Jeep XJ. Manual — part 402
NOTE: This flushes the main oil cooler core pas-
sages only.
(16) Turn pump OFF.
(17) Remove the thermostat cover from the oil
cooler.
(18) Remove Special Tool Cooler Plug 8414 from
the transmission oil cooler.
(19) Install a new thermostat spring, thermostat,
cover, and snap-ring into the transmission oil cooler.
(20) Install the transmission oil cooler onto the
vehicle.
(21) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(22) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(23) Place CLEAR suction line into a one quart
container of Mopar
t ATF Plus 3, type 7176 automatic
transmission fluid.
(24) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(25) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum trans-
mission case and valve body can be repaired by the
use of Heli-Coils, or equivalent. This repair consists
of drilling out the worn-out damaged threads. Then
tap the hole with a special Heli-Coil tap, or equiva-
lent, and installing a Heli-Coil insert, or equivalent,
into the hole. This brings the hole back to its original
thread size.
Heli-Coil, or equivalent, tools and inserts are readily
available from most automotive parts suppliers.
REMOVAL AND INSTALLATION
TRANSMISSION
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid component
damage. The converter drive plate, pump bushing, or
oil seal can be damaged if the converter is left
attached to the driveplate during removal.
REMOVAL
(1) Disconnect battery negative cable.
(2) Disconnect and lower or remove necessary
exhaust components.
(3) Remove engine-to-transmission bending braces.
(4) Disconnect fluid cooler lines at transmission.
(5) Remove starter motor.
(6) Disconnect and remove crankshaft position sen-
sor (Fig. 67). Retain sensor attaching bolts.
CAUTION: The crankshaft position sensor can be
damaged during transmission removal (or installa-
tion) if the sensor is left in place. To avoid damage,
remove the sensor before removing the transmis-
sion.
(7) Remove torque converter access cover.
(8) If transmission is being removed for overhaul,
remove transmission oil pan, drain fluid and reinstall
pan.
(9) Remove skid plate for access.
(10) Remove the fill tube bracket bolts and pull tube
out of transmission. Retain fill tube seal. On 4 x 4 mod-
els, it will also be necessary to remove bolt attaching
transfer case vent tube to converter housing.
(11) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.
(12) Mark propeller shaft and axle yokes for
assembly alignment. Then disconnect and remove
propeller shafts.
(13) Disconnect wires from park/neutral position
switch and vehicle speed sensor.
(14) Disconnect gearshift cable from transmission
manual valve lever.
(15) Disconnect throttle valve cable from transmis-
sion bracket and throttle valve lever.
(16) Disconnect shift rod from transfer case shift
lever or remove shift lever from transfer case.
Fig. 67 Crankshaft Position Sensor—2.5L Engine
1 – EXHAUST DOWN PIPE
2 – TRANSMISSION HOUSING
3 – CRANKSHAFT POSITION SENSOR
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AUTOMATIC TRANSMISSION—30RH
XJ
SERVICE PROCEDURES (Continued)
(17) Support rear of engine with safety stand or
jack.
(18) Raise transmission slightly with service jack
to relieve load on crossmember and supports.
(19) Remove bolts securing rear support and cush-
ion to transmission and crossmember. Raise trans-
mission slightly, slide exhaust hanger arm from
bracket and remove rear support.
(20) Remove bolts attaching crossmember to frame
and remove crossmember.
(21) Disconnect transfer case vent hose. Then dis-
connect vacuum switch harness.
(22) Remove transfer case.
(23) Remove all converter housing bolts.
(24) Carefully work transmission and torque con-
verter assembly rearward off engine block dowels.
(25) Hold torque converter in place during trans-
mission removal.
(26) Lower transmission and remove assembly
from under the vehicle.
(27) To remove torque converter, carefully slide
torque converter out of the transmission.
INSTALLATION
(1) Check torque converter hub and hub drive
notches for sharp edges burrs, scratches, or nicks.
Polish the hub and notches with 320/400 grit paper
and crocus cloth if necessary. The hub must be
smooth to avoid damaging pump seal at installation.
(2) Lubricate converter drive hub and oil pump
seal lip with transmission fluid.
(3) Align converter and oil pump.
(4) Carefully insert converter in oil pump. Then
rotate converter back and forth until fully seated in
pump gears.
(5) Check converter seating with steel scale and
straightedge (Fig. 68). Surface of converter lugs
should be 1/2 in. to rear of straightedge when con-
verter is fully seated.
(6) Temporarily secure converter with C-clamp.
(7) Lubricate the pocket in the rear of the crank-
shaft, in which the converter pilot hub rides, with a
light coating of Mopar
t High-Temp Grease.
(8) Position transmission on jack and secure it
with safety chains.
(9) Check
condition
of
converter
driveplate.
Replace the plate if cracked, distorted or damaged.
Also be sure transmission dowel pins are seated
in engine block and protrude far enough to
hold transmission in alignment.
(10) Raise transmission and align converter with
drive plate and converter housing with engine block.
(11) Move transmission forward. Then raise, lower
or tilt transmission to align converter housing with
engine block dowels.
(12) Carefully work transmission forward and over
engine block dowels until converter hub is seated in
crankshaft.
(13) Install and tighten bolts that attach transmis-
sion converter housing to engine block (Fig. 69).
CAUTION: Be sure the converter housing is fully
seated on the engine block dowels before tighten-
ing any bolts.
(14) Install
torque
converter
attaching
bolts.
Tighten bolts to following torque.
• 54 N·m (40 ft. lbs.) with 9.5 in. 3-lug converter
• 74 N·m (55 ft. lbs.) with 9.5 in. 4-lug converter
• 74 N·m (55 ft. lbs.) with 10.0 in. 4-lug converter
• 31 N·m (270 in. lbs.) with 10.75 in. 4-lug con-
verter
(15) Install crankshaft position sensor.
(16) Install transmission fill tube and seal. Install
new fill tube seal in transmission before installation.
(17) Connect transmission cooler lines to transmis-
sion.
(18) Install transfer case onto transmission.
(19) Install rear crossmember and attach trans-
mission rear support to crossmember.
(20) Remove engine support fixture.
(21) Remove transmission jack.
(22) Connect vehicle speed sensor wires.
(23) Connect wires to park/neutral position switch.
(24) Install crankshaft position sensor.
(25) Install converter housing access cover.
(26) Install exhaust pipes and support brackets, if
removed.
Fig. 68 Typical Method Of Checking Converter Seating
1 – SCALE
2 – STRAIGHTEDGE
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AUTOMATIC TRANSMISSION—30RH
21 - 145
REMOVAL AND INSTALLATION (Continued)
(27) Install starter motor and cooler line bracket.
(28) Install new plastic retainer grommet on any
shift linkage rod or lever that was disconnected.
Grommets should not be reused. Use pry tool to
remove rod from grommet and cut away old grom-
met. Use pliers to snap new grommet into lever and
to snap rod into grommet at assembly.
(29) Connect gearshift and linkage and throttle
cable.
(30) Connect transfer case shift linkage.
(31) Adjust gearshift linkage and throttle valve
cable if necessary.
(32) Align and connect propeller shaft(s).
(33) Install skid plate, rear cushion and bracket, if
removed.
(34) Fill transfer case to bottom edge of fill plug
hole.
(35) Lower vehicle and fill transmission to correct
level with Mopar
t ATF Plus 3, type 7176 fluid.
TORQUE CONVERTER
REMOVAL
(1) Remove transmission and torque converter
from vehicle.
(2) Place a suitable drain pan under the converter
housing end of the transmission.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pull the torque converter forward until the cen-
ter hub clears the oil pump seal.
(4) Separate the torque converter from the trans-
mission.
INSTALLATION
Check converter hub and drive notches for sharp
edges, burrs, scratches, or nicks. Polish the hub and
notches with 320/400 grit paper or crocus cloth if nec-
essary. The hub must be smooth to avoid damaging
the pump seal at installation.
(1) Lubricate converter hub and oil pump seal lip
with transmission fluid.
(2) Place torque converter in position on transmis-
sion.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
Fig. 69 Transmission Attachment
BOLT
SET-TO SERVE
TORQUE
A
35 N·m (26 ft-lbs)
B
33 N·m (24 ft-lbs)
C
57 N·m (42 ft-lbs)
D
16 N·m (138 in-lbs)
21 - 146
AUTOMATIC TRANSMISSION—30RH
XJ
REMOVAL AND INSTALLATION (Continued)
(3) Align torque converter to oil pump seal open-
ing.
(4) Insert torque converter hub into oil pump.
(5) While pushing torque converter inward, rotate
converter until converter is fully seated in the oil
pump gears.
(6) Check converter seating with a scale and
straightedge (Fig. 70). Surface of converter lugs
should be 1/2 in. to rear of straightedge when con-
verter is fully seated.
(7) If necessary, temporarily secure converter with
C-clamp attached to the converter housing.
(8) Install the transmission in the vehicle.
(9) Fill the transmission with the recommended
fluid.
YOKE SEAL REPLACEMENT
REMOVAL
(1) Raise vehicle.
(2) Mark propeller shaft and axle yoke for align-
ment reference.
(3) Disconnect and remove propeller shaft.
(4) Remove old seal with Seal Remover C-3985-B
(Fig. 71) from extension housing.
INSTALLATION
(1) Place seal in position on extension housing.
(2) Drive seal into extension housing with Seal
Installer C-3995-A or C-3972 (Fig. 72).
(3) Carefully guide propeller shaft slip yoke into
housing and onto output shaft splines. Align marks
made at removal and connect propeller shaft to rear
axle pinion yoke.
EXTENSION HOUSING BUSHING
REMOVAL
(1) Remove housing yoke seal.
(2) Insert Remover 6957 into extension housing.
Tighten tool to bushing and remove bushing (Fig.
73).
INSTALLATION
(1) Align bushing oil hole with oil slot in extension
housing.
(2) Tap bushing into place with Installer 6951 and
Handle C-4171.
(3) Install new oil seal in housing using Seal
Installer C-3995–A (Fig. 74).
ADAPTER HOUSING
REMOVAL
(1) Hoist and support vehicle on safety stands.
(2) Support transmission with a suitable lifting
device.
(3) Remove
transmission
skid
plate.
Refer
to
Group 13, Frame and Bumpers, for proper procedure.
Fig. 70 Checking Torque Converter Seating
1 – SCALE
2 – STRAIGHTEDGE
Fig. 71 Removing Extension Housing Yoke Seal
1 – SPECIAL TOOL C-3985–B
2 – SEAL
Fig. 72 Installing Extension Housing Yoke Seal
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3995–A
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AUTOMATIC TRANSMISSION—30RH
21 - 147
REMOVAL AND INSTALLATION (Continued)
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