l f ron t b ea rin g re t a in e r (F ig .

114). Be sure retainer is properly seated on case and

bearings.

Fig. 109 Detent Ball And Spring Installation

Fig. 110 Reverse Shift Arm And Bracket Installation

Fig. 111 Applying Sealer To Gear Case

Fig. 112 Installing Gear Case



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(11) Install and t ighten front bearing retainer bolts


(12) On m od el s w i t h ex t en s ion h ou s in g , i n st a l l

speedometer gear, lock ball and retaining rings (Fig.

115). Be sure lock ball is engaged in gear.

(13) I nspect con dit ion of r ever se pin ina da pter/extension housing (Fig. 116). I f pin is w orn or

damaged, replace it as follows:

(a ) Remove roll pin a ccess plug (Fig. 117).

(b ) Ta p ro ll p in ou t of h ou sin g w it h p in p u n ch

(Fig. 118). Then remove old reverse pin.

(c) Install new reverse pin and secure it with roll

pin. Then insta ll an d t ighten a ccess plug to 19 Nm

(14 ft. lbs.) torque.

(14) Clean sealing surfaces of adapter or extension

h o u sin g a n d in t e rm e d ia t e p la t e wit h wa x a n d g re a se

remover. Then w ipe dry w ith a clean cloth.

(15) Apply 3 m m (1/8 in.) w ide bead of Mopar G a s-

ket Ma ker, or L octite 518 to sealing surfa ce of a dapter

or e xt e n sion h ou sin g. K e ep se a ler b ea d in sid e b olt

holes as shown in Figure 111.

Fig. 113 Installing Front Bearing Snap Rings

Fig. 114 Installing Front Bearing Retainer

Fig. 115 Speedometer Gear Installation (2WD Mod-els)

Fig. 116 Reverse Pin Position

Fig. 117 Access Plug Removal/Installation



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(16) Align and install adapter or extension housing

on in t e rm ed ia t e p la t e (F ig . 1 19 ). B e su re h ou sin g is

seated on intermediate plate dowel pins.

(1 7) Co a t t h re a d s of h o u sin g a t t a ch in g b olt s w it hMopar silicone sealer. Then install and t ighten bolts


(18) Install detent ball (Fig. 120).

(19) Install detent spring (Fig. 121).

(20) Insta ll detent access plug (Fig. 122). Tighten

plug to 19 Nm (14 ft. lbs.) torque.

(21) Lu br ica t e s h if t a r m s h a ft a n d i ns t a ll i t i nadapter housing (Fig. 123).

(22) P o s it i on s h if t a r m i n a d a p t e r h ou s in g (F i g.

124). Be sure arm is engaged in shift rails.

(2 3) Alig n sh if t a rm wit h sh a f t a n d p u sh sh a f t in t o

a r m .

(2 4) Rot a t e sh if t a rm sh a f t u n t i l se t screw h oles in

s h a f t a n d a r m a r e a l ig n ed .

( 2 5 ) I n s t a l l a n d t i g h t e n s h i f t a r m s e t s c r e w t o 3 8

Nm (28 ft. lbs.) torque (Fig. 125).

( 2 6 ) I n st a l l a n d t ig h t e n re st rict o r p in s t o 1 9 Nm

(14 ft. lbs.) torqu e (Fig. 125).

(2 7) I n st a l l a n d t ig h t en sh if t a rm sh a f t a cce ss p lu g

to 19 Nm (14 ft. lbs.) torque (Fig. 126).

(28) P o s it i on n ew s h if t t ow e r g a s k et on a d a p t er

housing (Fig 127).

Fig. 118 Roll Pin Removal/Installation

Fig. 119 Adapter/Extension Housing Installation

Fig. 120 Installing Detent Ball

Fig. 121 Installing Detent Spring

Fig. 122 Installing Detent Access Plug



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(2 9) I n st a l l sh i ft t o we r (F ig . 12 8). Tig h t en t o we r

attaching bolts to 18 Nm (13 ft. lbs.) torque.

(3 0) I n st a l l n e w g a sk e t o n b a ck up l ig h t swit ch a n d

in st a l l sw it ch . Tig h t en swit ch t o 3 7 Nm (27 ft . lbs.)

torque.

(31) Install new washer on drain plug. Then install

and t ighten plug to 37 Nm (27 ft. lbs.) torque.

( 3 2 ) I f t ra n sm issio n wil l b e f i l le d wit h g e a r lu b ri-

cant before installat ion, place transmission in a level

posit ion. Then fill w ith Mopar 75W-90, gra de G L-5

gear lubricant . Correct f ill level is to bottom edge of

fill plug hole.

(3 3) I n st a l l n e w wa sh e r o n f i ll p lu g . Th e n in st a l l

and t ighten plug to 37 Nm (27 ft. lbs.) torque.

(34) Inst all clutch housing and hydra ulic concentric

bearing.

(35) On m odels w ith extension h ousing, insta ll new

sea l in h ou sin g w it h su it a b le siz e in st a l ler t o ol (F ig .

129). Lubricate seal lips with petroleum jelly before

installat ion.

(36) On m od el s w i t h e xt e n si on h ou s in g , i n st a l l

sp ee dom e t er d riven g e a r, sp ee d om e t er a d a p t er a n d

speed sensor.

Fig. 123 Installing Shift Arm Shaft

Fig. 124 Shift Arm Installation

Fig. 125 Set Screw And Restrictor Pin Installation

Fig. 126 Access Plug Installation



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Fig. 127 Shift Tower Gasket Installation

Fig. 128 Shift Tower Installation

Fig. 129 Installing Extension Housing Seal



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AW-4 AUTOMATIC TRANSMISSION

CONTENTS

page page

GENERAL INFORM ATION . . . . . . . . . . . . . . . . . 34AW-4 IN-VEHICLE SERVICE . . . . . . . . . . . . . . . 51AW-4 TRANSMISSION DIAGNOSIS . . . . . . . . . 45AW- 4 TRANSMISSI ON/CONVERTER REMOVAL AND

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 69AW-4 TRANSMISSION OVERHAUL . . . . . . . . . 72SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 3 4 5

GENERAL INFORMATION

INDEX

page page

Components and Operation . . . . . . . . . . . . . . . . . 35Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34FirstThirdReverse Gear Components . . . . . . . 37Fourth Gear Overdrive Components . . . . . . . . . . . 36Geartrain Operation and Application Charts . . . . . . 37

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . 38Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . 36Transmission Identification . . . . . . . . . . . . . . . . . . 35Transmission Ranges and Shift Lever Positions . . 35

DESCRIPTIONThe AW-4 is a 4-speed, electr onically cont rolled a u-

tomatic transmission (Fig. 1). Running gear consists

of a torque converter, oil pump, three planetary gear

se t s , c lu t ch a n d b ra k e u n it s , h yd ra u lic a ccu m u la t ors,

a valve body with electrical solenoids and a transmis-sion control module (TCM).

C a b les a r e u sed f or s h if t in g a n d t r a n s mi ss ion

t h ro t t le p ressu re con t ro l. A p a rk /n e u t ra l p osi t ion

s w i t c h p e r m i t s e n g i n e s t a r t i n g i n P a r k a n d N e u t r a l

range only.

The valve body solenoids are controlled by signals

f rom a t ra n sm ission con t ro l m od u le ( TCM ). S ig n a lsequence is determined by vehicle speed and thrott le

position.

Fig. 1 AW-4 Automatic Transmission

21 - 34 AW-4 AUTOMATIC TRANSMISSION Z


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F ou r t h g ea r i s a n 0. 75: 1 r a t i o o ver d r iv e r a n g e.

First , second, third and reverse gear are conventional

ra n g e s. T h ird g e a r ra t io is 1 :1 . A se p a ra t e p la n e t a ry

gear set provides overdrive opera tion in fourth gear.

TRANSMISSION RANGES AND SHIFT LEVER POSI-TIONS

Th e AW-4 t ra n sm ission h a s s ix ra n g e s a n d sh ift

le ve r p o si t io n s. Pa rk , Re ve rse a n d N e u t ra l a re co n -

ventional and mechanically operated. The 1-2, 3 and

D ranges provide electronically controlled shifting.

The 1-2 position provides fir st a nd second gear only.

The 3 posit ion provides first , second and third gear.

The D ra nge provides first through fourth gear. Over-

d r iv e f ou r t h g ea r r a n g e i s a v a i la b le on ly w i t h t h e

shift lever in D position (Fig. 2).

TRANSMISSI ON IDENTIFICATIONThe transmission identificat ion plate is at tached to

the case (Fig. 3). The plate contains the transmission

se ria l a n d m o d e l n u m b e rs. Re f e r t o t h e in f o rm a t io n

on this plate when ordering service parts.

COMPONENTS AND OPERATION

ELECTRONIC CONTROLS

The AW-4 is electronically controlled in the 1, 2, 3

a n d D r a n g es . C on t r ol s con s is t of t h e t r a n s m i ss ion

control module (TCM), valve body solenoids and vari-

ou s s en s or s . Th e s en s or s m on i t or v eh i cl e s pe ed ,

thrott le opening, shift lever posit ion and brake pedal

application.

TRANSMISSION CONTROL MODULE (TCM)

The m odule determines shift an d converter clutch

engagement t iming ba sed on signa ls from the sensors.

The va lve body solenoids a re a ctivated, or dea ctivatedaccordingly.

The module has a self diagnostic program. Compo-

n en t a n d ci r cu it r y m a l f un ct i on s ca n b e d i a g nos ed

w i t h t h e D R B I I s ca n t ool . O n ce a m a l fu n ct ion i s

n ot e d a n d s t or ed i n con t r ol m od u le m em or y, i t i s

re t a in e d e ve n a f t e r t h e p ro b le m h a s b e e n co rre ct e d .

To ca ncel a st ored ma lfunction, simply disconnect a nd

reconnect the Tra ns. fuse in the module harness.

TRANSMISSION VALVE BODY SOLENOIDS

T h e so le n o id s a re m o u n t e d o n t h e va lve b o d y a n d

op era t e d b y t h e t ra n sm ission con t ro l m o du le. Th e

solenoids control operation of the converter clutch and

s h if t v a l ves i n r e sp on s e t o i n pu t s ig n a l s f r om t h e

module.

SENSORS

Th e se nsors in clu d e t h e t h ro t t le p osi t ion se n sor

(TP S ), t ra n sm ission ou t p u t sp ee d se n sor, veh icle

speed sensor, par k/neutra l posit ion sw itch a nd brake

swit ch .

Th e t h r ot t l e p os it i on s en s or i s m ou n t ed on t h e

thr ott le body. I t electronically determines thr ott le po-

si t ion a n d re la ys t h is in f orm a t ion t o t h e t ra n sm ission

con t ro l m o d u le t o d e t erm in e sh if t p oin t s a n d con -verter clutch engagement.

Th e t ra n sm ission sp ee d se n sor con sist s of a ro t or

a n d m a g n e t o n t h e t r a n s m i s s i o n o u t p u t s h a f t a n d a

switch in the extension housing or adapter. The sen-

so r swit ch is a ct iva t e d e a ch t im e t h e ro t o r a n d m a g -

net complete one revolution. Sensor signals are sent

to t he t ra nsmission control module.

The par k/neutr al position sw itch is m ounted on th e

v a l v e b od y m a n u a l s h a f t . Th e s w i t ch s ig n a l s s h if t

l i n k a g e a n d m a n u a l v a l v e p o s i t i o n t o t h e t r a n s m i s -

sion control module through an interconnecting har-

Fig. 2 AW-4 Shift Lever Positions And TransmissionRanges

Fig. 3 Transmission Identification

Z AW-4 AUTOMATIC TRANSMISSION 21 - 35


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ness. The switch prevents engine start ing in all gears

o t h e r t h a n Pa rk o r N e u t ra l .

T h e b ra k e swit ch is in circu it wit h t h e t o rqu e co n -

verter clutch solenoid. The switch disengages the con-

vert e r clu t ch w h e n ever t h e b ra k e s a re a p p lied . Th e

s w i t ch i s m o u nt e d o n t h e b r a k e p ed a l b r a ck et a n d

s ig n a l s t h e t r a n s m i ss ion con t r ol m od u le w h e n t h e

pedal is pressed or released.

TORQUE CONVERTERA t h r e e e l em en t t or q u e con v er t e r i s u s ed f or a l l

applicat ions. The converter consists of a n impeller,

st a t or , a n d t u rb in e. Th e con vert e r a lso con t a in s a n

electronic modulated converter clutch mecha nism an d

an overrunning clutch in the stator hub.

The converter modulated clutch mechanism consists

of a s li di n g cl ut ch p is t on , cl ut ch s pr i n gs a n d t h e

clutch disc frict ion material (Fig. 4). The clutch pro-

v id es op t im u m t or q u e t r a n s f er a n d f ue l e con om y

when engaged.

T h e clu t ch d isc is a t t a ch e d t o t h e co n ve rt e r f ro n t

cover. Th e clu t ch p ist on a n d clu t ch sp rin g s a re a t -

t a ch e d t o t h e t u rb in e h u b . T h e sp rin g s d a m p e n e n -g in e f ir in g i mpu ls es a n d l oa d s d ur in g t h e i ni ti a l

phase of converter clutch engagement.

Clu t ch e n ga g e m en t is con t ro lled b y t ra n sm ission

v a l ve b od y s ol en oi d n u m ber t h r ee a n d b y t h e con -

verter clutch relay valve. The solenoid channels line

pr es su r e t o t h e cl ut ch t h r ou gh t h e r el a y v a lv e a t

clutch engagement speeds,.

Torque converter clutch engagement occurs in sec-

ond gear in 1-2 posit ion; third gear in 3 posit ion and

third and fourth gear in D posit ion.

FOURTH GEAR OVERDRIVE COMPONENTSTh e ove rdrive syst e m con sist s of t h e in pu t sh a f t ,o n e - wa y clu t ch , p la n e t a ry su n g e a r, r in g g e a r, p la n -

etary carrier, direct clutch and overdrive brake (Fig.

5). The overdrive elements are controlled and applied

t h ro u gh t ra n sm ission va lve b od y solen oid n u m b er

t wo .

I n ov er d r iv e f o ur t h g ea r , t h e b r a k e p r ev en t s t h e

ove rdrive su n g ea r f rom t u rn in g . D u rin g o p era t ion ,

the overdrive elements opera te a s follow s:

Th e ov er d r iv e i n pu t s h a f t a n d p la n e t a r y ca r r i er

r ot a t e a s a u n it . Th e s u n g ea r a n d ov er d r iv e d i r ect

clu t ch d ru m a re in m e sh a n d op era t e a s a s in g le u n it .

The direct clutch splines function as the hub for theoverdrive brake. The one-way clutch outer race is in

m e sh w i t h t h e p la n e t a r y ca r r i er. Th e i n ner r a c e i s

f ixe d t o t h e su n g e a r sh a f t .

Fig. 4 Torque Converter With Modulated Clutch

Fig. 5 Fourth Gear Overdrive Components



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FIRST THIRD REVERSE GEAR COMPONENTSF irst , t h ird a n d re ve rse g e a r co m p o n e n t s a re o u t -

lined in Figure 6.

The input shaft is meshed with the direct c lutch hub

an d the forwa rd clutch drum. These elements r otate a s a

u n i t . T h e f o r w a r d c l u t c h h u b r o t a t e s a s a u n i t w i t h t h e

f r on t p la n e t a r y r i ng g ea r . Th e d ir ect cl ut ch d r um i s

meshed with the forward end of the planetary sun gear.

T h e se co n d b ra k e h u b se rve s a s t h e o u t e r ra ce o f

one-way clutch No. 1. The clutch inner race is locked

wit h t h e f ron t /re a r su n g e a r. Th e in n er ra ce of on e -

wa y clu t ch N o . 2 is sp l in e d t o t h e t ra n sm issio n ca se

a n d is lo ck e d . T h e o u t e r ra ce ro t a t e s a s a u n it wit h

t h e re a r p la n e t a ry ca rrier .

T h e re a r p la n e t a ry r in g g e a r is sp l in e d t o t h e o u t -

put shaft . The front planetary carrier and rear carrier

r in g g ea r a r e m e sh ed a n d r ot a t e a s a u n it w i t h t h e

output shaft .

GEARTRAIN OPERATION AND APPLICATIONCHARTS

O per a t i on a n d a p pl ica t i on of t h e f ir s t t h r ou gh

f o u rt h a n d re ve rse g e a r e le m e n t s a re o u t l in e d in t h e

function and application charts.

The Component Function Cha rt (Fig. 7), describes

b a s ic f un ct i on of v a r i ou s g ea r t r a i n el em en t s . Th e

C om p on en t Ap pl ica t i on C h a r t (F i g. 8), i n di ca t e s

Fig. 6 First-Third-Reverse Gear Components

Fig. 7 Component Function Chart



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which elements (including valve body solenoids), are

applied in the various gear ranges.

HYDRAULIC SYSTEMThe ba sic hydra ulic system consists of the oil pump,

valve body and solenoids and four hydraulic accumu-

la t o rs . Th e oi l p u m p p rovid es t h e n e ce ssa ry syst e m

lubrication and operating pressure.

The valve body controls applicat ion of the clutches,

b ra k e s, se co n d co a st b a n d a n d t h e t o rqu e co n ve rt e r

clutch. The va lve body s olenoids control sequ encing ofth e 1-2, 2-3 an d 3-4 shift va lves w ithin the va lve body.

The solenoids are activated by signals from the trans-

mission control module.

Th e a ccum u la t o rs a re u se d in t h e clu t ch a n d b ra k e

feed circuits to control init ial apply pressure. Spring

loaded accumulator pistons modulate the init ial surge

of apply pressure for smooth engagement.

OIL PUMP

A gear-type oil pump is used. The pump gears are

m o u n t e d in t h e p u m p b o d y. T h e p u m p d rive g e a r is

operated by the torque converter hub. Drive tangs on

the hub engage in drive slots in the drive gear.

TRANSMISSION VALVE BODY COMPONENTS

Tra nsmission operat ing pressure is supplied to t he

cl ut ch a n d b r a k e a p pl y ci r cu i t s t h r ou g h t h e v a l ve

body. The valve body consists of an upper body, lower

b od y, s ep a r a t or p la t e a n d u pp er a n d l ow e r g a s k et s

(Fig. 9). The shift valves, sleeves, plugs and springs

are located within the two body sections.

Th e m a n u a l va lve, 1 -2 sh if t va lve, p rim a ry re g ula -

tor valve, accumulator control valve, check balls, sole-

n o id s a n d o i l s t ra in e rs a re lo ca t e d in t h e lo we r b o d y

sect ion (F ig . 1 0). Th e re m a in in g con t ro l a n d sh iftvalves plus check balls and one addit ional oil strainer

are located in the upper body section (Fig. 11).

Manual Valve

The manual valve is operated by the gearshift l ink-

a g e . T h e va lve d ive rt s f lu id t o t h e a p p ly circu it s a c-

cording to shift lever position.

Fig. 8 Component Application Chart

Fig. 9 Two-Section Transmission Valve Body



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Primary Regulator Valve

Th e p rim a ry re g ula t o r va lve (F ig . 1 3) m o d u la t e sline pressure to the clutches and brakes according to

e n g in e lo a d . T h e va lve is a ct u a t e d b y t h ro t t le va lve

pressure.

During high load operation, the valve increases line

p r es s ur e t o m a i n t a i n p os i t iv e cl ut ch a n d b r a k e e n -

gagement. At light load, t he va lve decreases line pres-

sure just enough to maintain smooth engagement.

Throttle Valve and Downshift Plug

Th e t h r ot t l e v a l ve a n d d ow n s h i ft p lu g (F i g. 14)con t r ol t h r ot t l e p re ss u r e t o t h e p r im a r y r eg u la t o r

valve.

The downshift plug and thrott le valve are operated

b y t h e t h r o t t le v a l v e c a m a n d t h r ot t l e c a b le i n r e-

s pon s e t o e ng in e t h r ot t l e p os it i on . Th r ot t l e v a l ve

p re ssu re is a lso m o d u la t e d b y t h e cu t - b a ck va lve in

second, third and fourth gear ranges.

Cut-Back Valve

The cut-ba ck va lve (Fig. 15) helps prevent excessive

pu mp pr es su re bu ild up in s econ d, t hir d a n d

Fig. 10 Upper Body Components

Fig. 11 Lower Body Components



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fourth gear. The valve is a ctuat ed by thr ott le pressure

an d by line pressure from t he second brake. The va lve

a lso h e lp s re g u la t e l in e p re ssu re b y co n t ro l l in g t h e

am ount of cut-back pressure to th e thr ott le valve.

Secondary Regulator Valve

Th e se con d a ry re g ula t o r va lve (F ig . 1 6) re g ula t e s

con vert e r clu t ch a n d t ra n sm ission lu brica t io n p res-

sure. When prima ry regulator va lve pressure exceeds

requirements for clutch engagement or transmission

lu brica t io n , t h e se con d a ry re g ula t o r va lve is m ove d

Fig. 12 Manual Valve

Fig. 13 Primary Regulator Valve

Fig. 14 Throttle Valve And Downshift Plug

Fig. 15 Cut-Back Valve



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u pw a r d ex pos in g t h e d r a i n p or t . E x ce ss p re ss u r e

then bleeds off as needed. As pressure drops, spring

t e n sio n m o ve s t h e va lve d o wn wa rd clo sin g t h e d ra in

port.

Converter Clutch Rel ay Valve

The relay valve (Fig. 17) controls f luid flow to the

converter clutch. The valve is operated by line pres-

sure from the 1-2 shift valve and is controlled by so-

lenoid valve number three.

1-2 Shift Valve

The 1-2 shift valve (Fig. 18) controls 1-2 upshifts

a n d d o wn sh if t s . T h e va lve is o p e ra t e d b y t h e N o . 2

va lve b od y solen oid a n d l in e p re ssu re f rom t h e m a n -

u a l va lve , se co n d co a st m o d u la t o r va lve a n d t h e 2 - 3

shift valve.

When the transmission control module deactivates

t h e s ol en oi d, l in e p re ss u r e a t t h e t op of t h e v a l ve

moves the valve down closing the second brake accu-

m u la t o r f e e d p o rt . A s t h e so le n o id is a ct iva t e d a n d

Fig. 16 Secondary Regulator ValveFig. 17 Converter Clutch Relay Valve

Fig. 18 1-2 Shift Valve



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the drain port opens, spring force moves the valve up

e xp osin g t h e se con d b ra k e f e ed p ort f or t h e sh ift t o

second gear.

2-3 Shift Valve

The 2-3 shift valve (Fig. 19) controls 2-3 upshifts

a n d d o w n s h i f t s . T h e v a l v e i s a c t u a t e d b y t h e N o . 1

v a l ve b od y s ol en oi d a n d b y l in e p r es s ur e f r om t h e

m a n u a l va lve a n d p rim a ry re g ula t o r va lve .

When t he tr an smission control module activat es so-

lenoid No. 1, l ine pressure at the top of the 2-3 valveis re le a sed t h ro u gh t h e solen oid d ra in p ort . S p rin g

t e n sio n m o ve s t h e va lve u p t o h o ld t h e va lve in se c-

ond gear posit ion. As the solenoid is deactivated, line

p re ss u r e t h en m ov es t h e v a l ve d ow n ex pos in g t h e

direct clutch feed port for th e shift t o third gear.

3-4 Shift Valve

The 3-4 shift va lve (Fig. 20) is opera ted by th e No. 2

solenoid and by line pressure from the manual valve,

2-3 valve and primary regulator valve.

Energizing the No. 2 solenoid causes line pressure

at the top of the 3-4 valve to be released through the

so le n o id va lve d ra in p o rt . S p rin g t e n sio n m o ve s t h eva lve u p e xp osin g t h e overd rive clu t ch a ccu m u la t or

feed port t o apply th e clutch.





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De-energizing the solenoid causes the drain port to

clo se . L in e p re ssu re t h e n m o ve s t h e va lve d o wn e x-

posing the overdrive brake accumulator feed port for

the shift to fourth gear.

In the 1-2 or 3 gearshift lever posit ions, line pres-

su re f ro m t h e 2 - 3 sh if t va lve is a p p lie d t o t h e lo we r

e n d o f t h e 3 - 4 va lve . T h is h o ld s t h e va lve u p wa rd ,

closing off t he overdrive brake feed port preventing ashift into fourth gear.

Second Coast M odulator Val ve

The second coast modulator valve (Fig. 21) momen-

tarily reduces line pressure from the 1-2 shift valve.

This cushions a pplicat ion of the second coast bra ke.

Th e v a lv e i s oper a t i ve w h en t h e s h if t l ev er a n d

m a n u a l va lve a re in t h e 3 p osi t ion .

Low Coast Modulator Valve

Th e low coa st m od u la t o r va lve (F ig . 2 2) m o m en -

ta rily reduces line pressure from the 2-3 shift va lve to

cushion applicat ion of the first/reverse bra ke. The

va lve op era t e s wh e n t h e sh ift lever a n d m a n u a l va lve

are in the 1-2 position.

Accumulator Control Valve

The accumulator control valve (Fig. 23) cushions

clu t ch a n d b ra k e a p p lica t io n b y re d u cin g b a ck p re s-

s u r e t o t h e a c cu m u la t o r s w h e n t h r ot t l e op en i ng i s

small. The valve is operated by oil pump (line) pres-

sure and by thrott le pressure.

Accumulators

Four accumulators are used to cushion application

of the clutches and brakes (Fig. 24). The accumula-

t o rs con sist of sp rin g loa d e d p ist o n s w h ich d a m p e n

the init ial surge of apply pressure to provide smoothengagement during shifts.

C on t r ol p r es s ur e f r om t h e a c cu m u la t o r con t r ol

va lve is con st a n t ly a p p lied t o t h e b a ck p ressu re sid e

of t he a ccumulat or pistons. This pressure plus spring

tension holds the pistons down. As line pressure from

the shift valves enters the opposite end of the piston

b ore , con t ro l p ressu re a n d sp rin g t e n sion m om e n -

ta rily delay applicat ion of full l ine pressure t o cushion

e n ga g e m en t . Th e a ccum u la t o rs a re a l l loca t e d in t h e

transmission case (Fig. 24).

Fig. 21 Second Coast Modulator Valve

Fig. 22 Low Coast Modulator Valve

Fig. 23 Accumulator Control Valve



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Transmission Valve Body Solenoids

Three solenoids are used (Fig. 25). The No. 1 and 2

solenoids control shift valve operation by applying or

releasing line pressure. The signa l to a pply or release

pressure is provided by the t ra nsmission control mod-

ule.

The No. 3 solenoid controls operat ion of th e t orque

converter clutch. The solenoid operates in response to

signals from the t ra nsmission control module.

Wh e n t h e N o . 1 a n d 2 so le n o id s a re a ct iva t e d , t h e

solen oid p lu n g er is m ove d o f f i t s se a t op en in g t h edrain port to release line pressure. When either sole-

noid is deactivated, t he plunger closes the dr ain port .

The No. 3 solenoid operat es in reverse. When the

solenoid is deactivated, the solenoid plunger is moved

of f i t s s ea t op en i ng t h e d r a i n p or t t o r el ea s e l in e

pressure. When the solenoid is act iva ted, t he plunger

closes t he dra in port .

Fig. 24 Accumulators

Fig. 25 Transmission Valve Body Solenoids



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AW-4 TRANSMISSION DIAGNOSIS

INDEX

page page

General Diagnosis Information . . . . . . . . . . . . . . . 45Hydraulic Pressure Test . . . . . . . . . . . . . . . . . . . . 46Manual Shifting Test . . . . . . . . . . . . . . . . . . . . . . . 46

Preliminary Inspection and Adjustment . . . . . . . . . 46Time Lag Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Torque Converter Stall Test . . . . . . . . . . . . . . . . . 47

GENERAL DIAGNOSIS INFORMATIONShift points are controlled by the transmission con-

trol module (TCM). Before at tempting repair, deter-

mine if a ma lfunction is electrical or mecha nical.

The TCM used with the AW-4 transmission has a

se lf -d ia g n ost ic p rog ra m com p a t ib le wit h t h e D RB I I

scan tool. The tester will identify fa ults in the electri-

cal control system.

D i a g n os is s h ou ld b eg in w i t h t h e P r e l im i n a r y I n -

sp ect ion An d Ad ju st m e n t p roced u re . I t is wil l h e lp

d et e rm in e i f a p rob lem is m e ch a n ica l or e le ct rica l .

The first procedure step is Init ial Inspection and Ad-

justment.

Fig. 26 Preliminary Diagnosis Check Procedure

Z AW-4 TRANSMISSION DIAGNOSIS 21 - 45


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PRELIMINARY INSPECTION AND ADJUSTMENT(1) C h eck a n d a d ju s t t r a n s m i ss ion s h if t ca b l e i f

necessary.

(2) Verify tr an smission thrott le cable operat ion. R e-

pair or replace cable if necessary.

(3) Check engine thrott le operation. Operate accel-

erator pedal and observe injector thrott le plate move-

m e n t . Ad ju st l ink a g e i f t h rot t le p la t e d oe s n o t re a chwide open position.

(4) Check transmission fluid level when fluid is at

n or m a l op er a t i n g t e m pe ra t u r e . S t a r t e ng in e. S h i ft

t r a n s m i ss ion t h r ou g h a l l g ea r r a n g es t h en b a ck t o

N eu t r a l. C or r ect l ev el i s t o F u ll or Ad d m a r k on

dipstick w ith engine a t curb idle speed.

(5) Ch eck a nd a djust par k/neutr a l position sw itch if

necessary.

(6 ) Ch e ck t h rot t le p osi t ion se n sor a d ju st m en t a n d

operation. Adjust the sensor if necessary.

MANUAL SHIFTING TEST(1 ) Th is t e st d e t erm in es i f p rob lem is re la t e d t omechanical or electrical component.

(2) St op engine a nd disconnect tr an smission contr ol

module or module fuse.

(3 ) Ro a d t e st veh icle. S h if t t ra n sm ission in t o e a ch

gear ra nge. Tra nsmission sh ould opera te a s follow s:

lock in Park

back up in Reverse

not move in Neutral

provide first gear only with shift lever in 1-2 posi-

tion

op er a t e i n t h ir d g ea r on ly w i t h s h if t l ev er i n 3

position opera te in overdrive fourth gear in D posit ion

(4) If tra nsmission operat es a s described, proceed

t o n e x t s t e p . H o w e v e r , i f f o r w a r d g e a r r a n g e s w e r e

difficult to dist inguish (all feel the same), or vehicle

wo u ld n o t b a ck u p , re f e r t o d ia g n o sis ch a rt s . D o n o t

perform stall or t ime lag tests.

CAUTION: Do not overspeed the engine during the

next test step. Ease off the throttle and allow the

vehicle to slow before downshifting.

( 5 ) Co n t in u e ro a d t e st . M a n u a lly d o wn sh if t t ra n s-mission from D to 3, and from 3 to 1-2 position. Then

m a n u a ll y u ps h if t t r a n s mi ss ion t h r ou gh f or w a r d

ra n g e s a g a in .

( 6 ) I f t ra n sm issio n o p e ra t io n is OK , p e rf o rm st a l l ,

t im e la g a n d p re ssu re t e st s . I f t ra n sm issio n sh if t in g

problem is encountered, refer t o diagnosis char ts.

(7 ) I f a p rob lem st i l l e xist s , con t in u e t e st in g wit h

D RB I I sca n t ool .

HYDRAULIC PRESSURE TEST

PRESSURE TEST PROCEDURE

(1) C on n ect p r es s ur e t e st g a u g e t o t e st p or t on

passenger side of transmission. Use Adapter 7554 to

co n n e ct g a u g e . B e su re t e st g a u g e h a s m in im u m ca -

pacity of 2100 kP a (300 psi).

( 2 ) B e su re t ra n sm issio n f lu id is a t n o rm a l o p e ra t -

ing temperature.

(3) Apply pa rking bra kes an d block w heels.

WARNING: DO NOT ALLOW ANYONE TO STAND AT

THE FRONT OR REAR OF THE VEHICLE WHILE

PERFORMING THE FOLLOWING STEPS IN THE

PRESSURE TEST.

(4) Check an d a djust engine curb idle speed.

(5) Apply service brakes.

(6) S h i ft t r a n s m i ss i on i n t o D r a n g e a n d n ot e l in e

p r es s ur e w i t h e ng in e a t cu r b i dl e s p ee d. P r e s s ur e

should be 421-481 kP a (61-70 psi) .

(7 ) P re ss a cce le ra t o r p ed a l t o wid e op en t h ro t t le

p o si t io n a n d n o t e l in e p re ssu re . Pre ssu re sh o u ld b e

1196-1442 kP a (173-209 ps i).

CAUTION: Do not maintain wide open throttle for

more than three or four seconds at a time.

(8 ) S h ift t ra n sm ission in t o Re verse a n d n ot e l in e

p r es s ur e w i t h e ng in e a t cu r b i dl e s p ee d. P r e s s ur e

should be 519-618 kP a (75-90 psi).

(9) Press accelerator to wide open thrott le posit ion

an d note line pressure in Reverse. P ressure should be

1471-1814 kP a (213-263 ps i).

Fig. 27 Pressure Test Gauge Connection

21 - 46 AW-4 TRANSMISSION DIAGNOSIS Z


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more than 3-4 seconds at a time.

(1 0) I f l in e p ressu re is n ot wit h in sp ecif ica t ion s,

a d ju s t t r a n s m i ss ion t h r ot t l e ca b l e a n d r e pe a t p r es -

su re t e st .

PRESSURE TEST ANALYSIS

I f pr es su r es i n D a n d R ev er s e a r e h ig h er t h a n

specified, check for t he follow ing:

thrott le cable loose, worn, binding or out of adjust-

ment

thrott le valve, downshift plug, thrott le cam, or pri-

m a ry re g ula t o r va lve a re st ick in g , wo rn o r d a m a g e d

I f p re ssure s in D a n d Re verse a r e lowe r t h a n sp eci-

fied, check for follow ing:

thrott le cable loose, worn, binding or out of adjust-

ment

t h ro t t le va lve , d o wn sh if t p lu g , t h ro t t le ca m st ick -

in g , wo rn or d a m a g ed

primary regulator valve st icking, worn, or damaged

oil pump gears or housing worn or damaged

overdrive clutch worn or damaged

I f p r es s ur es a r e l ow i n D r a n g e on l y, ch eck f or

following:

f orwa rd clu t ch w orn or d a m a g ed

f lu id lea k a g e in D ra n g e circuit (com p on e n t se a l

an d O-rings)

If pressures are low in Reverse only, check for fol-

lowing:

sh ift ca b le a n d m a n u a l va lve o ut of a d ju st m e n t

fluid leakage in reverse circuit (component seal and

O-rings) direct clutch worn or damaged

f irst/reverse brake worn or da ma ged

TORQUE CONVERTER STALL TESTStall test ing checks the holding ability of the trans-

m issio n clu t ch e s a n d b ra k e s a n d o f t h e t o rqu e co n -

verter stator overrunning clutch.

( 1 ) B e su re t ra n sm issio n f lu id is a t n o rm a l o p e ra t -

ing temperature.

(2) Connect tachometer to engine. Posit ion tachom-

eter so it can be viewed from drivers seat .

(3) Apply parking br akes a nd block wheels.(4) Apply and hold service brakes.

(5) Shift transfer case into 2H posit ion. On models

wit h N P2 4 9 t ra n sf e r ca se , le a ve t ra n sf e r ca se in 4 H

position.

(6) Start engine.

WARNING: DO NOT ALLOW ANYONE TO STAND AT

THE FRONT OR REAR OF THE VEHICLE DURING

THE TEST.

(7) Shift transmission into D range.

(8 ) P re ss a cce le ra t o r p ed a l t o wid e op en t h ro t t le

p o si t io n a n d n o t e m a xim u m e n g in e rp m . S t a l l sp e e d

should be 2100 to 2400 rpm in D range.


more than 3-4 seconds at a time.

(9) R el ea s e t h r ot t l e a n d s h if t t r a n s m i ss i on i n t o

Neutral. Allow tra nsmission fluid t o cool for 15-20

seconds.

(10) Shift tra nsmission int o Reverse.

(11 ) P re ss a cce le ra t o r d own t o wid e op en t h ro t t le

p o si t io n a n d n o t e m a xim u m e n g in e rp m . S t a l l sp e e d

should be 2100-2400 rpm in Reverse.

STALL SPEED TEST ANALYSIS

I f en gi ne r pm i s l ow e r t h a n s peci fi ed i n D a n d

Reverse, check for the following:

engine output/performa nce insufficient

st a t or ove rru n n in g clu t ch in t o rqu e con vert e r n ot

holding if engine speed was 1500 rpm or less.I f s t a l l sp e e d in D ra n g e is h ig h e r t h a n sp e cif ie d ,

check for the following:

line pressure low

forw ar d clutch slipping

No. 2 one-way clutch not holding

overdrive one-way clutch not holding

If stall speed in Reverse was higher than specified,

check for the following:

line pressure low

direct clutch slipping

f irst/reverse bra ke slipping


If stall speeds were higher than specified in both D

and Reverse, check for the following:

low fluid level

line pressure low


TIME LAG TESTThis test checks general condit ion of the overdrive

clu t ch , f orwa rd clu t ch , re a r clu t ch a n d f irst /re verse

b ra k e . Co n d it io n is in d ica t e d b y t h e a m o u n t o f t im e

requ ired for clutch/bra ke enga gement w ith t he engine

a t curb id le sp ee d . E n g a g e m e n t t im e is m e a su re d f o r

D a n d R ev er s e p os it ion s . A s t op w a t c h i s r ecom -

mended for test accuracy.

TEST PROCEDURE

(1) Check and adjust t ra nsmission fluid level if nec-

essary.

(2) B r i ng t r a n s m i ss ion t o n or m a l op er a t i n g t e m -

perature.

(3) Apply par king bra kes and turn off a ir condit ion-

ing unit .

(4) S h i ft t r a n s f er ca s e i n t o 2 H r a n g e. O n m od el s

wit h N P2 4 9 t ra n sf e r ca se , le a ve t ra n sf e r ca se in 4 H

ra n g e .

Z AW-4 TRANSMISSION DIAGNOSIS 21 - 47


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(5) Start engine and check curb idle speed. Adjust

sp e e d i f n e ce ssa ry. Cu rb id le m u st b e co rre ct t o e n -

sure accurate test results.

(6) S h i ft t r a n s m i ss i on i n t o N e ut r a l a n d s et s t op

w a t c h .

( 7 ) D u rin g f o l lo win g t e st s t e p s, s t a rt s t o p wa t ch a s

soon as shift lever reaches D and Reverse ranges.

(8) Shift transmission into D

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