Jeep Wrangler TJ. Manual — part 477
When steering pump pressure exceeds 5860 kPa ±
690 kPa (850 psi ± 100 psi), the normally closed
switch will open and the PCM will increase the
engine idle speed. This will prevent the engine from
stalling.
When pump pressure drops to approximately 1379
kPa (200 psi), the switch circuit will re-close and
engine idle speed will return to its previous setting.
REMOVAL
This switch is not used with 4.0L six-cylinder
engines.
The power steering pressure switch is installed in
the power steering high-pressure hose (Fig. 5).
(1) Disconnect electrical connector from power
steering pressure switch.
(2) Place a small container or shop towel beneath
switch to collect any excess fluid.
(3) Remove switch. Use back-up wrench on power
steering line to prevent line bending.
INSTALLATION
This switch is not used with 4.0L six-cylinder
engines.
(1) Install power steering switch into power steer-
ing line.
(2) Tighten to 14–22 N·m (124–195 in. lbs.) torque.
(3) Connect electrical connector to switch.
(4) Check power steering fluid and add as neces-
sary.
(5) Start engine and again check power steering
fluid. Add fluid if necessary.
PULLEY
REMOVAL
CAUTION: On vehicles equipped with the 4.0L, Do
not reuse the old power steering pump pulley it is
not intended for reuse. A new pulley must be
installed if removed.
(1) Remove pump assembly.
(2) Remove pulley from pump with Puller C-4333
or equivalent puller (Fig. 6).
INSTALLATION
NOTE: The pulley is marked front for installation.
CAUTION: On vehicles equipped with the 4.0L, Do
not reuse the old power steering pump pulley it is
not intended for reuse. A new pulley must be
installed if removed.
(1) Replace pulley if bent, cracked, or loose.
(2) Install pulley on pump with Installer C-4063-B
or equivalent installer (Fig. 7). The pulley must be
flush with the end of the shaft. Ensure the tool and
pulley are aligned with the pump shaft.
(3) Install pump assembly.
(4) With Serpentine Belt, run engine until warm (5
min.) and note any belt chirp. If chirp exists, move
pulley outward approximately 0.5 mm (0.020 in.). If
noise increases, press on 1.0 mm (0.040 in.). Be
careful that pulley does not contact mounting
bolts.
Fig. 6 Pulley Removal
1 - POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL C-4333
Fig. 7 Pulley Installation
1- POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL C-4063-B
TJ
PUMP
19 - 25
POWER STEERING PRESSURE SWITCH (Continued)
RESERVOIR
REMOVAL
REMOVAL - 4.0L
(1) Remove power steering pump. (Refer to 19 -
STEERING/PUMP - REMOVAL).
(2) Clean exterior of pump.
(3) Clamp the pump body in a soft jaw vice.
(4) Pry up tab and slide the retaining clips off
(Fig. 8).
NOTE: Use new retaining clips for installation.
(5) Remove
fluid
reservoir
from
pump
body.
Remove and discard O-ring seal.
REMOVAL - 2.4L
(1) Remove the pump return hoses from the reser-
voir and drain the reservoir.
(2) Remove the push-in fastener from the reservoir
(Fig. 9).
(3) Slide the reservoir up out of the fan shroud
mount.
INSTALLATION
INSTALLATION - 4.0L
(1) Lubricate new O-ring Seal with Mopar Power
Steering Fluid or equivalent.
(2) Install O-ring seal in housing.
(3) Install reservoir onto housing.
(4) Slide and tap in new reservoir retainer clips
until tab locks to housing.
(5) Install power steering pump. (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(6) Add power steering fluid, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - 2.4L
(1) Slide reservoir down onto the fan shroud
mount until it clicks in place.
(2) Install the push-in fastener.
(3) Install the hoses.
(4) Fill reservoir to proper level, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
Fig. 8 Pump Reservoir Clips
1 - RESERVOIR
2 - RETAINING CLIPS
Fig. 9 POWER STEERING GEAR & PUMP - 2.4L
1 - REMOTE RESERVOIR
2 - POWER STEERING PUMP
3 - PUMP MOUNT BRACKET
4 - MOUNTING BOLTS (3)
5 - PRESSURE SWITCH LOCATION
6 - PRESSURE OUTLET HOSE (GEAR TO PUMP)
7 - RETURN HOSE (RESERVOIR TO PUMP)
8 - CLAMPS
9 - STEERING GEAR
10 - INLET HOSE (RESERVOIR TO GEAR)
19 - 26
PUMP
TJ
TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page
page
AUTOMATIC TRANSMISSION - 42RLE
. . . . . . . . . . . . . . . . 165
. . . . . . . . . . . . . . . . 201
MANUAL TRANSMISSION - NSG370
TABLE OF CONTENTS
page
page
MANUAL TRANSMISSION - NSG370
STANDARD PROCEDURE - DRAIN AND FILL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . 34
. . . . . . . . . . . . . . . . . . . . . . . 34
MANUAL TRANSMISSION -
NSG370
DIAGNOSIS AND TESTING
MANUAL TRANSMISSION - NSG370
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill or incorrect
lubricant level check.
Rear transmission leaks will be from the oil
seals or component mating surfaces.
Front transmission leaks will be from the front
input shaft retainer seal. Lubricant may drip from
the clutch housing after extended operation. If leak is
severe, it may contaminate the clutch disc.
Lubricant level check can only be made when
the vehicle is level and allowing the lubricant to set-
tle for a minute before checking. This will ensure an
accurate check and avoid an underfill or overfill con-
dition.
HARD SHIFTING
Hard shifting is usually caused by low lubricant
level, improper or contaminated lubricants. This will
cause noise, excessive wear, internal bind, and hard
shifting. Substantial lubricant leaks can result in
gear, shift rail, synchro, and bearing damage. The
first indications of component damage is usually hard
shifting and noise.
Shift component damage, clutch adjustment, worn
pressure plate or disc are also causes of increased
shift effort. If clutch problem is advanced, gear clash
during shifts can result. Worn or damaged synchro-
nizer rings can cause gear clash when shifting into
any forward gear. In some new or rebuilt transmis-
sions, new synchro rings may tend to stick slightly
causing hard or noisy shifts. In most cases, this con-
dition will decline as the rings wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears generate a mild
whine that is audible, but generally only at extreme
speeds.
Severe, highly audible transmission noise is gener-
ally the initial indicator of a lubricant problem.
Insufficient, improper or contaminated lubricant will
promote rapid wear of gears, synchros, shift rails,
forks and bearings. The overheating caused by a
lubricant problem, can also lead to gear and bearing
damage.
TJ
TRANSMISSION AND TRANSFER CASE
21 - 1
STANDARD PROCEDURE - DRAIN AND FILL
(1) With vehicle in neutral, position vehicle on hoist.
(2) Remove drain plug (1) (Fig. 1) and drain fluid.
(3) Install drain plug and remove fill plug (1) (Fig. 2).
(4) Fill transmission with 1.5L (3.17 pts.) of
Mopar
t Manual Transmission Lubricant MS-9224 or
to the bottom of the fill plug (1) hole.
REMOVAL
(1) Disconnect negative battery cable.
(2) With vehicle in neutral, position vehicle on
hoist.
(3) Remove drain plug (1) (Fig. 3) and drain fluid.
(4) Mark installation reference marks on propeller
shaft/shafts and remove shafts.
(5) Remove transfer case shift linkage, wiring con-
nector, and vent hose, if equipped.
(6) Remove transfer case, if equipped.
(7) Support transmission with jack.
(8) Remove transmission mount (1) and crossmem-
ber (2).
Fig. 1 DRAIN PLUG
1 - DRAIN PLUG
Fig. 2 FILL PLUG
1 - FILL PLUG
Fig. 3 DRAIN PLUG
1. DRAIN PLUG
Fig. 4 2.4L CATALYST ASSEMBLY - 4x4
1- FLANGED NUT
2- CATALYST ASSEMBLY
3- BOLT
4- HANGER
5- NUT
21 - 2
MANUAL TRANSMISSION - NSG370
TJ
MANUAL TRANSMISSION - NSG370 (Continued)
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