Jeep XJ. Manual — part 429
(19) Connect transmission cooler lines.
(20) Connect transmission throttle cable at engine.
(21) Install new O–ring seal on upper half of
transmission fill tube. Then connect upper and lower
tube halves.
(22) Lower vehicle.
(23) Fill transmission with Mopar
t Dexron IIE/
Mercon automatic transmission 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.
(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. 48). 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.
ADAPTER HOUSING SEAL
REMOVAL
(1) Raise vehicle.
(2) Disconnect or remove components necessary to
gain access to seal (e.g. propeller shaft, crossmember,
shift linkage, transfer case, exhaust components,
hoses, wires).
(3) On 4X2 vehicles, remove dust shield from the
adapter housing by tapping gently with a brass drift
and hammer (Fig. 49).
(4) On 4X2 vehicles, remove the adapter housing
seal with Seal Puller 7550.
(5) On 4X4 vehicles, remove the adapter housing
seal using a slide hammer mounted screw.
INSTALLATION
(1) Install new adapter housing seal with Seal
Installer 7888.
(2) On 4X2 vehicles, install dust shield using Spe-
cial Tool D-187-B.
(3) Reinstall components removed to gain access to
seal.
(4) Top off transmission fluid if necessary.
SPEED SENSOR
REMOVAL
(1) Disconnect sensor wire harness connector.
Fig. 48 Checking Torque Converter Seating
1 – SCALE
2 – STRAIGHTEDGE
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AW–4 AUTOMATIC TRANSMISSION
XJ
REMOVAL AND INSTALLATION (Continued)
(2) Remove sensor retainer bolt and remove sensor
(Fig. 50).
(3) Remove and discard speed sensor O–ring.
INSTALLATION
(1) Install new O–ring on speed sensor and install
sensor in transmission case.
(2) Install
sensor
bracket
and
retainer
bolt.
Tighten bolt to 7.4 N·m (65 in. lbs.) torque.
(3) Connect sensor wire harness connector.
SPEEDOMETER ADAPTER
Rear axle gear ratio and tire size determine speed-
ometer pinion requirements.
REMOVAL
(1) Raise vehicle.
(2) Disconnect wires from vehicle speed sensor.
(3) Remove adapter clamp and screw (Fig. 51).
(4) Remove speed sensor and speedometer adapter
as assembly.
(5) Remove speed sensor retaining screw and
remove sensor from adapter.
(6) Remove speedometer pinion from adapter.
(7) Inspect sensor and adapter O-rings (Fig. 51).
Remove and discard O-rings if worn or damaged.
(8) Inspect terminal pins in speed sensor. Clean
pins with Mopar
t electrical spray cleaner if dirty or
oxidized. Replace sensor if faulty, or pins are loose,
severely corroded, or damaged.
INSTALLATION
(1) Thoroughly clean adapter flange and adapter
mounting surface in housing. Surfaces must be clean
for proper adapter alignment and speedometer oper-
ation.
(2) Install new O-rings on speed sensor and speed-
ometer adapter if necessary (Fig. 51).
(3) Lubricate sensor and adapter O-rings with
transmission fluid.
(4) Install vehicle speed sensor in speedometer
adapter. Tighten sensor attaching screw to 2-3 N·m
(15-27 in. lbs.) torque.
(5) Install speedometer pinion in adapter.
(6) Count number of teeth on speedometer pinion.
Do this before installing assembly in housing. Then
lubricate pinion teeth with transmission fluid.
(7) Note index numbers on adapter body (Fig. 52).
These numbers will correspond to number of teeth on
pinion.
(8) Install speedometer assembly in housing.
(9) Rotate adapter until required range numbers
are at 6 o’clock position. Be sure range index num-
bers correspond to number of teeth on pinion gear.
Fig. 49 Adapter Housing Seals
1 – 4WD ADAPTER HOUSING
2 – SEAL
3 – BUSHING
4 – OIL TUBE
5 – 2WD EXTENSION HOUSING
6 – SEAL
7 – SPEED SENSOR
8 – SPEED SENSOR
Fig. 50 Transmission Speed Sensor Removal/
Installation
1 – RETAINER BOLT
2 – SPEED SENSOR
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AW–4 AUTOMATIC TRANSMISSION
21 - 253
REMOVAL AND INSTALLATION (Continued)
(10) Install speedometer adapter clamp and retain-
ing screw. Tighten clamp screw to 10-12 N·m (90-110
in. lbs.) torque.
(11) Connect wires to vehicle speed sensor.
(12) Lower vehicle and top off transmission fluid
level, if necessary.
SPEED SENSOR ROTOR-SPEEDOMETER DRIVE
GEAR
REMOVAL
(1) Raise vehicle.
(2) Remove components necessary to gain access to
rotor and drive gear such as propeller shaft, transfer
case, crossmember, and shift linkage.
(3) Disengage wire connector from the output
speed sensor.
(4) Remove the bolt holding the output speed sen-
sor to the adapter housing.
(5) Remove the output speed sensor from the
adapter housing.
(6) Remove the bolts holding the adapter housing
to the transmission case.
(7) Tap the adapter housing at the joint line gently
with a rubber mallet to separate the adapter housing
from the transmission case.
(8) Remove the adapter housing from the trans-
mission case.
(9) Remove speedometer drive gear snap ring (Fig.
53).
(10) Remove
the
speedometer
drive
gear
and
spacer, if equipped.
(11) Remove rotor from the output shaft. It may be
necessary to use a wood dowel or hammer handle
(Fig. 54) to gently pry the rotor from the output
Fig. 51 Speedometer Pinion Adapter Components
1 – SENSOR O-RING
2 – SPEEDOMETER ADAPTER
3 – ADAPTER O-RING
4 – SPEEDOMETER PINION
5 – ADAPTER CLAMP
6 – VEHICLE SPEED SENSOR
ITEM
TORQUE
A
2-3 N·m (15-27 in. lbs.)
B
10-12 N·m (90-110 in. lbs.)
Fig. 52 Index Numbers On Speedometer Pinion
Adapter
1 – SPEEDOMETER ADAPTER
2 – INDEX NUMBER LOCATION
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AW–4 AUTOMATIC TRANSMISSION
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REMOVAL AND INSTALLATION (Continued)
shaft. Be sure to retrieve the rotor locating key from
the output shaft or rotor.
INSTALLATION
(1) Clean sealing surfaces of transmission case and
extension/adaptor housing.
(2) Install rotor, spacer (if equipped) and drive
gear on output shaft. Then install drive gear snap
ring (Fig. 53).
(3) Apply 1/8 3/16 inch wide bead of Threebond
t
Liquid Gasket TB1281, P/N 83504038, to transmis-
sion case sealing surface and install extension/
adapter housing on case.
(4) Tighten adaptor housing bolts to 34 N·m (25 ft.
lbs.) torque.
(5) Install components removed to gain access to
rotor and drive gear.
PARK/NEUTRAL POSITION SWITCH
REMOVAL
(1) Raise vehicle.
(2) Disconnect switch wire harness connector.
(3) Pry washer lock tabs upward and remove
switch attaching nut and tabbed washer (Fig. 55).
(4) Remove switch adjusting bolt (Fig. 55).
(5) Slide switch off manual valve shaft.
Fig. 55 Park/Neutral Position Switch Removal/
Installation
1 – ADJUSTING BOLT
2 – ATTACHING NUT
3 – NEUTRAL SWITCH
4 – TABBED WASHER
Fig. 53 Removing/Installation Speedometer Drive
Gear
1 – ROTOR
2 – SPEEDOMETER DRIVE GEAR
3 – SNAP RING
Fig. 54 Removing Speed Sensor Rotor
1 – WOOD DOWEL OR HAMMER HANDLE
2 – ROTOR
3 – OUTPUT SHAFT
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AW–4 AUTOMATIC TRANSMISSION
21 - 255
REMOVAL AND INSTALLATION (Continued)
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