Jeep XJ. Manual — part 430
INSTALLATION
(1) Disconnect shift linkage rod from shift lever on
left side of transmission.
(2) Rotate manual shift lever all the way rear-
ward. Then rotate lever forward two detent positions
to Neutral.
(3) Install switch on manual valve shaft and
install switch adjusting bolt finger tight. Do not
tighten bolt at this time.
(4) Install tabbed washer on manual valve shaft
and install switch attaching nut. Tighten nut to 6.9
N·m (61 in. lbs.) torque but do not bend washer lock
tabs over nut at this time.
(5) Verify that transmission is in Neutral.
(6) Rotate switch to align neutral standard line
with vertical groove on manual valve shaft (Fig. 56).
(7) Align switch standard line with groove or flat
on manual valve shaft.
(8) Tighten switch adjusting bolt to 13 N·m (9 ft.
lbs.) torque.
(9) Bend at least two washer lock tabs over switch
attaching nut to secure it.
(10) Connect shift linkage rod to shift lever on left
side of case.
(11) Connect switch wires to harness and lower
vehicle.
(12) Check switch operation. Engine should start
in Park and Neutral only.
GEARSHIFT CABLE
REMOVAL
(1) Shift transmission into Park.
(2) Remove shift lever bezel and necessary console
parts for access to shift lever assembly.
(3) Disconnect cable at shift lever and feed cable
through dash panel opening to underside of vehicle.
(4) Raise vehicle.
(5) Disengage cable eyelet at transmission shift
lever and pull cable adjuster out of mounting
bracket. Then remove old cable from vehicle.
INSTALLATION
(1) Route cable through hole in dash panel. Fully
seat cable grommet into dash panel.
(2) Place the auto transmission manual shift con-
trol lever in “Park” detent (rearmost) position and
rotate prop shaft to ensure transmission is in park.
(3) Connect shift cable to shifter mechanism by
snapping cable retaining ears into shifter bracket
and press cable end fitting onto lever ball stud.
(4) Place the floor shifter lever in park position.
Ensure that the pawl is seated within the confines of
the adjustment gauge clip.
(5) Snap the cable into the transmission bracket so
the retaining ears are engaged and connect cable end
fitting onto the manual control lever ball stud.
(6) Lock shift cable into position by pushing
upward on the adjusting lock button.
(7) Remove and discard the shift cable adjustment
gauge clip from the park gate of the shifter.
BRAKE TRANSMISSION SHIFT INTERLOCK
REMOVAL
(1) Remove lower steering column cover. Refer to
Group 8E, Instrument Panel and Gauges, for proper
procedure.
(2) Remove lower steering column shroud. Refer to
Group 19, Steering, for proper procedure.
(3) Remove tie strap near the solenoid retaining
the brake transmission interlock cable to the steering
column.
(4) Disengage wire connector from solenoid.
(5) With the ignition removed or in the unlocked
position, disengage lock tab holding cable end to
steering column (Fig. 57).
(6) Pull cable end from steering column.
(7) Remove the floor console and related trim.
Refer to Group 23, Body, for proper procedure.
(8) Disconnect the cable eyelet from the bellcrank
(Fig. 58).
(9) Disconnect and remove the cable from the shift
bracket.
Fig. 56 Park/Neutral Position Switch Adjustment
1 – NEUTRAL STANDARD LINE
2 – ADJUSTING BOLT
3 – VERTICAL GROOVE ON MANUAL VALVE SHAFT
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AW–4 AUTOMATIC TRANSMISSION
XJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Route
replacement
cable
behind
instrument
panel and under floor console area to shift mechanism
(Fig. 58).
(2) Insert cable end into opening in steering column
hub under ignition lock. Push cable inward until lock
tab engages.
(3) Connect
the
cable
end
eyelet
onto
shifter
bellcrank pin.
(4) Place gear selector in PARK.
(5) Push the spring-loaded cable adjuster forward
and snap cable into bracket.
(6) Adjust the brake transmission shifter interlock
cable. Refer to the Adjustment portion of this section
for proper procedures.
(7) Verify that the cable adjuster lock clamp is
pushed downward to the locked position.
(8) Test the park-lock cable operation.
(9) Install the floor console and related trim.
Fig. 58 Cable and Shifter
1 – SHIFT MECHANISM
2 – LOCK-TAB
3 – IGNITION LOCK INTERLOCK
4 – STEERING COLUMN
5 – SOLENOID
6 – WIRE CONNECTOR
7 – LEVER
8 – MOUNT BRACKET
9 – SHIFT CABLE
10 – AUTOMATIC TRANSMISSION
11 – TIE STRAP
12 – PARK/BRAKE INTERLOCK CABLE
Fig. 57 Brake/Park Interlock Cable
1 – IGNITION LOCK
2 – LOCK TAB
3 – CABLE END
XJ
AW–4 AUTOMATIC TRANSMISSION
21 - 257
REMOVAL AND INSTALLATION (Continued)
(10) Install tie strap to hold cable to base of steer-
ing column.
(11) Install lower steering column shroud and igni-
tion lock.
(12) Install lower steering column cover.
TRANSMISSION VALVE BODY SOLENOIDS
REMOVAL
(1) Remove transmission oil pan drain plug and
drain fluid.
(2) Remove pan bolts and remove oil pan.
(3) Remove oil screen bolts and remove screen
(Fig. 59) and gasket. Discard the gasket.
(4) Disconnect solenoid wire connector (Fig. 60).
(5) If all solenoids are being removed, mark or tag
wires for assembly reference before disconnecting
them.
(6) Remove bolt attaching solenoids to valve body
and remove solenoids (Fig. 61). Do not allow any
valve body components to fall out when solenoids are
removed.
(7) Clean oil filter and pan with solvent and dry
with compressed air.
(8) Remove old sealer material from oil pan and
transmission case.
INSTALLATION
(1) Position solenoids on valve body and install
solenoid bolts. Tighten bolts to 10 N·m (7 ft. lbs.)
torque.
(2) Connect feed wires to solenoids.
(3) Install new gaskets on oil screen and install
screen. Tighten screen bolts to 10 N·m (7 ft. lbs.)
torque.
(4) Apply bead of Threeebond
t Liquid Gasket
TB1281, P/N 83504038, sealer to oil pan sealing sur-
face. Sealer bead should be at least 3.0 mm (1/8 in.)
wide.
(5) Install oil pan on transmission. Tighten pan
bolts to 7 N·m (65 in. lbs.) torque.
(6) Install and tighten oil pan drain plug to 20
N·m (15 ft. lbs.) torque.
(7) Fill transmission with Mopar
t Dexron IIE/Mer-
con.
Fig. 59 Oil Screen Removal/Installation
1 – OIL SCREEN BOLTS
2 – OIL SCREEN
Fig. 60 Solenoid Wire Connectors
1 – SOLENOID WIRE CONNECTORS
Fig. 61 Transmission Valve Body Solenoids
1 – VALVE BODY SOLENOIDS
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AW–4 AUTOMATIC TRANSMISSION
XJ
REMOVAL AND INSTALLATION (Continued)
TRANSMISSION VALVE BODY
REMOVAL
(1) Remove oil pan plug and drain transmission
fluid.
(2) Remove oil pan and oil screen. Clean pan and
screen in solvent and dry them with compressed air.
(3) Disconnect solenoid wire connectors (Fig. 62).
Mark wires for assembly reference.
(4) Remove valve body oil tubes (Fig. 63). Carefully
pry tubes out of valve body with screwdriver.
(5) Disconnect throttle cable from throttle cam
(Fig. 64).
(6) Remove valve body bolts. Bolt locations are
outlined in (Fig. 65).
(7) Lower valve body and remove overdrive clutch
accumulator
springs,
direct
clutch
accumulator
springs and second brake accumulator spring (Fig.
66).
(8) Remove valve body and check ball and spring
(Fig. 67).
INSTALLATION
(1) Connect cable to throttle cam (Fig. 64).
(2) Install check ball and spring (Fig. 67).
(3) Position accumulator springs and spacers on
valve body.
(4) Align valve body manual valve with shift sector
(Fig. 68) and carefully position valve body on case.
(5) Install valve body bolts (Fig. 65). Tighten bolts
evenly to 10 N·m (7 ft. lbs.) torque.
(6) Install valve body oil tubes. Be sure tube ends
(L) and (M) are installed as shown in (Fig. 69).
(7) Remove old sealer material from oil pan and
transmission case.
(8) Clean oil screen and oil pan with solvent (if not
done previously). Dry both components with com-
pressed air only. Do not use shop towels.
(9) Install new gaskets on oil screen and install
screen on case. Tighten screen attaching bolts to 10
N·m (7 ft. lbs.) torque.
Fig. 62 Solenoid Wire Connectors
1 – SOLENOID WIRE CONNECTORS
Fig. 63 Removing Transmission Valve Body Oil
Tubes
1 – OIL TUBES
Fig. 64 Removing/Installing Throttle Cable
1 – THROTTLE CABLE
2 – CABLE BRACKET
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AW–4 AUTOMATIC TRANSMISSION
21 - 259
REMOVAL AND INSTALLATION (Continued)
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