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Home >> Jeep >> 1990 >> Cherokee Laredo, 2D Utility, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul - Aw-4 >> Transmission Disassembly

Transmission Disassembly

  1. Remove torque converter. Remove dipstick and both halves of oil filter tube. Remove clamp attaching wire harness and throttle pressure cable to transmission. Remove shift lever from manual valve shaft. Remove neutral safety switch, speedometer driven gear and speed sensor.
  2. Remove converter housing bolts. Gently pull housing from case. Remove extension housing.
  3. On 2WD models, measure inside diameter of extension housing bushing with cylinder bore gauge or inside micrometer. See Fig 1 . Diameter should be 1.50" (38.10 mm) or less. Replace housing as assembly if inside diameter exceeds specified limit.
  4. Remove the speedometer drive gear snap ring and remove gear and gear spacer (if equipped). Remove speed sensor rotor and key. Use wood dowel or hammer handle to loosen and remove rotor.
    5. NOTE: Special tools needed to overhaul the AW-4 transmission are provided in Tool Kit 6294 (B. Vi FM-23). However, pressure Test Port Adapter 7554 is not included and will have to be ordered separately.
  5. Remove transmission oil pan, oil screen and screen gaskets. Mount transmission in holding fixture. Remove valve body oil feed tubes. Disconnect solenoid wires. Remove harness bolt and bracket.
  6. Noting location and length of valve body bolts, remove valve body. See VALVE BODY  under REMOVAL & INSTALLATION. Remove second brake and clutch accumulator pistons. See COMPONENT DISASSEMBLY & REASSEMBLY  . Remove throttle cable.
  7. Remove oil pump and race with Bridge-type Puller (B.Vi FM-25). Remove fourth gear overdrive planetary gear and overdrive direct clutch assembly. Remove race. Remove thrust bearing, race and overdrive planetary ring gear.
  8. Measure stroke length of overdrive brake piston. See Fig 2 . Mount Gauge Tool (B.Vi FM-35) on piston and dial indicator on case. Apply 57-114 psi air pressure through piston feed port and note piston stroke on dial indicator. Stroke length should be .055-.070" (1.40-1.78 mm) on 6-cylinder models and .052-.064" (1.32-1.62 mm) on 4-cylinder models. If stroke is not within limits, replace brake pack retainer.
  9. Remove overdrive brake snap ring, discs and plates. Measure overdrive brake clutch pack disc thickness with a micrometer. See Fig 3 . Minimum disc thickness is .072" (1.84 mm). Replace discs if thickness is less than specified. Remove overdrive support lower race, upper bearing and race and bolts. Remove overdrive support snap ring with Tool (B.Vi FM-29). Remove overdrive with Bridge-type Puller Tool (B.Vi FM-25).
  10. Measure stroke length of second coast brake piston rod. Make reference mark on piston rod. See Fig 4 . Apply 57-114 psi air pressure through piston feed hole and check stroke length with Gauge (B.Vi FM-40141). Stroke length should be .059-.118" (1.5-3.0 mm). If stroke length is incorrect, install new piston rod and recheck stroke. If stroke is still incorrect, replace second coast brake band. Replacement piston rods are available in lengths of 2.811" (71.4 mm) and 2.870" (72.9 mm).
  11. Remove second coast brake piston snap ring using Tool (B.Vi FM-29). Remove piston cover and assembly with compressed air applied through piston feed hole. Disassemble second coast brake piston. Remove direct and forward clutch assembly. Remove thrust bearing and race from clutch hub. Remove second coast brake band "E" ring from band pin. Remove brake band.
  12. Remove front planetary ring gear front bearing race and ring gear. Remove thrust bearing and rear race from ring gear. Remove planetary thrust race. Relieve load on planetary snap ring. Loosen transmission holding fixture. Turn transmission over and allow output shaft to support transmission weight. Place wood blocks under shaft to protect splines. Remove planetary snap ring and gear. Remove sun gear, input drum and one-way clutch as assembly.
  13. Measure second brake clutch pack clearance. See Fig 5 . Clearance should be .024-.079" (.62-2.00 mm) on 6-cylinder transmissions and .035-.085" (.89-2.15 mm) on 4-cylinder transmissions. Replace discs if not within specifications. Remove second brake clutch pack snap ring. Remove second brake clutch pack. See Fig 6 . Measure disc thickness with micrometer. Minimum thickness should be .072" (1.84 mm). Replace discs if not within specifications.
  14. Remove park rod bracket-to-case bolts. Disconnect park rod from manual shaft lever. Remove rod and bracket. Remove park pawl spring, pin and pawl.
  15. Measure clearance of first-reverse brake clutch pack. See Fig 7 . Clearance should be .028-.079" (.71-2.00 mm) on 6-cylinder transmissions and .024-.069" (.61-1.75 mm) on 4-cylinder transmissions. Replace discs if clearance is not within specifications.
  16. Remove second coast brake piston sleeve. Cover remover tool with tape to avoid damaging case. Remove rear planetary gear, second brake drum and output shaft as an assembly. Remove planetary and brake drum thrust bearing and race assembly.
  17. Remove second brake, drum gasket from case with gasket scraper or screwdriver. Measure inside diameter of transmission case rear bushing with bore gauge or inside micrometer. See Fig 8 . Maximum diameter is 1.503" (38.18 mm). Replace transmission case if bushing I.D. is greater than specified. Bushing is NOT serviceable.
Fig 1: Checking Bushing Diameter (2WD Housing)
G00158869Courtesy of CHRYSLER CORP.
Fig 2: Measuring Overdrive Brake Piston Stroke
G92G13462Courtesy of CHRYSLER CORP.
Fig 3: Remove/Measure Overdrive Brake Disc Thickness
G00158870Courtesy of CHRYSLER CORP.
Fig 4: Measuring Second Coast Brake Piston Stroke
G92J13465Courtesy of CHRYSLER CORP.
Fig 5: Checking Second Brake Clutch Pack Clearance
G92A13466Courtesy of CHRYSLER CORP.
Fig 6: Removing/Measuring Second Brake Clutch Disc Thickness
G00158871Courtesy of CHRYSLER CORP.
Fig 7: Checking First-Reverse Brake Clutch Pack Clearance
G92C13468Courtesy of CHRYSLER CORP.
Fig 8: Checking Rear Bushing Inside Diameter
G00158872Courtesy of CHRYSLER CORP.
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