Jeep XJ. Manual — part 420
Seal Remover—C-3985-B
Bushing, Remover—6957
Flusher, Oil Cooler—6906
Installer—C-3995-A
Universal Handle—C-4171
Remover/Installer—C-4470
Nut, Bushing Remover—SP-1191
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AUTOMATIC TRANSMISSION—30RH
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SPECIAL TOOLS (Continued)
AW–4 AUTOMATIC TRANSMISSION
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
AW–4 AUTOMATIC TRANSMISSION . . . . . . . . . 218
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . 222
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
TRANSMISSION VALVE BODY COMPONENTS . 228
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
TRANSMISSION RANGES AND SHIFT LEVER
POSITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
TRANSMISSION CONTROL MODULE (TCM) . . . 237
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . 237
TRANSMISSION COOLER . . . . . . . . . . . . . . . . . 237
BRAKE TRANSMISSION SHIFT INTERLOCK
MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . 238
DIAGNOSIS AND TESTING
GENERAL DIAGNOSIS INFORMATION . . . . . . . 239
EFFECTS OF INCORRECT FLUID LEVEL . . . . . 239
CAUSES OF BURNT FLUID . . . . . . . . . . . . . . . . 240
FLUID CONTAMINATION . . . . . . . . . . . . . . . . . . 240
PRELIMINARY INSPECTION AND
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . 241
MANUAL SHIFTING TEST . . . . . . . . . . . . . . . . . 241
HYDRAULIC PRESSURE TEST . . . . . . . . . . . . . 241
PRESSURE TEST ANALYSIS . . . . . . . . . . . . . . . 242
TIME LAG TEST. . . . . . . . . . . . . . . . . . . . . . . . . 242
TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . 242
TIME LAG TEST ANALYSIS . . . . . . . . . . . . . . . . 243
SERVICE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 243
TRANSMISSION SOLENOID TESTING . . . . . . . . 245
PARK/NEUTRAL POSITION SWITCH . . . . . . . . . 245
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . 246
THROTTLE VALVE CABLE . . . . . . . . . . . . . . . . . 246
SPEED SENSOR TESTING . . . . . . . . . . . . . . . . 246
FLOW TESTING TRANSMISSION MAIN
COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
TORQUE CONVERTER STATOR CLUTCH
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . 247
SERVICE PROCEDURES
CHECKING FLUID LEVEL . . . . . . . . . . . . . . . . . 247
CHECKING FLUID CONDITION . . . . . . . . . . . . . 248
REFILLING AFTER OVERHAUL OR FLUID/
FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . 248
TRANSMISSION CONTROL MODULE (TCM)
SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
OIL PUMP VOLUME CHECK . . . . . . . . . . . . . . . 248
FLUSHING COOLERS AND TUBES . . . . . . . . . . 248
ALUMINUM THREAD REPAIR . . . . . . . . . . . . . . 249
REMOVAL AND INSTALLATION
TRANSMISSION AND TORQUE CONVERTER . . 250
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . 252
ADAPTER HOUSING SEAL . . . . . . . . . . . . . . . . 252
SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 252
SPEEDOMETER ADAPTER . . . . . . . . . . . . . . . . 253
SPEED SENSOR ROTOR-SPEEDOMETER
DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . 254
PARK/NEUTRAL POSITION SWITCH . . . . . . . . . 255
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . 256
BRAKE TRANSMISSION SHIFT INTERLOCK . . . 256
TRANSMISSION VALVE BODY SOLENOIDS . . . 258
TRANSMISSION VALVE BODY. . . . . . . . . . . . . . 259
TRANSMISSION CONTROL MODULE . . . . . . . . 260
SOLENOID HARNESS ADAPTER SEAL . . . . . . . 261
MANUAL VALVE SHAFT SEAL . . . . . . . . . . . . . . 262
ACCUMULATOR PISTONS AND SPRINGS . . . . . 264
SECOND COAST BRAKE SERVO . . . . . . . . . . . 265
PARK ROD AND PAWL. . . . . . . . . . . . . . . . . . . . 266
TRANSMISSION THROTTLE CABLE . . . . . . . . . 267
OIL PUMP SEAL. . . . . . . . . . . . . . . . . . . . . . . . . 268
DISASSEMBLY AND ASSEMBLY
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . 269
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
OVERDRIVE PLANETARY GEAR AND
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
OVERDRIVE SUPPORT . . . . . . . . . . . . . . . . . . . 309
DIRECT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 312
FORWARD CLUTCH . . . . . . . . . . . . . . . . . . . . . 317
FRONT PLANETARY GEAR . . . . . . . . . . . . . . . . 322
SUN GEAR AND NO. 1 ONE–WAY CLUTCH. . . . 324
SECOND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 327
PLANETARY/BRAKE PACK/OUTPUT SHAFT . . . 329
TRANSMISSION VALVE BODY. . . . . . . . . . . . . . 333
CLEANING AND INSPECTION
TRANSMISSION PARTS CLEANING AND
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . 336
ADJUSTMENTS
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . 336
BRAKE TRANSMISSION SHIFT INTERLOCK
CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . 336
TRANSMISSION THROTTLE VALVE CABLE
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . 337
SPECIFICATIONS
AW-4 AUTOMATIC TRANSMISSION . . . . . . . . . . 338
SPECIAL TOOLS
AW-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
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AW–4 AUTOMATIC TRANSMISSION
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DESCRIPTION AND OPERATION
AW–4 AUTOMATIC TRANSMISSION
DESCRIPTION
The AW–4 is a 4–speed, electronically controlled
automatic transmission (Fig. 1).
The running gear consists of an oil pump, plane-
tary gear sets, clutch and brake units, hydraulic
accumulators, a valve body with electrical solenoids,
and a transmission control module (TCM). Cables are
used to provide shift and throttle pressure control
information. A park/neutral position switch permits
engine starting in the Park and Neutral ranges only.
TRANSMISSION IDENTIFICATION
The transmission I. D. plate is attached to the case
(Fig. 2). The plate contains the transmission serial
and model numbers. Refer to the information on this
plate when ordering service parts.
ELECTRONIC CONTROLS
The AW–4 is electronically controlled in 1, 2, 3 and
D ranges. Controls consist of the transmission control
module (TCM), valve body solenoids and various sen-
sors. The sensors monitor vehicle speed, throttle
opening, shift lever position and brake pedal applica-
tion.
TRANSMISSION GEAR RATIOS
Fourth gear is an 0.75:1 ratio overdrive range.
First, second, third and reverse gear are conventional
ranges. Third gear ratio is 1:1. A separate planetary
gear set provides overdrive operation in fourth gear.
OPERATION
GEARTRAIN OPERATION AND APPLICATION CHARTS
Operation and application of the first through
fourth and reverse gear elements are outlined in the
function and application charts.
The Component Function Chart describes basic
function of various geartrain elements. The Compo-
nent Application Chart indicates which elements
(including valve body solenoids), are applied in the
various gear ranges.
Fig. 1 AW–4 Automatic Transmission
Fig. 2 Transmission Identification
1 – TRANSMISSION I. D. PLATE
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AW–4 AUTOMATIC TRANSMISSION
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COMPONENT FUNCTION CHART
COMPONENT NAME
COMPONENT FUNCTION
Overdrive Direct Clutch
Connects overdrive sun gear and overdrive carrier.
Overdrive Brake
Prevents overdrive sun gear from turning either clockwise or
counter-clockwise.
Overdrive One-Way Clutch
When transmission is driven by engine, connects overdrive sun gear
and overdrive carrier.
Forward Clutch
Connects input shaft and front ring gear.
Direct Clutch
Connects input shaft to the front and rear ring gears.
Second Coast Brake
Prevents front and rear sun gear from turning either clockwise or
counter-clockwise.
Second Brake
Prevents outer race of number 1 one-way clutch from turning either
clockwise or counter-clockwise, thus preventing the front and rear sun
gears from turning counter-clockwise.
First/Reverse Brake
Prevents the rear planetary carrier from turning either clockwise or
counter-clockwise.
Number 1 One-way Clutch
When second brake is operating, prevents the front and rear sun
gears from turning counter-clockwise.
Number 2 One-Way Clutch
Prevents the rear planetary carrier from turning counter-clockwise.
COMPONENT APPLICATION CHART
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AW–4 AUTOMATIC TRANSMISSION
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DESCRIPTION AND OPERATION (Continued)
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