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Home >> Jeep >> 2001 >> Cherokee SE, 2D Utility, RWD, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul - Aw-4 Automatic Transmission >> Transmission Disassembly

Transmission Disassembly

  1. Remove torque converter. Remove lower section of filler tube (if not previously removed). Remove clamp attaching wire harness and throttle cable to transmission.
  2. Remove shift lever from manual valve shaft. Remove transmission range sensor and speed sensors. Remove bolts and torque converter housing. Remove bolts and adapter (4WD) or extension housing (2WD).
    NOTE: On 2WD models, measure inside diameter of extension housing bushing. Replace extension housing if bushing inside diameter exceeds 1.500" (38.10 mm).
  3. Remove speedometer drive gear-to-output shaft snap ring. Remove speedometer drive gear and spacer (if equipped) from output shaft. Using a wooden dowel, pry speed sensor rotor from output shaft. See Fig 5 . Remove speed sensor rotor key from output shaft.
  4. Mount transmission in holding fixture. Remove bolts and oil pan. Remove bolts, oil screen and gasket. Disconnect harness connectors from valve body solenoids. Mark electrical connection location for reassembly reference. Carefully pry valve body oil tubes from valve body and transmission case. Note location of valve body oil tubes for reassembly reference. See Fig 1 .
  5. Disconnect throttle cable from throttle valve cam on valve body. Remove valve body-to-transmission case bolts. Note bolt length and location for reassembly reference. See Fig 2 . Remove valve body. Remove check ball and spring. See Fig 3 .
  6. Remove accumulator pistons and springs. Place shop towel over accumulator piston. Apply air pressure through small hole next to each accumulator piston to force accumulator piston from transmission case. See Fig 4 .
  7. Remove throttle cable from transmission case. Remove oil pump bolts. Using Puller (7536), remove oil pump from transmission case. See Fig 7 .
    Fig 1: Identifying Valve Body Oil Tubes
    G94J38405Courtesy of DAIMLERCHRYSLER CORPORATION
    Fig 2: Identifying Valve Body Bolt Locations
    G95G20368Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    Fig 3: Removing & Installing Check Ball & Spring In Transmission Case
    G92J13457Courtesy of DAIMLERCHRYSLER CORPORATION
    Fig 4: Removing Accumulator Pistons
    G00064126Courtesy of DAIMLERCHRYSLER CORPORATION
  8. Note location of thrust bearings and races. See Fig 6 . Remove race from rear of oil pump. Remove overdrive planetary gear and overdrive direct clutch. See Fig 5 . Remove race from rear of overdrive planetary gear. Remove thrust bearing, race and overdrive planetary ring gear.
  9. Overdrive brake piston stroke must be checked to see if proper clearance is present or if components must be replaced. Mount dial indicator on transmission case with appropriate gauge tool contacting overdrive brake piston. See Fig 8 .
  10. Apply 57-114 psi (4-8 kg/cm2 ) of air pressure to feed hole and note overdrive brake piston stroke reading on dial indicator. See Fig 8 .
  11. Overdrive brake piston stroke should be .055-.067" (1.40-1.70 mm). If overdrive brake piston stroke is incorrect, check for worn clutch discs. Overdrive brake piston stroke will be rechecked during reassembly.
    Fig 5: Exploded View Of Transmission Components
    G94A38406Courtesy of DAIMLERCHRYSLER CORPORATION
    Fig 6: Identifying Transmission Thrust Bearing & Race Locations
    G92E13460Courtesy of DAIMLERCHRYSLER CORPORATION
    Fig 7: Removing Oil Pump
    G92F13461Courtesy of DAIMLERCHRYSLER CORPORATION
    Fig 8: Measuring Overdrive Brake Piston Stroke
    G92G13462Courtesy of DAIMLERCHRYSLER CORPORATION
    12. CAUTION: Note direction of overdrive brake clutch pack component installation and number of each component for reassembly reference. Components must be installed in original location. See Fig 9 .
  12. Remove overdrive direct clutch pack snap ring, retainer plate, clutch discs and clutch plates. See Fig 9 . Using a micrometer, measure overdrive brake clutch disc thickness. Replace clutch disc if thickness is less than .072" (1.83 mm).
  13. Remove thrust bearing and races from front of overdrive support. See Fig 5 . Remove overdrive support bolts from transmission case bolts. See Fig 10 .
  14. Remove overdrive support-to-transmission case snap ring. Using appropriate puller, remove overdrive support. See Fig 10 . Remove race from hub on rear side of overdrive support.
  15. Second coast brake piston stroke must be checked to see if proper clearance is present or if components must be replaced. Place reference mark on piston rod. See Fig 11 .
  16. Apply 57-114 psi (4-8 kg/cm2 ) air pressure to piston feed hole. Using Gauge Tool (7552), check second coast brake piston stroke. Second coast brake piston stroke should be .059-.118" (1.50-3.00 mm).
    Fig 9: Removing & Installing Overdrive Brake Clutch Pack
    G92H13463Courtesy of DAIMLERCHRYSLER CORPORATION
    Fig 10: Removing Overdrive Support
    G92I13464Courtesy of DAIMLERCHRYSLER CORPORATION
    Fig 11: Measuring Second Coast Brake Piston Stroke
    G92J13465Courtesy of DAIMLERCHRYSLER CORPORATION
  17. If second coast brake piston stroke is incorrect, install different length piston rod. Recheck second coast brake piston stroke. Replacement piston rods are available in lengths of 2.811" (71.40 mm) and 2.870" (72.90 mm). If second coast brake piston stroke is still incorrect, replace second coast brake band.
  18. Remove second coast brake servo snap ring from transmission case. See Fig 12 . Apply air pressure to oil hole in transmission case to force servo cover and piston from transmission case. Disassemble second coast brake servo if necessary. See Figure .
  19. Remove direct clutch and forward clutch assembly. See Fig 5 . Remove thrust bearing and race from direct clutch hub. Remove "E" ring, pin and second coast brake band. See Fig 13 .
  20. Remove race and front planetary ring gear. See Fig 5 . Remove thrust bearing and race from rear of front planetary ring gear. Remove race from front of front planetary gear.
  21. Relieve load on front planetary gear snap ring by positioning wooden blocks under output shaft. Allow output shaft to support transmission weight. Remove snap ring and front planetary gear. See Fig 14 .
  22. Remove sun gear, input drum, one-way clutch and thrust washer as an assembly. Using a feeler gauge, measure second brake clutch pack clearance. See Fig 15 . Second brake clutch pack clearance should be .024-.078" (.61-1.98 mm). Replace clutch discs if clearance is not within specification.
    Fig 12: Removing Second Coast Brake Servo
    G92I13456Courtesy of DAIMLERCHRYSLER CORPORATION
    Fig 13: Removing Second Coast Brake Band
    G00064119Courtesy of DAIMLERCHRYSLER CORPORATION
    Fig 14: Removing/Installing Front Planetary Snap Ring
    G00064120Courtesy of DAIMLERCHRYSLER CORPORATION
    Fig 15: Measuring Second Brake Clutch Pack Clearance
    G92A13466Courtesy of DAIMLERCHRYSLER CORPORATION
    23. CAUTION: Note direction of second brake clutch pack component installation and number of each component for reassembly reference. Components must be installed in original location. See Fig 17 .
    Fig 16: Removing Second Brake Clutch Snap Ring
    G00064121Courtesy of DAIMLERCHRYSLER CORPORATION
    Fig 17: Removing & Installing Second Brake Clutch Pack
    G92B13467Courtesy of DAIMLERCHRYSLER CORPORATION
  23. Remove snap ring and second brake clutch pack. See Fig 16 and Fig 17 . Using a micrometer, measure second brake clutch disc thickness. Replace clutch disc if thickness is less than .072" (1.83 mm).
  24. Remove park rod bracket-to-transmission case bolts. See Fig 18 . Disconnect park rod from shift sector on manual valve shaft. Remove park rod and park rod bracket. Remove spring, pin and pawl.
  25. Using a feeler gauge, measure first-reverse brake clutch pack clearance. See Fig 19 . First-reverse clutch pack clearance should be .028-.047" (.71-1.19 mm). Replace clutch discs if clearance is not within specification.
    Fig 18: Identifying Park Rod & Pawl Components
    G92H13455Courtesy of DAIMLERCHRYSLER CORPORATION
    Fig 19: Measuring First-Reverse Brake Clutch Pack Clearance
    G92C13468Courtesy of DAIMLERCHRYSLER CORPORATION
    26. CAUTION: Apply tape to end of screwdriver for removing second coast brake piston sleeve to prevent damage to transmission case.
  26. Remove second coast brake piston sleeve and snap ring. Remove rear planetary gear, second brake drum, first-reverse brake clutch pack and output shaft as an assembly. See Fig 5 . Remove rear planetary and second brake drum thrust bearing from transmission case.
  27. Note location of second brake drum gasket. See Fig 20 . Using a screwdriver, remove second brake drum gasket from transmission case.
  28. Measure inside diameter of transmission case rear bushing. Replace transmission case if bushing inside diameter exceeds 1.503" (38.18 mm), as bushing is not serviceable.
    Fig 20: Removing & Installing Second Brake Drum Gasket
    G92D13469Courtesy of DAIMLERCHRYSLER CORPORATION
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