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ZJ                                                                         TRANSMISSION AND TRANSFER CASE                                         21 - 1

                        TRANSMISSION AND TRANSFER CASE

                                                             CONTENTS

                                                              page                                                                                        page

42RE AUTOMATIC TRANSMISSION . . . . . . . . . 36                        NP231 TRANSFER CASE . . . . . . . . . . . . . . . . . 291
46RH AUTOMATIC TRANSMISSION . . . . . . . . 164                         NP242 TRANSFER CASE . . . . . . . . . . . . . . . . . 315
AX 15 MANUAL TRANSMISSION . . . . . . . . . . . . 1                     NP249 TRANSFER CASE . . . . . . . . . . . . . . . . . 343



                                          AX 15 MANUAL TRANSMISSION


                                                                   INDEX
                                                              page                                                                                        page

General Information . . . . . . . . . . . . . . . . . . . . . . . . 1   Transmission   Identification . . . . . . . . . .     .   .   .   .   .   .   .   .   .   2
Speedometer Service . . . . . . . . . . . . . . . . . . . . . . . 3     Transmission   Installation . . . . . . . . . . . .   .   .   .   .   .   .   .   .   .   5
Transmission Assembly and Adjustment . . . . . . . . . 22               Transmission   Lubricant . . . . . . . . . . . . .    .   .   .   .   .   .   .   .   .   2
Transmission Diagnosis . . . . . . . . . . . . . . . . . . . . . 2      Transmission   Removal . . . . . . . . . . . . .      .   .   .   .   .   .   .   .   .   4
Transmission Disassembly and Overhaul . . . . . . . . . 6               Transmission   Shift Pattern . . . . . . . . . . .    .   .   .   .   .   .   .   .   .   2
Transmission Gear Ratios . . . . . . . . . . . . . . . . . . . . 2      Transmission   Switch and Plug Locations              .   .   .   .   .   .   .   .   .   2

GENERAL INFORMATION                                                     mounted in the shift tower portion of the adapter
  The AX 15 is a five speed, synchromesh, manual                        housing (Fig. 1). The AX 15 is used with 4.0L (I6) en-
transmission. Fifth gear is an overdrive range with a                   gines.
ratio of 0.79:1. The shift mechanism is integral and




                                                 Fig. 1 AX 15 Manual Transmission
21 - 2    AX 15 MANUAL TRANSMISSION                                                                           ZJ

TRANSMISSION IDENTIFICATION                              TRANSMISSION SWITCH AND PLUG LOCATIONS
  The AX 15 identification code numbers are on the         The fill plug is at the driver side of the gear case
bottom surface of the transmission gear case (Fig. 2).   (Fig. 4).
  The first number represents year of manufacture.         The drain plug and backup light switch are on the
For example, 4 would represent 1994. The second          passenger side of the gear case (Fig. 5).
and third numbers indicate month of manufacture.
For example, 11 would represent November. The last
series of numbers is the transmission serial number.

TRANSMISSION SHIFT PATTERN




                                                                        Fig. 4 Fill Plug Location




 Fig. 2 Transmission Identification Code Location
  The AX 15 shift pattern is shown in Figure 3. First
and second and third and fourth gear ranges are in
an H pattern. Fifth and reverse gear ranges are also
in line at the right of the H pattern (Fig. 3).




                                                         Fig. 5 Drain Plug And Backup Light Switch Location
                                                         TRANSMISSION GEAR RATIOS
                                                           AX 15 transmission gear ratios are:
                                                           First gear - 3.83:1
                                                           Second gear - 2.33:1
                                                           Third gear - 1.44:1
                                                           Fourth gear - 1.00:1
                                                           Fifth gear - 0.79:1
              Fig. 3 AX 15 Shift Pattern                   Reverse - 4.22:1
TRANSMISSION LUBRICANT
  Recommended lubricant for AX 15 transmissions is       TRANSMISSION DIAGNOSIS
Mopar SAE 75W-90, API Grade GL-5 gear lubricant.
                                                         LOW LUBRICANT LEVEL
  Correct lubricant level is from the bottom edge, to
                                                           A low transmission lubricant level is generally the
no more than 6 mm (1/4 in.) below the bottom edge of     result of a leak, inadequate lubricant fill, or an incor-
the fill plug hole.                                      rect lubricant level check.
  Lubricant capacity is approximately 3.10 liters          Leaks can occur at the mating surfaces of the gear
(3.27 qts.).                                             case, intermediate plate and adapter housing, or
ZJ                                                                   AX 15 MANUAL TRANSMISSION               21 - 3

from the front/rear seals. A suspected leak could also      recommended lubricants is noise, excessive wear,
be the result of an overfill condition.                     internal bind and hard shifting.
  Leaks at the rear of the adapter housing will be            Improper clutch release is a frequent cause of hard
from the housing oil seals. Leaks at component mat-         shifting. Incorrect adjustment or a worn, damaged
ing surfaces will probably be the result of inadequate      pressure plate or disc can cause incorrect release. If
sealer, gaps in the sealer, incorrect bolt tightening, or   the clutch problem is advanced, gear clash during
use of a non-recommended sealer.                            shifts can result.
  A leak at the front of the transmission are from the        Worn or damaged synchro rings can cause gear clash
front bearing retainer or retainer seal. Lubricant may      when shifting into any forward gear. In some new or re-
be seen dripping from the clutch housing after extended     built transmissions, new synchro rings may tend to
operation. If the leak is severe, it may also contaminate   stick slightly causing hard or noisy shifts. In most
the clutch disc causing slip, grab and chatter.             cases, this condition will decline as the rings wear-in.
  Transmissions filled from air or electrically powered
lubricant containers can be underfilled. This generally     TRANSMISSION NOISE
happens when the container delivery mechanism is im-          Most manual transmissions make some noise during
properly calibrated. Always check the lubricant level af-   normal operation. Rotating gears can generate a mild
ter filling to avoid an under fill condition.               whine that may only be audible at extreme speeds.
  A correct lubricant level check can only be made            Severe transmission noise is generally the result of
when the vehicle is level; use a drive-on hoist to en-      a lubricant problem, or internal component damage.
sure this. Also allow the lubricant to settle for a         Insufficient, improper, or contaminated lubricant can
minute or so before checking. These recommenda-             promote rapid wear of gears, synchros, shift rails,
tions will ensure an accurate check and avoid an un-
                                                            forks and bearings. The overheating caused by a lu-
der-or-overfill condition.
                                                            bricant problem, can also lead to gear breakage.
HARD SHIFTING
  Hard shifting is usually the result of a low lubri-       SPEEDOMETER SERVICE
cant level, improper or contaminated lubricants, com-         Rear axle gear ratio and tire size determine speed-
ponent damage, incorrect clutch adjustment, or by a         ometer pinion requirements. If the pinion must be re-
damaged clutch pressure plate or disc.                      placed, refer to the parts catalogue information for
  Substantial lubricant leaks can result in gear, shift     the correct part.
rail, synchro and bearing damage. If a leak goes un-
detected for an extended period, the first indications      SPEEDOMETER ASSEMBLY REMOVAL
of a problem are hard shifting and noise.                    (1) Raise vehicle.
  Incorrect or contaminated lubricants also contrib-         (2) Disconnect wires from vehicle speed sensor.
ute to hard shifting. The consequence of using non-          (3) Remove adapter clamp and screw (Fig. 6).




                                        Fig. 6 Speedometer Components
21 - 4    AX 15 MANUAL TRANSMISSION                                                                        ZJ

  (4) Remove speed sensor and speedometer adapter
as assembly.
  (5) Remove speed sensor retaining screw and re-
move sensor from adapter.
  (6) Remove speedometer pinion from adapter.
  (7) Inspect sensor and adapter O-rings (Fig. 6). Re-
move and discard O-rings if worn or damaged.
  (8) Inspect terminal pins in speed sensor. Clean
pins with Mopar electrical spray cleaner if dirty or
oxidized. Replace sensor if faulty, or pins are loose,
severely corroded, or damaged.

SPEEDOMETER INSTALLATION AND
INDEXING
  (1) Thoroughly clean adapter flange and adapter
mounting surface in housing. Surfaces must be clean
for proper adapter alignment and speedometer oper-       Fig. 7 Location Of Index Numbers On Speedometer
ation.                                                                         Adapter
  (2) Install new O-rings on speed sensor and speed-
ometer adapter if necessary (Fig. 6).
  (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 N⅐m
(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. 7).
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-         Fig. 8 Marking Propeller Shaft And Axle Yoke
bers correspond to number of teeth on pinion gear.         (9) Disconnect wires at transfer case electrical
  (10) Install speedometer adapter clamp and retain-     switch.
ing screw. Tighten clamp screw to 10-12 N⅐m (90-110        (10) Support transmission with transmission jack.
in. lbs.) torque.                                        Secure transmission on jack with safety chains.
  (11) Connect wires to vehicle speed sensor.              (11) Support engine with jack positioned under
  (12) Lower vehicle and top off transmission fluid      clutch housing or oil pan flange.
level if necessary.                                        (12) Remove bolts/nuts attaching rear mount to
                                                         crossmember (Fig. 9).
TRANSMISSION REMOVAL                                       (13) Remove rear crossmember.
  (1) Shift transmission into Neutral.
                                                           (14) Remove transfer case attaching nuts and re-
  (2) Raise vehicle on hoist.
                                                         move transfer case from transmission.
  (3) Remove skid plate.
                                                           (15) Lower transmission enough to provide access
  (4) Mark front and rear propeller shafts for instal-
                                                         to shift lever.
lation alignment (Fig. 8). Then remove shafts.
  (5) Disconnect transfer case shift linkage from          (16) Reach up and around transmission case and
shift lever, or range lever.                             unseat shift lever dust boot from transmission shift
  (6) Disconnect harness wires at vehicle speed sen-     tower (Fig. 10). Move boot upward on shift lever for
sor (Fig. 6).                                            access to lever retainer.
  (7) Remove harness wires from clips on transmis-         (17) Disengage transmission shift lever as follows:
sion case.                                                   (a) Reach up and around transmission case and
  (8) Disconnect transmission and transfer case vent       press shift lever retainer downward with your fin-
hoses.                                                     gers.
ZJ                                                                  AX 15 MANUAL TRANSMISSION             21 - 5




         Fig. 9 Transmission Rear Mounting                            Fig. 10 Shift Lever Attachment
    (b) Turn retainer counterclockwise to release it.        (6) Reach up and around transmission and insert
    (c) Lift lever and retainer out of shift tower (Fig.   shift lever in shift tower. Press lever retainer down-
  10). It is not necessary to remove shift lever           ward and turn it clockwise to lock it in place. Then
  from floorpan boot. Simply leave lever in                install lever dust boot on shift tower.
  place for later installation.                              (7) Align transfer case and transmission shafts and
  (18) Disconnect and remove engine timing sensor.         install transfer case. Tighten transfer attaching nuts
Retain sensor attaching screws.                            to 35 N⅐m (26 ft. lbs.) torque.
  (19) Remove clutch slave cylinder from clutch              (8) Move adjustable support stand from under en-
housing. Move cylinder aside for working clearance         gine and reposition it under transmission. Then re-
and access to other components.                            move transmission jack.
  (20) Remove bolts attaching clutch housing to en-          (9) Install rear crossmember. Tighten crossmem-
gine.                                                      ber-to-frame bolts to 41 N⅐m (30 ft. lbs.) torque.
  (21) Pull transmission rearward until clutch hous-       Tighten transmission-to-rear support bolts/nuts to 45
ing is clear of engine. Then remove transmission           N⅐m (33 ft. lbs.) torque.
from under vehicle.                                          (10) Install slave cylinder in clutch housing.
                                                           Tighten cylinder attaching nuts securely.
TRANSMISSION INSTALLATION                                    (11) Connect or install engine timing sensor, if re-
  (1) Mount transmission and clutch housing assem-         moved.
bly on transmission jack. Secure assembly with               (12) Connect transfer case electrical switch wires.
safety chains.                                               (13) Connect transfer case shift rod to range lever.
  (2) Lubricate pilot bearing and transmission input         (14) Connect transmission and transfer case vent
shaft splines with Mopar high temperature grease.          hoses and indicator switch wires.
  (3) Align transmission input shaft and clutch disc         (15) Connect backup light switch wires.
splines and seat clutch housing on engine.
                                                             (16) Connect vehicle speed sensor wires.
  (4) Install and tighten bolts that clutch housing to
                                                             (17) Align and install front/rear propeller shafts.
engine. Tighten bolts to 61 N⅐m (45 ft. lbs.) torque.
                                                           Tighten shaft U-joint clamp bolts to 19 N⅐m (170 in.
  (5) Lower transmission for access to transmission
shift tower.                                               lbs.) torque.
21 - 6      AX 15 MANUAL TRANSMISSION                                                                      ZJ

  (18) Install skid plate if removed. Tighten bolts to   (4) Remove gasket from shift tower (Fig. 3).
42 N⅐m (31 ft. lbs.) torque. Tighten stud nuts to 17
N⅐m (150 in. lbs.) torque.
  (19) Top off transmission and transfer lubricant
levels.
  (20) Lower vehicle.

TRANSMISSION DISASSEMBLY AND OVERHAUL
ADAPTER HOUSING REMOVAL
  (1) Remove release bearing, release lever and re-
lease fork from clutch housing. Then remove clutch
housing from transmission.
  (2) Remove backup light switch. Then remove
drain plug (Fig. 1) and drain transmission lubricant
into pan.


                                                           Fig. 3 Shift Tower Gasket Removal/Installation
                                                         (5) Remove shift arm retainer bolt (Fig. 4).




Fig. 1 Drain Plug And Backup Light Switch Location
  (3) Remove shift tower bolts and remove tower
from adapter or extension housing (Fig. 2).
                                                         Fig. 4 Shift Arm Retainer Bolt Removal/Installation
                                                         (6) Loosen and remove restrictor pins (Fig. 5).




         Fig. 2 Shift Tower Removal/Installation




                                                             Fig. 5 Removing/Installing Restrictor Pins
ZJ                                                             AX 15 MANUAL TRANSMISSION             21 - 7

(7) Remove shift arm shaft plug (Fig. 6).                 (10) Remove plug for reverse shift head lock ball.
                                                       Plug is at right side of adapter housing near backup
                                                       light switch (Fig. 9).




  Fig. 6 Removing/Installing Shift Arm Shaft Plug
                      (4WD)                                 Fig. 9 Removing/Installing Lock Ball Plug
  (8) Remove shift arm shaft with large magnet (Fig.     (11) Remove lock ball spring with pencil magnet
7).                                                    (Fig. 10).




                                                           Fig. 10 Removing/Installing Lock Ball Spring
 Fig. 7 Removing/Installing Shift Arm Shaft (4WD)
                                                         (12) Remove shift head lock ball with pencil mag-
 (9) Remove shift arm (Fig. 8).
                                                       net (Fig. 11).




                                                         Fig. 11 Removing/Installing Shift Head Lock Ball
       Fig. 8 Shift Arm Removal/Installation
21 - 8      AX 15 MANUAL TRANSMISSION                                                             ZJ

                                                   (13) Remove adapter housing bolts (Fig. 12).
                                                   (14) Loosen adapter/extension housing with rubber
                                                  mallet (Fig. 13).




                                                          Fig. 13 Loosening Adapter Housing
                                                   (15) Remove housing after loosening it (Fig. 14)




                                                          Fig. 14 Adapter Housing Removal
                                                    (16) Remove adapter housing oil seal with a pry
                                                  tool (Fig. 15).




                                                       Fig. 15 Removing Adapter Housing Seal
         Fig. 12 Adapter Housing Bolt Locations
ZJ                                                              AX 15 MANUAL TRANSMISSION          21 - 9

GEAR CASE REMOVAL
  (1) Remove bearing retainer bolts and remove re-
tainer (Fig. 16).




                                                          Fig. 18 Removing Input Shaft Bearing Snap Ring


       Fig. 16 Front Bearing Retainer Removal
 (2) Remove retainer oil seal with pry tool (Fig. 17).




                                                         Fig. 19 Removing Cluster Gear Front Bearing Snap
                                                                               Ring



     Fig. 17 Front Bearing Retainer Seal Location
  (3) Remove input shaft bearing snap ring (Fig. 18).
  (4) Remove cluster gear front bearing snap ring
(Fig. 19).
  (5) Loosen gear case by tapping it away from inter-
mediate plate with rubber mallet (Fig. 20).




                                                                   Fig. 20 Loosening Gear Case
21 - 10    AX 15 MANUAL TRANSMISSION                                                                    ZJ

  (6) Remove gear case from geartrain and interme-       (2) Remove three lock ball springs and lock balls
diate plate (Fig. 21).                                 from intermediate plate with pencil magnet (Fig. 23).
  (7) Remove speedometer gear snap ring and re-
move speedometer gear and spacer from output
shaft.




            Fig. 21 Gear Case Removal
FIFTH GEAR AND SYNCHRO ASSEMBLY
REMOVAL
  (1) Remove three lock ball plugs from intermediate
plate (Fig. 22).




                                                        Fig. 23 Removing/Installing Lock Ball And Spring




          Fig. 22 Lock Ball Plug Locations
ZJ                                                              AX 15 MANUAL TRANSMISSION          21 - 11




                          Fig. 24 Mounting Intermediate Plate And Geartrain In Vise
  (3) Mount intermediate plate and geartrain assem-        (5) Remove E-ring that secures reverse shift arm
bly in vise as follows:                                  to fork (Fig. 26).
    (a) Insert two spare bolts in one bottom bolt hole
  in intermediate plate. Insert bolts from opposite
  sides of plates (Fig. 24).
    (b) Install enough flat washers under each bolt
  head to prevent bolts from touching (Fig. 24).
    (c) Tape bolts and washers in place and mount
  intermediate plate in vise (Fig. 24).
    (d) Clamp vise jaws securely against bolt heads
  (Fig. 24). Do not clamp vise jaws on intermedi-
  ate plate. Clamp only on bolt heads.
  (4) Remove fifth gear snap ring (Fig. 25). Retain
snap ring for assembly reference. It is a select fit
component.



                                                             Fig. 26 Reverse Shift Arm E-Ring Removal




       Fig. 25 Fifth Gear Snap Ring Removal
21 - 12     AX 15 MANUAL TRANSMISSION                                                                     ZJ

  (6) Remove bolts attaching reverse shift arm
bracket to intermediate plate. Then remove bracket
(Fig. 27).




                                                             Fig. 29 Fifth Gear Fork Set Screw Removal


    Fig. 27 Reverse Shift Arm Bracket Removal
  (7) Remove reverse shift arm and shoe (Fig. 28).




                                                               Fig. 30 Fifth Gear Shift Fork Removal




   Fig. 28 Reverse Shift Arm And Shoe Removal
   (8) Remove fifth gear shift fork set screw (Fig. 29).
   (9) Move fifth gear shift rail forward until it clears
shift fork.
   (10) Remove fifth gear shift fork from synchro
sleeve (Fig. 30).
   (11) Remove reverse shift rail and reverse shift
head as assembly (Fig. 31).
   (12) Measure thrust clearance between counter
fifth gear and thrust ring with feeler gauge. Clear-
ance should be 0.10 to 0.40 mm (0.003 to 0.019 in.).
If clearance exceeds limits, gear and/or ring will have
to be replaced.                                             Fig. 31 Reverse Shift Head And Rail Removal
ZJ                                                            AX 15 MANUAL TRANSMISSION           21 - 13

  (13) Loosen fifth spline gear with standard two-jaw
puller (Fig. 32). Position puller jaws behind fifth
counter gear as shown.




                                                            Fig. 34 Fifth Gear Synchro Ring Removal



        Fig. 32 Loosening Fifth Spline Gear
 (14) Remove fifth spline gear (Fig. 33).




                                                        Fig. 35 Counter Fifth Gear And Synchro Assembly
                                                                             Removal



         Fig. 33 Fifth Spline Gear Removal
  (15) Remove fifth gear synchro ring (Fig. 34).
  (16) Remove fifth gear synchro and sleeve assem-
bly (Fig. 35).
  (17) Remove counter fifth gear thrust ring (Fig.
36).




                                                             Fig. 36 Fifth Gear Thrust Ring Removal
21 - 14    AX 15 MANUAL TRANSMISSION                                                                 ZJ

  (18) Remove thrust ring lock ball with pencil mag-
net (Fig. 37).




                                                       Fig. 39 Output Shaft Rear Bearing Retainer Removal


      Fig. 37 Thrust Ring Lock Ball Removal
  (19) Remove bolts attaching output shaft rear
bearing retainer to intermediate plate (Fig. 38).




                                                          Fig. 40 Reverse Idler Gear And Shaft Removal




  Fig. 38 Output Shaft Rear Bearing Retainer Bolt
                     Removal
 (20) Remove rear bearing retainer (Fig. 39).
 (21) Remove reverse idler gear and shaft (Fig. 40).
ZJ                                                                  AX 15 MANUAL TRANSMISSION             21 - 15




                                         Fig. 41 Shift Rail Identification
SHIFT RAIL AND FORK REMOVAL
  There are a total of five shift rails in the AX 15
transmission. The 1-2, 3-4, fifth gear and front re-
verse shift rails are shown in Figure 41.
  Two shift rails are used for reverse gear range. The
front reverse rail is at the forward side of the inter-
mediate plate (Fig. 41). The short rear reverse rail
and reverse shift head are at the rear side of the in-
termediate plate.
  It is not necessary to remove the shift rails if
they are in good condition. Only the shift forks
need be removed for access to the shafts and
gears.
  (1) Remove fifth gear shift rail (Fig. 41). Catch lock
ball in your hand as rail comes out of intermediate
plate.
  (2) Remove 1-2 and 3-4 shift rail C-rings with two
screwdrivers of equal size and length (Fig. 42).




                                                                      Fig. 42 Shift Rail C-Ring Removal
21 - 16      AX 15 MANUAL TRANSMISSION                                                                      ZJ

 (3) Remove shift fork set screws (Fig. 43).             (6) Remove 1-2 shift rail from shift fork and inter-
                                                        mediate plate (Fig. 46).




          Fig. 43 Shift Fork Set Screw Removal                    Fig. 46 Removing 1-2 Shift Rail
 (4) Remove 3-4 shift rail from shift fork and inter-     (7) Remove 1-2 shift rail interlock pin from shift
mediate plate (Fig. 44).                                rail (Fig. 47).




                                                            Fig. 47 Removing 1-2 Shift Rail Interlock Pin
             Fig. 44 Removing 3-4 Shift Rail
                                                         (8) Remove 1-2 shift rail interlock plug from inter-
 (5) Remove 3-4 shift rail interlock plug from inter-
                                                        mediate plate (Fig. 48).
mediate plate with magnet (Fig. 45).




                                                           Fig. 48 Removing 1-2 Shift Rail Interlock Plug
   Fig. 45 Removing 3-4 Shift Rail Interlock Plug
ZJ                                                         AX 15 MANUAL TRANSMISSION           21 - 17

  (9) Lift reverse shift fork upward and remove fifth
gear shift rail lock ball (Fig. 49).




  Fig. 49 Fifth Gear Shift Rail Lock Ball Removal
 (10) Remove 3-4 shift fork (Fig. 50).
 (11) Remove 1-2 shift fork (Fig. 50).




                                                         Fig. 51 Reverse Shift Rail C-Ring Removal




                                                        Fig. 52 Reverse Shift Rail And Fork Removal




             Fig. 50 Shift Fork Removal
  (12) Remove reverse shift rail C-ring with two
equal length and size screwdrivers (Fig. 51).
  (13) Remove reverse shift rail and fork (Fig. 52).
21 - 18     AX 15 MANUAL TRANSMISSION                                                                          ZJ

  (14) Remove interlock pin from reverse shift rail           (3) Tap end of output shaft with mallet to unseat and
(Fig. 53).                                                  start rear bearing out of intermediate plate (Fig. 55).
  (15) Position shift rails, shift forks, lock balls, in-
terlock plugs and interlock pins on the workbench in
order of removal. This will help in identifying compo-
nents during inspection and assembly.




                                                                Fig. 55 Unseating Output Shaft Rear Bearing
                                                              (4) Remove output shaft by rocking it lightly until
                                                            rear bearing comes out of intermediate plate (Fig. 56).
  Fig. 53 Reverse Shift Rail Interlock Pin Removal
OUTPUT SHAFT AND CLUSTER GEAR
REMOVAL
  (1) Remove output shaft rear bearing snap ring
(Fig. 54).
  (2) Remove cluster gear rear bearing snap ring
(Fig. 54).




                                                                  Fig. 56 Input And Output Shaft Removal
                                                              (5) Remove cluster gear by pulling it straight out
                                                            of rear bearing (Fig. 57).




                                                                        Fig. 57 Cluster Gear Removal
       Fig. 54 Removing Bearing Snap Rings
ZJ                                                            AX 15 MANUAL TRANSMISSION              21 - 19

  (6) Remove cluster gear rear bearing from interme-     (9) Remove synchro ring from input shaft (Fig. 61).
diate plate (Fig. 58).                                   (10) Remove bearing snap ring and press bearing
                                                       off input shaft (Fig. 61).




     Fig. 58 Removing Cluster Gear Rear Bearing
                                                                 Fig. 61 Input Shaft Components
 (7) Remove input shaft from output shaft (Fig. 59).
                                                       OUTPUT SHAFT DISASSEMBLY
                                                         (1) Measure thrust clearance of output shaft first,
                                                       second and third gears with feeler gauge (Fig. 62).
                                                       • First gear clearance should be 0.10 to 0.40 mm
                                                       (0.003 to 0.0197 in).
                                                       • Second-third gear clearance should be 0.10 to 0.30
                                                       mm (0.003 to 0.0118 in.).
                                                         (2) If first gear thrust clearance is incorrect, re-
                                                       place gear and thrust washer. If second or third
                                                       gear clearance is incorrect, either gear and
                                                       bearing, or output shaft flange is worn. Refer to
                                                       output shaft inspection in Cleaning and Inspec-
                                                       tion section.




            Fig. 59 Input Shaft Removal
  (8) Remove output shaft pilot bearing from input
shaft (Fig. 60).




                                                           Fig. 62 Checking Output Shaft Gear Thrust
      Fig. 60 Input Shaft Pilot Bearing Removal                            Clearance
21 - 20    AX 15 MANUAL TRANSMISSION                                                                     ZJ




                                      Fig. 63 Output Shaft And Gears
  (3) Press fifth gear and rear bearing off rear of       Inspect the transmission case. Replace the case if
output shaft.                                           cracked or porous or if any of the bearing and gear
  (4) Remove thrust washer, pin, and first gear and     bores are damaged.
bearing (Fig. 62).
  (5) Remove first/reverse hub snap ring (Fig. 63).     Output Shaft Inspection
  (6) Remove synchro ring.                                Measure thickness of the output shaft flange with
  (7) Press reverse gear and first/reverse hub off      a micrometer (Fig. 64). Minimum allowable flange
shaft as assembly.                                      thickness is 4.70 mm (0.185 in).
  (8) Remove remaining synchro ring and second            If shaft flange thickness is OK but previously
gear and bearing (Fig. 63).                             measured second/third gear thrust clearance
  (9) Remove snap ring at front of output shaft (Fig.   was incorrect (Fig. 62), replace the necessary
63).                                                    gear and needle bearing as an assembly.
  (10) Press 3-4 hub and sleeve off output shaft as       Check diameter of the first, second and third gear
assembly (Fig. 63).                                     bearing surfaces of the output shaft (Fig. 64). Mini-
  (11) Remove synchro ring.                             mum allowable diameters are:
  (12) Remove third gear and needle bearing (Fig.       • 38.86 mm (1.529 in.) for first gear surface
63).                                                    • 46.86 mm (1.844 in.) for second gear surface
                                                        • 37.86 mm (1.490 in.) for third gear surface
TRANSMISSION CLEANING AND INSPECTION                      Check output shaft runout with V-blocks and a dial
  Clean the transmission components in solvent.         indicator (Fig. 64). Maximum allowable runout is
Then dry the cases, gears, shift mechanism and          0.06 mm (0.0024 in.).
shafts with compressed air. Dry the bearings with         Replace the output shaft if any surface measured
clean, dry shop towels only. Never use com-             fails to meet stated tolerance.
pressed air on the bearings. This could damage
the bearing rollers.                                    Cluster Gear Inspection
  Replace components that are obviously worn,             Inspect the cluster gear teeth. Replace the gear if
cracked, chipped or damaged.                            any teeth are worn or damaged or if the bearing sur-
                                                        faces are damaged.
ZJ                                                           AX 15 MANUAL TRANSMISSION              21 - 21

                                                      GEAR AND SYNCHRO INSPECTION
                                                        Install the synchro rings on their respective gears.
                                                      Rotate each ring on the gear and note synchro action.
                                                      Replace any synchro ring that exhibits a lack of
                                                      braking action or binds on the gear. Also replace any
                                                      ring that is worn or has chipped or broken teeth.
                                                        Measure end clearance between the synchro ring
                                                      and the gear with a feeler gauge (Fig. 66). Clearance
                                                      should be 0.06 mm to 1.6 mm (0.024 to 0.063 in.).




                                                         Fig. 66 Checking Synchro Ring End Clearance
                                                        Install the needle bearings in the first, second and
                                                      third gears. Then install the gears on the output
                                                      shaft and check shaft-to-gear clearance with a dial
                                                      indicator (Fig. 67).

     Fig. 64 Checking Output Shaft Tolerances
  Check diameter of the cluster gear journal with a
micrometer (Fig. 65). Minimum allowable diameter is
27.860 mm (1.096 in.).




  Fig. 65 Checking Cluster Gear Journal Diameter
 Check condition of the cluster gear front bearing.
Replace the bearing if worn, noisy, or damaged.

                                                           Fig. 67 Checking Gear-To-Shaft Clearance
21 - 22     AX 15 MANUAL TRANSMISSION                                                                        ZJ

  Maximum allowable clearance is 0.16 mm (0.0063            Inspect the threads in the case, housing and plate.
in.). If any gear exhibits excessive clearance, replace   Minor thread damage can be repaired with steel
the gear and needle bearing.                              thread inserts if necessary. However, do not attempt
  Check clearance between the shift forks and syn-        to repair if the cracks are evident around any
chro sleeves with a feeler gauge (Fig. 68). Clearance     threaded hole.
should not exceed 1.0 mm (0.039 in.). Replace the           Inspect the reverse pin in the adapter/extension
synchro sleeve (and matching hub) if clearance ex-        housing. Replace the pin if worn or damaged. Refer
ceeds the stated limit.                                   to the replacement procedure in the Transmission As-
                                                          sembly section.

                                                          TRANSMISSION ASSEMBLY AND ADJUSTMENT
                                                            Lubricate the transmission components with gear
                                                          lubricant during assembly. Use petroleum jelly to lu-
                                                          bricate seal lips and/or hold parts in place during in-
                                                          stallation.

                                                          FRONT BEARING/BEARING SEAL/REVERSE
                                                          SHAFT PIN INSTALLATION
                                                            (1) Press front bearing on input shaft. Then secure
                                                          bearing with thickest snap ring that will fit in shaft
                                                          groove (Fig. 70).




  Fig. 68 Checking Shift Fork-To-Sleeve Clearance
  Check condition of the reverse idler gear bushing
(Fig. 69). Replace the gear if the bushing is scored or
worn.




                                                            Fig. 70 Selecting Input Shaft Front Bearing Snap
                                                                                  Ring
                                                            (2) Press front bearing on cluster gear. Then se-
                                                          cure bearing with thickest snap ring that will fit in
                                                          ring groove on gear (Fig. 71).
                                                            (3) Install new oil seals in front bearing retainer
                                                          and adapter housing (Fig. 72). Installation depth for
          Fig. 69 Reverse Idler Gear Bushing              bearing retainer seal is 10.5 to 11.5 mm (0.414 to
Gear Case, Housing And Intermediate Plate                 0.453 in.).
                                                            (4) Install reverse shaft and shaft retaining pin in
  Clean the case, housing and plate with solvent and
                                                          adapter housing. Then install access hole plug with
dry with compressed air. Replace any component that
                                                          torx bit (Fig. 73).
is cracked, warped or damaged in any way.
ZJ                                                          AX 15 MANUAL TRANSMISSION               21 - 23




 Fig. 71 Selecting Cluster Gear Front Bearing Snap           Fig. 73 Installing Reverse Shaft Pin
                        Ring
                                                     OUTPUT SHAFT ASSEMBLY
                                                       (1) Lubricate output shaft journals, gears and nee-
                                                     dle bearings with recommended gear lubricant.
                                                       (2) Install third gear and needle bearing on shaft
                                                     (Fig. 63)
                                                       (3) Install synchro ring on third gear (Fig. 63).
                                                       (4) Assemble 1-2 and 3-4 synchro hubs and sleeves
                                                     (Fig.74).




                                                        Fig. 74 Synchro Sleeve And Hub Identification



            Fig. 72 Oil Seal Installation
 (5) Lubricate reverse shaft and gear components
with Mopar 75W-90 gear lubricant.
21 - 24    AX 15 MANUAL TRANSMISSION                                                                         ZJ

  (5) Install inserts and springs in synchro sleeves.
Position open ends of springs 180° apart as shown
(Fig. 75).




                                                                Fig. 77 Checking Third Gear Clearance
           Fig. 75 Insert Spring Position                  (12) Assemble first/reverse hub, insert springs, in-
                                                         serts, reverse gear and 1-2 sleeve (Fig. 78). Be sure
  (6) Install 3-4 synchro hub and sleeve on output
                                                         spring ends are 180° apart. Note that splines in
shaft. Press hub onto shaft if necessary.
                                                         hub bore are chamfered on one side. Install
  (7) Install 3-4 synchro hub snap ring (Fig. 76). Use
                                                         hub so chamfered side faces front of output
thickest snap ring that will fit in shaft groove.        shaft.
                                                           (13) Press assembled hub and sleeve on output
                                                         shaft.
                                                           (14) Install selective snap ring (Fig. 78). Use thick-
                                                         est snap ring that will fit in output shaft groove.




   Fig. 76 Installing 3-4 Synchro Hub Snap Ring
  (8) Verify third gear thrust clearance with feeler
gauge (Fig. 56). Clearance should be 0.10 to 0.25 mm
(0.004 to 0.010 in.).
  (9) Lubricate remaining output shaft gears and             Fig. 78 Second Gear And Synchro Assembly
bearings with gear lubricant.
                                                           (15) Install synchro ring on first gear (Fig. 79).
  (10) Install second gear and needle bearing on           (16) Install first gear spacer on shaft and against
shaft (Fig. 78).                                         selective fit snap ring (Fig. 79).
  (11) Install synchro ring on second gear (Fig. 78).      (17) Install first gear and needle bearing (Fig. 79)
                                                         on output shaft.
ZJ                                                                  AX 15 MANUAL TRANSMISSION              21 - 25

  (18) Install locating pin and thrust washer on              (22) Lubricate input shaft pilot bearing with petro-
shaft (Fig. 79).                                            leum jelly and install bearing in shaft (Fig. 60).
                                                              (23) Install input shaft on output shaft (Fig. 59). Be
                                                            sure output shaft hub is fully seated in pilot bearing.

                                                            OUTPUT SHAFT AND CLUSTER GEAR
                                                            INSTALLATION
                                                              (1) Mount intermediate plate in vise (Fig. 24).
                                                              (2) Lubricate cluster gear journal and rear bearing
                                                            with petroleum jelly or gear lubricant.
                                                              (3) Install cluster gear rear bearing in intermedi-
                                                            ate plate (Fig. 81). Be sure snap ring groove in bear-
                                                            ing is rearward as shown.




      Fig. 79 First And Fifth Gear Components
  (19) Press rear bearing on shaft. Position bearing
snap ring groove so it is closest to end of output shaft.
  (20) Check first and second gear thrust clearance
with feeler gauge (Fig. 62).
• First gear clearance should be 0.10 to 0.40 mm
(0.003 to 0.0197 in.)
• Second gear clearance should be 0.10 to 0.30 mm
(0.003 to 0.0118 in.)
  (21) Press fifth gear onto output shaft. Then install
select fit snap ring (Fig. 80). Use thickest snap ring
that will fit in shaft groove.
                                                                Fig. 81 Installing Cluster Gear Rear Bearing
                                                              (4) Start cluster gear into bearing (Fig. 57). Then
                                                            hold bearing and push gear into place. Use plastic or
                                                            rawhide mallet to seat bearing if necessary.
                                                              (5) Start output shaft rear bearing in intermediate
                                                            plate. Push shaft rearward and tap intermediate
                                                            plate with mallet to seat bearing.
                                                              (6) Install snap rings on cluster and output shaft
                                                            rear bearings only (Fig. 82). Do not install front
                                                            bearing snap rings at this time.




       Fig. 80 Selecting Fifth Gear Snap Ring                    Fig. 82 Installing Rear Bearing Snap Rings
21 - 26    AX 15 MANUAL TRANSMISSION                                                                        ZJ




  Fig. 83 Installing Reverse Idler Gear And Shaft               Fig. 84 Installing Rear Bearing Retainer
  (7) Install reverse idler gear and shaft (Fig. 83).    SHIFT RAIL AND FORK INSTALLATION
  (8) Position rear bearing retainer over output shaft     The shift rail interlock pins, balls and plugs must
and rear bearing. Be sure bearing retainer tab is        be installed in the correct sequence for proper shift-
engaged in reverse idler shaft notch (Fig. 84).          ing. Refer to the installation diagram (Fig. 85) during
  (9) Install and tighten rear bearing retainer bolts    assembly.
to 18 N⅐m (13 ft-lbs).                                     Coat the intermediate plate shift rail bores
                                                         and the interlock balls, pins and plugs with a
                                                         thick covering of petroleum jelly before assem-




                                   Fig. 85 Shift Rail Ball-Plug-Pin Position
ZJ                                                               AX 15 MANUAL TRANSMISSION               21 - 27

bly. The jelly will hold the interlock compo-
nents in place making installation easier. Use a
pencil magnet to hold and insert the interlocks.
Then use a small screwdriver to push the inter-
lock components into place.
  (1) Coat reverse rail interlock pin with petroleum
jelly and install pin in rail (Fig. 86).
  (2) Install reverse shift rail in intermediate plate
(Fig. 87).
  (3) Install reverse shift rail C-ring (Fig. 51).




  Fig. 86 Installing Reverse Shift Rail Interlock Pin
                                                                      Fig. 88 Shift Fork Installation




     Fig. 87 Installing Reverse Shift Rail And Fork
  (4) Position 1-2 and 3-4 shift forks in synchro            Fig. 89 Installing Reverse Shift Rail Lock Ball
sleeves (Fig. 88).                                          (9) Coat 3-4 shift rail interlock plug with petro-
  (5) Coat reverse rail lock ball with petroleum jelly.   leum jelly and install plug in intermediate plate (Fig.
Then tilt reverse shift fork upward and insert ball in    93).
intermediate plate (Fig. 89).                               (10) Install 3-4 shift rail in intermediate plate and
  (6) Coat 1-2 shift rail interlock plug with petro-      in both shift forks (Fig. 94).
leum jelly and install it in intermediate plate bore        (11) Verify that none of the interlock balls, plugs,
(Fig. 90).                                                or pins were displaced during shift rail installation.
  (7) Coat 1-2 shift rail interlock pin with petroleum      (12) Install and tighten shift fork setscrews to 20
jelly and insert it in shift rail (Fig. 91).              N⅐m (14 ft. lbs.) torque (Fig. 95).
  (8) Install 1-2 shift rail in intermediate plate and
1-2 fork (Fig. 92).
21 - 28    AX 15 MANUAL TRANSMISSION                                                                     ZJ




   Fig. 90 Installing 1-2 Shift Rail Interlock Plug   Fig. 93 Installing 3-4 Shift Rail Interlock Plug




    Fig. 91 Installing 1-2 Shift Rail Interlock Pin          Fig. 94 Installing 3-4 Shift Rail




           Fig. 92 Installing 1-2 Shift Rail             Fig. 95 Installing Shift Fork Set Screws
ZJ                                                              AX 15 MANUAL TRANSMISSION            21 - 29

  (13) Install 1-2 and 3-4 shift rail C-rings (Fig. 96).
  (14) Insert fifth gear shift rail through reverse
shift fork. Then slide rail into intermediate plate
just far enough to secure interlock ball. Do not
fully install shift rail at this time.




                                                              Fig. 98 Installing Fifth Gear Thrust Ring




         Fig. 96 Installing Shift Rail C-Rings
FIFTH-REVERSE GEAR AND SHIFT
COMPONENT INSTALLATION
  (1) Install thrust ring lock ball in cluster gear jour-
nal (Fig. 97). Use petroleum jelly to hold ball in
place.
  (2) Install fifth gear thrust ring (Fig. 98). Be sure
thrust ring notch fits over lock ball.




                                                             Fig. 99 Assembling Fifth Gear And Synchro
                                                                             Assembly




       Fig. 97 Installing Thrust Ring Lock Ball
  (3) Assemble counter fifth gear, synchro sleeve, in-
serts and insert springs (Fig. 99).
  (4) Lubricate two-piece bearing with petroleum
jelly and install it in counter fifth gear (Fig. 100).
                                                            Fig. 100 Installing Counter Fifth Gear Bearing
21 - 30     AX 15 MANUAL TRANSMISSION                                                                             ZJ

  (5) Install counter fifth gear and synchro assembly       (8) Install fifth gear selective snap ring (Fig. 104).
on cluster gear journal (Fig. 101).                        Use thickest snap ring that will fit in shaft groove.




 Fig. 101 Installing Counter Fifth Gear And Sleeve
 (6) Install synchro ring in synchro sleeve (Fig. 102).




                                                                  Fig. 104 Installing Fifth Gear Snap Ring
                                                            (9) Install reverse shift head and rail (Fig. 105).
                                                           Then install lock ball in shift head.


     Fig. 102 Installing Fifth Gear Synchro Ring
  (7) Install fifth spline gear on cluster journal (Fig.
103). Tap spline gear into place with plastic mallet if
necessary.




                                                              Fig. 105 Installing Reverse Shift Head And Rail
                                                             (10) Position fifth gear shift fork in synchro sleeve
                                                           (Fig. 106).
                                                             (11) Install fifth gear shift rail (Fig. 107). Slide rail
                                                           through fork, shift head, intermediate plate and re-
                                                           verse shift fork. Be sure interlock ball is not dis-
          Fig. 103 Installing Fifth Spline Gear            placed during installation.
ZJ                                                               AX 15 MANUAL TRANSMISSION             21 - 31




      Fig. 106 Fifth Gear Shift Fork Installation




                                                              Fig. 109 Detent Ball And Spring Installation
                                                            (14) Install reverse shift arm bracket (Fig. 110).
                                                          Tighten bracket bolts to 18 N⅐m (13 ft. lbs.) torque.
                                                            (15) Install reverse shift arm (Fig. 110). Position
      Fig. 107 Fifth Gear Shift Rail Installation         arm on reverse fork pin and engage it with pin on
                                                          shift arm bracket.
  (12) Align screw holes in shift fork and rail and in-
                                                            (16) Verify that shift arm shoe is engaged in re-
stall set screw (Fig. 108). Tighten screw to 20 N⅐m
                                                          verse idler gear. Then secure shift arm to pin on re-
(15 ft. lbs.) torque.
                                                          verse fork with new E-clip.




      Fig. 108 Shift Fork Set Screw Installation
  (13) Install lock balls and springs in intermediate     Fig. 110 Reverse Shift Arm And Bracket Installation
plate (Fig. 109). Then install and tighten lock ball      GEAR CASE AND ADAPTER INSTALLATION
plugs to 19 N⅐m (14 ft. lbs.) torque.                       (1) Dismount intermediate plate and gear assem-
                                                          blies from vise.
21 - 32     AX 15 MANUAL TRANSMISSION                                                                          ZJ

  (2) Clean mating surfaces of intermediate plate
and transmission gear case with wax and grease re-
mover. Then wipe dry with a clean cloth.
  (3) Apply 3 mm (1/8 in.) wide bead of Mopar Gas-
ket Maker, or Loctite 518 to mating surface of gear
case. Keep sealer bead inside bolt holes as shown
(Fig. 111).




                                                               Fig. 113 Front Bearing Snap Ring Installation
       Fig. 111 Applying Sealer To Gear Case                  (10) Align and install front bearing retainer (Fig.
  (4) Install gear case (Fig. 112). Align shift rails and   114). Be sure retainer is properly seated on case and
bearings in case and tap case into position.                bearings.
  (5) Verify that gear case is seated on intermediate
plate dowel pins.




                                                                 Fig. 114 Installing Front Bearing Retainer
                                                              (11) Install and tighten front bearing retainer bolts
           Fig. 112 Gear Case Installation                  to 17 N⅐m (12 ft. lbs.) torque.
  (6) Install front bearing snap rings (Fig. 113).            (12) On models with extension housing, install
  (7) Clean gear case and front bearing retainer seal-      speedometer gear, lock ball and retaining rings (Fig.
ing surfaces with wax and grease remover. Then              115). Be sure lock ball is engaged in gear.
wipe dry with a clean cloth.                                  (13) Inspect condition of reverse pin in adapter/ex-
  (8) Install new seal in front bearing retainer. Then      tension housing (Fig. 116). If pin is worn or damaged,
lubricate seal lip with petroleum jelly. Installation       replace it as follows:
depth for seal is 10.5 to 11.5 mm (0.413 to 0.453               (a) Remove roll pin access plug (Fig. 117).
in.).                                                           (b) Tap roll pin out of housing with pin punch
  (9) Apply a 3 mm (1/8 in.) wide bead of Mopar               (Fig. 118). Then remove old reverse pin.
Gasket Maker, or Loctite 518 to front bearing re-
tainer sealing surface.
ZJ                                                              AX 15 MANUAL TRANSMISSION                21 - 33




     Fig. 115 Speedometer Gear Installation (2WD                Fig. 118 Roll Pin Removal/Installation
                      Models)                              (14) Clean sealing surfaces of adapter or extension
                                                         housing and intermediate plate with wax and grease
                                                         remover. Then wipe dry with a clean cloth.
                                                           (15) Apply 3 mm (1/8 in.) wide bead of Mopar Gas-
                                                         ket Maker, or Loctite 518 to sealing surface of
                                                         adapter or extension housing. Keep sealer bead in-
                                                         side bolt holes as shown in Figure 111.
                                                           (16) Align and install adapter or extension housing
                                                         on intermediate plate (Fig. 119). Be sure housing is
                                                         seated on intermediate plate dowel pins.
                                                           (17) Coat threads of housing attaching bolts with
                                                         Mopar silicone sealer. Then install and tighten bolts
                                                         to 37 N⅐m (27 ft. lbs.) torque.




            Fig. 116 Reverse Pin Position




                                                           Fig. 119 Adapter/Extension Housing Installation
                                                           (18) Install detent ball (Fig. 120).
                                                           (19) Install detent spring (Fig. 121).
                                                           (20) Install detent access plug (Fig. 122). Tighten
                                                         plug to 19 N⅐m (14 ft. lbs.) torque.
      Fig. 117 Access Plug Removal/Installation            (21) Lubricate shift arm shaft and install it in
   (c) Install new reverse pin and secure it with roll   adapter housing (Fig. 123).
 pin. Then install and tighten access plug to 19 N⅐m       (22) Position shift arm in adapter housing (Fig.
 (14 ft. lbs.) torque.                                   124). Be sure arm is engaged in shift rails.
                                                           (23) Align shift arm with shaft and push shaft into
                                                         arm.
21 - 34    AX 15 MANUAL TRANSMISSION                                                                      ZJ




           Fig. 120 Installing Detent Ball                        Fig. 123 Installing Shift Arm Shaft




          Fig. 121 Installing Detent Spring                         Fig. 124 Shift Arm Installation
                                                           (26) Install and tighten restrictor pins to 19 N⅐m
                                                         (14 ft. lbs.) torque (Fig. 125).




       Fig. 122 Installing Detent Access Plug
  (24) Rotate shift arm shaft until set screw holes in
shaft and arm are aligned.                                Fig. 125 Set Screw And Restrictor Pin Installation
  (25) Install and tighten shift arm set screw to 38
N⅐m (28 ft. lbs.) torque (Fig. 125).
ZJ                                                          AX 15 MANUAL TRANSMISSION              21 - 35

  (27) Install and tighten shift arm shaft access plug
to 19 N⅐m (14 ft. lbs.) torque (Fig. 126).




                                                           Fig. 127 Shift Tower Gasket Installation

          Fig. 126 Access Plug Installation
  (28) Position new shift tower gasket on adapter
housing (Fig 127).
  (29) Install shift tower (Fig. 128). Tighten tower
attaching bolts to 18 N⅐m (13 ft. lbs.) torque.
  (30) Install new gasket on backup light switch and
install switch. Tighten switch to 37 N⅐m (27 ft. lbs.)
torque.
  (31) Install new washer on drain plug. Then install
and tighten plug to 37 N⅐m (27 ft. lbs.) torque.
  (32) If transmission will be filled with gear lubri-
cant before installation, place transmission in a level
position. Then fill with Mopar 75W-90, grade GL-5
gear lubricant.
                                                               Fig. 128 Shift Tower Installation
  (33) Install new washer on fill plug. Then install
and tighten plug to 37 N⅐m (27 ft. lbs.) torque.
  (34) Install clutch housing and hydraulic concen-
tric bearing.
  (35) On models with extension housing, install new
seal in housing with suitable size installer tool (Fig.
129). Lubricate seal lips with petroleum jelly before
installation.
  (36) On models with extension housing, install
speedometer driven gear, speedometer adapter and
speed sensor.




                                                          Fig. 129 Installing Extension Housing Seal
21 - 36       42RE AUTOMATIC TRANSMISSION                                                                                                                                                              ZJ

                                         42RE AUTOMATIC TRANSMISSION


                                                                                       CONTENTS

                                                                                           page                                                                                                    page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . 36                                            42RE TRANSMISSION OVERHAUL . . . . . . . . . . 98
42RE TRANSMISSION DIAGNOSIS . . . . . . . . . . 42                                                  42RE TRANSMISSION/OVERDRIVE
42RE OVERDRIVE UNIT OVERHAUL . . . . . . . . 146                                                     REMOVAL AND INSTALLATION . . . . . . . . . . . 89
42RE IN-VEHICLE SERVICE . . . . . . . . . . . . . . . 77



                                                       GENERAL INFORMATION


                                                                                               INDEX
                                                                                           page                                                                                                    page

Converter Clutch Engagement . .              ...   .   .   .   .   .   .   .   .   .   .   .   40   Recommended Fluid . . . . . . . . .        . . . . . . . . . . . . . . 38
Converter Drainback Valve . . . .            ...   .   .   .   .   .   .   .   .   .   .   .   40   Torque Converter . . . . . . . . . . .     . . . . . . . . . . . . . . 38
Electronic Governor Components                ..   .   .   .   .   .   .   .   .   .   .   .   38   Transmission Changes and Parts
Gear Ratios . . . . . . . . . . . . . . .    ...   .   .   .   .   .   .   .   .   .   .   .   38     Interchangeability . . . . . . . . . .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   41
Governor Pressure Curves . . . .             ...   .   .   .   .   .   .   .   .   .   .   .   40   Transmission Description . . . . . .       .   .   .   .   .   .   .   .   .   .   .   .   .   .   36
Overdrive Off Switch . . . . . . . . .       ...   .   .   .   .   .   .   .   .   .   .   .   40   Transmission Identification . . . .        .   .   .   .   .   .   .   .   .   .   .   .   .   .   38
Quick Fill Valve . . . . . . . . . . . . .   ...   .   .   .   .   .   .   .   .   .   .   .   40   Transmission Shifting . . . . . . . .      .   .   .   .   .   .   .   .   .   .   .   .   .   .   40

TRANSMISSION DESCRIPTION                                                                              The overdrive clutch is applied in fourth gear only.
  The Chrysler 42RE is a 4-speed, fully automatic                                                   The direct clutch is applied in all ranges except
transmission with an electronic governor. It is used                                                fourth gear.
with 4.0L engines.                                                                                    The 42RE valve body transfer plate is different. It
  Mechanical and hydraulic components in the 42RE                                                   is designed to accept a governor body and different
are similar to those in RH series transmissions. The                                                hydraulic circuitry. The governor pressure solenoid
main difference involves the method of producing                                                    valve and sensor are mounted in this body. The
governor pressure for shift control. The 42RE uses                                                  transfer plate channels line pressure to the solenoid
electronic components to develop governor pressure.                                                 valve through the governor body. It also channels
A mechanical governor is used to generate governor                                                  governor pressure from the solenoid valve to the gov-
pressure in the RH series.                                                                          ernor circuit. It is the solenoid valve that develops
  First through third gear ranges are provided by the                                               necessary governor pressure.
clutches, bands, overrunning clutch and planetary                                                     The 42RE overdrive unit is different from previous
gear sets in the transmission unit. Fourth gear range                                               overdrive units. It is shorter in length as a result of
is provided by the overdrive unit which contains an
                                                                                                    eliminating the mechanical governor assembly in-
overdrive clutch, direct clutch, planetary gear set and
                                                                                                    cluding the governor tubes and governor support.
overrunning clutch.
ZJ
                                                   42RE AUTOMATIC TRANSMISSION




Fig. 1 42RE Automatic Transmission (4 x 2 Model)
                                                   21 - 37
21 - 38    42RE AUTOMATIC TRANSMISSION                                                                      ZJ

TORQUE CONVERTER
  A three element torque converter is used for all ap-
plications (Fig. 1). Converter elements consist of the
turbine, stator and impeller. The converter also con-
tains an overrunning clutch and a converter clutch
mechanism.
  The converter clutch is an electronically controlled
mechanism. The clutch provides reduced engine
speed and greater fuel economy when engaged.
Clutch engagement also provides reduced transmis-
sion fluid temperatures.
  The converter clutch is engaged in fourth gear and
in third gear when the overdrive control switch is in
the OFF position.
  An overrunning clutch is mounted in the stator
hub. This one-way clutch prevents the stator from
                                                             Fig. 2 Transmission Identification Number And
turning in a direction opposite to engine rotation.
                                                                            Code Location
This retains the torque multiplication feature of the
converter.                                               •   governor pressure sensor
  The torque converter is not a serviceable compo-       •   fluid temperature thermister
nent. It should be replaced as an assembly when di-      •   transmission speed sensor
agnosis indicates a malfunction has occurred, or         •   throttle position sensor
when a major malfunction causes debris to enter the      •   transmission control module (TCM)
converter.
                                                         Governor Pressure Solenoid Valve
GEAR RATIOS                                                The solenoid valve generates the governor pressure
  Forward Gear ratios for the 42RE transmission          needed for upshifts and downshifts. It is an electro-
are:                                                     hydraulic device and is located in the governor body
• First gear = 2.74:1                                    on the valve body transfer plate (Fig. 3).
• Second gear = 1.54:1                                     The inlet side of the solenoid valve is exposed to
• Third gear = 1.00:1                                    normal transmission line pressure. The outlet side of
• Fourth gear = 0.69:1.                                  the valve leads to the valve body governor circuit.
                                                           The solenoid valve regulates line pressure to pro-
RECOMMENDED FLUID                                        duce governor pressure. The average current sup-
  The only fluid recommended for the 42RE trans-         plied to the solenoid controls governor pressure. One
mission is Mopar ATF Plus, type 7176.                    amp current produces zero kPa/psi governor pres-
  Dexron II is not really recommended and should
                                                         sure. Zero amps sets the maximum governor pres-
only be used when ATF Plus is not available.
                                                         sure.
                                                           The transmission control module (TCM) supplies
TRANSMISSION IDENTIFICATION
                                                         electrical power to the solenoid valve. Operating volt-
  The transmission part/identification numbers and
codes are stamped on the left side of the case just      age is 12 volts (DC) and is provided through the bat-
above the oil pan gasket surface (Fig. 2).               tery terminal on the module.
  The first letter/number group is the assembly part       The solenoid is polarity sensitive. The TCM ener-
number. The next number group the transmission           gizes the solenoid by grounding it through the power
build date. The last number group is the transmis-       ground terminal on the transmission control module.
sion serial number. Refer to this information when
ordering replacement parts.                              Governor Pressure Sensor
                                                           The governor pressure sensor measures output
ELECTRONIC GOVERNOR COMPONENTS                           pressure of the governor pressure solenoid valve (Fig.
  Governor pressure is developed and controlled elec-    4).
tronically in the 42RE transmission. Components            The sensor output signal provides the necessary
used for development and control of governor pres-       feedback to the transmission control module. This
sure include:                                            feedback is needed to adequately control governor
• governor body                                          pressure.
• new design valve body transfer plate
• governor pressure solenoid valve
ZJ                                                            42RE AUTOMATIC TRANSMISSION              21 - 39

                                                         clutch, when fluid temperature is below approxi-
                                                         mately 1°C (30°F).
                                                           If fluid temperature exceeds 126°C (260°F), the
                                                         transmission control module will cause a 4-3 down-
                                                         shift and engage the converter clutch. Engagement is
                                                         according to the third gear converter clutch engage-
                                                         ment schedule.
                                                           The overdrive OFF lamp in the instrument panel,
                                                         also illuminates when the shift back to third occurs.
                                                         The transmission will not allow fourth gear operation
                                                         until fluid temperature decreases to approximately
      Fig. 3 Governor Pressure Solenoid Valve            110°C (230°F).
                                                           The thermistor is mounted on the solenoid assem-
                                                         bly (Fig. 6). It is immersed in transmission fluid at
                                                         all times.




          Fig. 4 Governor Pressure Sensor
Governor Body And Transfer Plate
  A different transfer plate is used with the 42RE
                                                                      Fig. 6 Thermister Location
valve body. The transfer plate is designed to supply
transmission line pressure to the governor pressure      Transmission Speed Sensor
solenoid valve and to return governor pressure. The        The speed sensor (Fig. 7), is located in the over-
governor pressure solenoid valve is mounted in the       drive gear case. The sensor is positioned over the
governor body. The body is bolted to the lower side of   park gear and monitors transmission output shaft ro-
the transfer plate (Fig. 5).                             tating speed. The sensor used with the 42RE trans-
                                                         mission is the same as is used in Chrysler 41TE and
                                                         42LE front drive automatic transmissions.
                                                           Speed sensor signals are triggered by the park gear
                                                         lugs as they rotate past the sensor pickup face. Input
                                                         signals from the sensor are sent to the transmission
                                                         control module for processing.
                                                           The vehicle speed sensor also serves as backup to
                                                         the transmission speed sensor. Signals from this sen-
                                                         sor are shared with the powertrain control module.



               Fig. 5 Governor Body
Transmission Fluid Temperature Thermister
  Transmission fluid temperature readings are sup-
plied to the transmission control module by the ther-
mister (Fig. 6). The temperature readings are used to
control engagement of the fourth gear overdrive
clutch, the converter clutch, and governor pressure.
Normal resistance value for the thermister at room
temperature is approximately 1000 ohms.
  The transmission control module (TCM) prevents                  Fig. 7 Transmission Speed Sensor
engagement of the converter clutch and overdrive
21 - 40    42RE AUTOMATIC TRANSMISSION                                                                       ZJ

Throttle Position Sensor (TPS)                           CONVERTER CLUTCH ENGAGEMENT
  The TPS provides throttle position input signals to      The torque converter clutch is engaged by the
both the transmission control module and powertrain      clutch solenoid on the valve body. The clutch can be
controller. This input signal is used to determine       engaged in third and fourth gear ranges depending
overdrive and converter clutch shift schedule and to     on overdrive control switch position.
select the proper governor curve.                          If the overdrive control switch is in the normal ON
                                                         position, the clutch will engage after the shift to
Transmission Control Module (TCM)                        fourth gear, and above approximately 72 km/h (45
  The TCM controls operation of the converter clutch,    mph).
overdrive clutch, and governor pressure solenoid.          If the control switch is in the OFF position, the
  The control module determines transmission shift       clutch will engage after the shift to third gear, at ap-
points based on input signals from the transmission      proximately 56 km/h (35 mph) at light throttle.
thermistor, transmission output shaft speed sensor,
crankshaft position sensor, vehicle speed sensor and     OVERDRIVE OFF SWITCH
throttle position sensor.                                   The overdrive Off switch is located in the instru-
  Operating voltage is supplied through the battery      ment panel. The switch is a momentary contact de-
terminal on the control module. The ignition voltage     vice that signals the TCM to toggle current status of
signal is supplied through a terminal on the ABS         the overdrive function. At key-on, overdrive operation
control module.                                          is allowed.
  The DRB scan tool can be used to check operation          Pressing the switch once causes the overdrive Off
of the control module and transmission electrical        mode to be entered and the overdrive Off switch
components. The diagnostic connector (for the scan       lamp to be illuminated. Pressing the switch a second
tool) is located under the driver side of the instru-    time causes normal overdrive operation to be re-
ment panel. The connector has a 6-way terminal and       stored and the overdrive lamp to be turned off.
is blue in color.                                           The normal position for the control switch is the
                                                         ON position. The switch must be in this position to
GOVERNOR PRESSURE CURVES                                 energize the solenoid and allow a fourth gear upshift.
  There are four governor pressure curves pro-              The control switch has an indicator light. The light
grammed into the transmission control module. The
                                                         illuminates when the overdrive switch is turned to
different curves allow the control module to adjust
                                                         the OFF position, or when illuminated by the trans-
governor pressure for varying conditions.
                                                         mission control module.
  One curve is used for operation when fluid temper-
                                                            The control switch indicator light is also used to
ature is at, or below 10°C (50°F).
  A second curve is used when fluid temperature is       signal fault flash codes for diagnostic purposes.
at, or above 10°C (50°F) during normal city, or high-
way driving.
                                                         QUICK FILL VALVE
  A third curve is used during wide open throttle op-      The 3-4 quick fill valve provides faster engagement
eration. The fourth curve is used when driving with      of the overdrive clutch during 3-4 upshifts. The valve
the transfer case in low range.                          temporarily bypasses the clutch piston feed orifice at
                                                         the start of a 3-4 upshift. This exposes a larger pas-
TRANSMISSION SHIFTING                                    sage into the piston retainer resulting in a much
  Shift valve operation with the electronic governor     faster clutch fill and apply sequence.
is basically unchanged. The 1-2 and 2-3 upshift se-        The quick fill valve does not bypass the regular
quence occurs exactly the same as in non-electronic      clutch feed orifice throughout the 3-4 upshift. In-
governor transmissions.                                  stead, once a predetermined pressure develops within
  The shift valves are still moved by a combination of   the clutch, the valve closes the bypass. Clutch fill is
throttle and governor pressure. The only real differ-    then completed through the regular feed orifice.
ence is that governor pressure is generated by elec-
trical components instead of a mechanical valve and      CONVERTER DRAINBACK VALVE
weight assembly.                                           The drainback valve is located in the transmission
  The conditions under which a shift to fourth will      cooler outlet (pressure) line. The valve prevents fluid
not occur, also remain the same. These being:            from draining from the converter into the cooler and
• shift to third not yet completed                       lines when the vehicle is shut down for lengthy peri-
• overdrive switch is in OFF position                    ods.
• vehicle speed too low for 3-4 shift to occur             Production valves have a hose nipple at one end,
• transmission fluid temperature is below 10°C           while the opposite end is threaded for a flare fitting.
(50°F) or above 121°C (250°F).                           Some early valves have hose nipples at both ends. All
ZJ                                                          42RE AUTOMATIC TRANSMISSION              21 - 41

valves have an arrow mark (or similar mark) to in-     annulus support hub has been remachined to accom-
dicate direction of flow through the valve.            modate the new plate tabs.
                                                         Plastic check balls are now used in some valve bod-
TRANSMISSION CHANGES AND PARTS                         ies. The new check balls entered production as a run-
INTERCHANGEABILITY                                     ning change. The plastic and steel check balls are not
  1995 transmissions are similar to previous models    interchangeable.
but only in appearance. Current transmissions are        A converter drainback check valve has been added
dimensionally different and have different hydraulic   to the fluid cooler system. The one-way valve is lo-
circuitry. Do not interchange parts.                   cated in the transmission outlet (pressure) line. The
  Transmission changes affect the governor weight      valve prevents fluid drainback when the vehicle is
assembly, low-reverse drum, front annulus, boost       parked for lengthy periods.
valve tube retainer, fluid cooling system, and valve     The boost valve tube retainer has been lengthened
body check balls.                                      and an extra tab added to better secure the tube.
  The thrust plate and front annulus have changed.
The thrust plate now has two locating tabs and the
21 - 42        42RE TRANSMISSION DIAGNOSIS                                                                                                                                   ZJ

                                          42RE TRANSMISSION DIAGNOSIS


                                                                                      INDEX
                                                                                  page                                                                                   page
Air Testing Transmission Clutch and Band
  Operation . . . . . . . . . . . . . . . . . . . . . .   .   .   .   .   .   .   .   48   Effects of Incorrect Fluid Level . . . . . . . . . .          .   .   .   .   .   43
Analyzing the Road Test . . . . . . . . . . . . .         .   .   .   .   .   .   .   44   Fluid Contamination . . . . . . . . . . . . . . . . . .       .   .   .   .   .   43
Causes of Burned Fluid . . . . . . . . . . . . . .        .   .   .   .   .   .   .   43   Hydraulic Pressure Test . . . . . . . . . . . . . . .         .   .   .   .   .   45
Checking Fluid Level and Condition . . . . .              .   .   .   .   .   .   .   42   Overdrive Electrical Controls . . . . . . . . . . . .         .   .   .   .   .   43
Converter Housing Fluid Leak Diagnosis .                  .   .   .   .   .   .   .   49   Preliminary Diagnosis . . . . . . . . . . . . . . . . .       .   .   .   .   .   42
Converter Stall Test . . . . . . . . . . . . . . . . .    .   .   .   .   .   .   .   47   Road Testing . . . . . . . . . . . . . . . . . . . . . . .    .   .   .   .   .   44
Diagnosis and Hydraulic Flow Charts . . . .               .   .   .   .   .   .   .   51   Stall Test Analysis . . . . . . . . . . . . . . . . . . . .   .   .   .   .   .   48
Diagnosis Procedures . . . . . . . . . . . . . . .        .   .   .   .   .   .   .   42   Transmission Throttle Valve and Shift Cables                  .   .   .   .   .   44
Diagnostic Trouble Flash Codes . . . . . . .              .   .   .   .   .   .   .   44

DIAGNOSIS PROCEDURES                                                                         (7) Perform air pressure test to check clutch-band
  Begin diagnosis by checking the easily accessible                                        operation.
items such as fluid level, fluid condition and throttle
cable/shift linkage adjustments. A road test will de-                                      VEHICLE IS DISABLED
termine if further diagnosis is necessary.                                                   (1) Check fluid level and condition.
  Procedures outlined in this section should be per-                                         (2) Check for broken, disconnected, binding throt-
formed in the following sequence to realize the most                                       tle valve cable, or lever.
accurate results:                                                                            (3) Check for cracked, leaking cooler lines, or loose,
  (1) Preliminary diagnosis                                                                missing pressure port plugs.
  (2) Fluid Level and condition                                                              (4) Raise vehicle, start engine, shift transmission
  (3) Leak tests (if fluid level is low)                                                   into gear and note following:
  (4) Linkage Adjustment                                                                       (a) If propeller shafts turn but wheels do not,
  (5) Overdrive control switch test                                                          problem is with differential or axle shafts.
  (6) Road test                                                                                (b) If propeller shafts do not turn and transmis-
  (7) Stall test                                                                             sion is noisy, stop engine. Remove oil pan, and
  (8) Hydraulic pressure test                                                                check for debris. If pan is clear, remove transmis-
  (9) Air pressure tests                                                                     sion and check for damaged drive plate, converter,
  (10) Analyze test results and consult diagnosis                                            oil pump or input shaft.
charts                                                                                         (c) If propeller shafts do not turn and transmis-
                                                                                             sion is not
PRELIMINARY DIAGNOSIS                                                                          noisy, perform hydraulic pressure test to deter-
  Two basic procedures are required. One procedure                                           mine if problem is a hydraulic or mechanical.
for vehicles that are driveable and an alternate pro-
cedure for disabled vehicles (will not back up or move                                     CHECKING FLUID LEVEL AND CONDITION
forward).                                                                                    (1) Place vehicle on level surface. This is important
                                                                                           for an accurate reading.
VEHICLE IS DRIVEABLE                                                                         (2) Do not check level until fluid is at normal hot
  (1) Check for TCM fault codes with DRB scan tool,                                        operating temperature of approximately 180°F. This
or with fault flash codes at lamp in overdrive Off                                         is necessary to avoid false readings which could pro-
switch.                                                                                    duce under or over fill condition.
  (2) Check fluid level and condition.                                                       (3) Start and run engine at curb idle speed and ap-
  (3) Adjust throttle and gearshift linkage if com-                                        ply parking brakes.
plaint was based on delayed, erratic, or harsh shifts.                                       (4) Shift transmission through all gear ranges and
  (4) Road test and note how transmission upshifts,                                        back to Neutral.
downshifts and engages.                                                                      (5) Clean top of filler tube and dipstick to keep dirt
  (5) Perform stall test if complaint is based on slug-                                    out of tube.
gish acceleration. Or, if abnormal throttle opening is                                       (6) Remove dipstick and check fluid level as fol-
needed to maintain normal speeds with a properly                                           lows:
tuned engine.                                                                                  (a) Dipstick has three fluid level indicating
  (6) Perform hydraulic pressure test if shift prob-                                         marks which are a MIN dot mark, an OK mark
lems were noted during road test.                                                            and a MAX fill arrow mark:
ZJ                                                               42RE TRANSMISSION DIAGNOSIS              21 - 43

   (b) Correct level is to Full, or MAX arrow mark         an auxiliary transmission fluid cooler, a heavy duty
 on dipstick. This is correct maximum hot fluid            cooling system, and the engine/axle ratio combination
 level. Acceptable level is between OK mark and            needed to handle heavy loads.
 max arrow mark on dipstick.
   (c) If level is at, or below MIN/ADD level, add         FLUID CONTAMINATION
 only enough fluid to restore correct level. Mopar           Fluid contamination is generally a result of:
 ATF Plus, type 7176 is the required fluid.                • adding incorrect fluid
                                                           • failure to clean dipstick and fill tube when check-
CAUTION: Do not overfill the transmission. Overfill-       ing level
ing may cause leakage out the pump vent which              • engine coolant entering fluid
can be mistaken for a pump seal leak. In addition,         • internal failure that generates debris
overfilling will also cause fluid aeration and foam-       • overheat that generates sludge (fluid breakdown)
ing as the excess fluid is picked up and churned by        • failure to reverse flush cooler and lines after re-
the gear train. This will reduce the life of the fluid
                                                           pair
significantly.
                                                           • failure to replace contaminated converter during
  (7) Check fluid condition. Fluid color should range      repair
from dark rad to pink and be free of particles and           The use of non-recommended fluids can result in
sludge.                                                    transmission failure. The usual results are erratic
    (a) If fluid is discolored, or smells burned but       shifts, slippage, abnormal wear and eventual failure
  transmission operation was OK, flush cooler and          due to fluid breakdown and sludge formation. Avoid
  lines and change fluid and filter. Then road test        this condition by using recommended fluids only.
  again to confirm proper operation.                         The dipstick cap and fill tube should be wiped
    (b) If fluid is black, dark brown, turned to           clean before checking fluid level. Dirt, grease and
  sludge, contains extensive amount of metal or fric-      other foreign material on the cap and tube could fall
  tion material particles, transmission will need over-    into the tube if not removed beforehand. Take the
  haul (especially if shift problems were evident          time to wipe the cap and tube clean before withdraw-
  during road test).                                       ing the dipstick.
                                                             Engine coolant in the transmission fluid is gener-
EFFECTS OF INCORRECT FLUID LEVEL                           ally caused by a cooler malfunction. The only remedy
   A low fluid level allows the pump to take in air        is to replace the radiator as the cooler in the radiator
along with the fluid. Air in the fluid will cause fluid    is not a serviceable part. If coolant has circulated
pressures to be low and develop slower than normal.        through the transmission for some time, an overhaul
   If the transmission is overfilled, the gears churn
                                                           may also be necessary; especially if shift problems
the fluid into foam, aerating the fluid and causing
                                                           had developed.
the same conditions that occur with a low level. In
                                                             The transmission cooler and lines should be reverse
either case, air bubbles cause fluid overheating, oxi-
                                                           flushed whenever a malfunction generates sludge
dation and varnish buildup which interferes with
valve, clutch and servo operation.                         and/or debris. The torque converter should also be re-
   Foaming also causes fluid expansion which can re-       placed at the same time.
sult in fluid overflow from the transmission vent or         Failure to flush the cooler and lines will result in
fill tube. Fluid overflow can easily be mistaken for a     re-contamination and a shop comeback. Flushing ap-
leak if inspection is not careful.                         plies to auxiliary coolers as well. The torque con-
                                                           verter and drainback valve should also be replaced
CAUSES OF BURNED FLUID                                     whenever a failure generates sludge and debris. This
  Burned, discolored fluid is a result of overheating      is necessary because converter flushing procedures
which has two primary causes.                              will not remove all of the contaminants.
  The first cause is a result of restricted fluid flow
through the main and/or auxiliary cooler. This condi-      OVERDRIVE ELECTRICAL CONTROLS
tion is usually the result of a faulty or improperly in-     The electrical controls governing the shift into
stalled drainback valve, a damaged main cooler, or         fourth gear consist of the overdrive off switch in the
severe restrictions in the coolers and lines caused by     instrument panel and the overdrive solenoid on the
debris.                                                    valve body.
  The second primary cause is heavy duty operation           The overdrive off switch, valve body solenoid, case
with a vehicle not properly equipped for this type of      connectors and related wiring can all be tested with
operation. Trailer towing or similar high load opera-      a 12 volt test lamp or a volt/ohmmeter. Check conti-
tion will overheat the transmission fluid if the vehi-     nuity of each component when diagnosis indicates
cle is improperly equipped. Such vehicles should have      this is necessary.
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95ZJ_21.PDF

  • 1. ZJ TRANSMISSION AND TRANSFER CASE 21 - 1 TRANSMISSION AND TRANSFER CASE CONTENTS page page 42RE AUTOMATIC TRANSMISSION . . . . . . . . . 36 NP231 TRANSFER CASE . . . . . . . . . . . . . . . . . 291 46RH AUTOMATIC TRANSMISSION . . . . . . . . 164 NP242 TRANSFER CASE . . . . . . . . . . . . . . . . . 315 AX 15 MANUAL TRANSMISSION . . . . . . . . . . . . 1 NP249 TRANSFER CASE . . . . . . . . . . . . . . . . . 343 AX 15 MANUAL TRANSMISSION INDEX page page General Information . . . . . . . . . . . . . . . . . . . . . . . . 1 Transmission Identification . . . . . . . . . . . . . . . . . . . 2 Speedometer Service . . . . . . . . . . . . . . . . . . . . . . . 3 Transmission Installation . . . . . . . . . . . . . . . . . . . . . 5 Transmission Assembly and Adjustment . . . . . . . . . 22 Transmission Lubricant . . . . . . . . . . . . . . . . . . . . . . 2 Transmission Diagnosis . . . . . . . . . . . . . . . . . . . . . 2 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . 4 Transmission Disassembly and Overhaul . . . . . . . . . 6 Transmission Shift Pattern . . . . . . . . . . . . . . . . . . . . 2 Transmission Gear Ratios . . . . . . . . . . . . . . . . . . . . 2 Transmission Switch and Plug Locations . . . . . . . . . 2 GENERAL INFORMATION mounted in the shift tower portion of the adapter The AX 15 is a five speed, synchromesh, manual housing (Fig. 1). The AX 15 is used with 4.0L (I6) en- transmission. Fifth gear is an overdrive range with a gines. ratio of 0.79:1. The shift mechanism is integral and Fig. 1 AX 15 Manual Transmission
  • 2. 21 - 2 AX 15 MANUAL TRANSMISSION ZJ TRANSMISSION IDENTIFICATION TRANSMISSION SWITCH AND PLUG LOCATIONS The AX 15 identification code numbers are on the The fill plug is at the driver side of the gear case bottom surface of the transmission gear case (Fig. 2). (Fig. 4). The first number represents year of manufacture. The drain plug and backup light switch are on the For example, 4 would represent 1994. The second passenger side of the gear case (Fig. 5). and third numbers indicate month of manufacture. For example, 11 would represent November. The last series of numbers is the transmission serial number. TRANSMISSION SHIFT PATTERN Fig. 4 Fill Plug Location Fig. 2 Transmission Identification Code Location The AX 15 shift pattern is shown in Figure 3. First and second and third and fourth gear ranges are in an H pattern. Fifth and reverse gear ranges are also in line at the right of the H pattern (Fig. 3). Fig. 5 Drain Plug And Backup Light Switch Location TRANSMISSION GEAR RATIOS AX 15 transmission gear ratios are: First gear - 3.83:1 Second gear - 2.33:1 Third gear - 1.44:1 Fourth gear - 1.00:1 Fifth gear - 0.79:1 Fig. 3 AX 15 Shift Pattern Reverse - 4.22:1 TRANSMISSION LUBRICANT Recommended lubricant for AX 15 transmissions is TRANSMISSION DIAGNOSIS Mopar SAE 75W-90, API Grade GL-5 gear lubricant. LOW LUBRICANT LEVEL Correct lubricant level is from the bottom edge, to A low transmission lubricant level is generally the no more than 6 mm (1/4 in.) below the bottom edge of result of a leak, inadequate lubricant fill, or an incor- the fill plug hole. rect lubricant level check. Lubricant capacity is approximately 3.10 liters Leaks can occur at the mating surfaces of the gear (3.27 qts.). case, intermediate plate and adapter housing, or
  • 3. ZJ AX 15 MANUAL TRANSMISSION 21 - 3 from the front/rear seals. A suspected leak could also recommended lubricants is noise, excessive wear, be the result of an overfill condition. internal bind and hard shifting. Leaks at the rear of the adapter housing will be Improper clutch release is a frequent cause of hard from the housing oil seals. Leaks at component mat- shifting. Incorrect adjustment or a worn, damaged ing surfaces will probably be the result of inadequate pressure plate or disc can cause incorrect release. If sealer, gaps in the sealer, incorrect bolt tightening, or the clutch problem is advanced, gear clash during use of a non-recommended sealer. shifts can result. A leak at the front of the transmission are from the Worn or damaged synchro rings can cause gear clash front bearing retainer or retainer seal. Lubricant may when shifting into any forward gear. In some new or re- be seen dripping from the clutch housing after extended built transmissions, new synchro rings may tend to operation. If the leak is severe, it may also contaminate stick slightly causing hard or noisy shifts. In most the clutch disc causing slip, grab and chatter. cases, this condition will decline as the rings wear-in. Transmissions filled from air or electrically powered lubricant containers can be underfilled. This generally TRANSMISSION NOISE happens when the container delivery mechanism is im- Most manual transmissions make some noise during properly calibrated. Always check the lubricant level af- normal operation. Rotating gears can generate a mild ter filling to avoid an under fill condition. whine that may only be audible at extreme speeds. A correct lubricant level check can only be made Severe transmission noise is generally the result of when the vehicle is level; use a drive-on hoist to en- a lubricant problem, or internal component damage. sure this. Also allow the lubricant to settle for a Insufficient, improper, or contaminated lubricant can minute or so before checking. These recommenda- promote rapid wear of gears, synchros, shift rails, tions will ensure an accurate check and avoid an un- forks and bearings. The overheating caused by a lu- der-or-overfill condition. bricant problem, can also lead to gear breakage. HARD SHIFTING Hard shifting is usually the result of a low lubri- SPEEDOMETER SERVICE cant level, improper or contaminated lubricants, com- Rear axle gear ratio and tire size determine speed- ponent damage, incorrect clutch adjustment, or by a ometer pinion requirements. If the pinion must be re- damaged clutch pressure plate or disc. placed, refer to the parts catalogue information for Substantial lubricant leaks can result in gear, shift the correct part. rail, synchro and bearing damage. If a leak goes un- detected for an extended period, the first indications SPEEDOMETER ASSEMBLY REMOVAL of a problem are hard shifting and noise. (1) Raise vehicle. Incorrect or contaminated lubricants also contrib- (2) Disconnect wires from vehicle speed sensor. ute to hard shifting. The consequence of using non- (3) Remove adapter clamp and screw (Fig. 6). Fig. 6 Speedometer Components
  • 4. 21 - 4 AX 15 MANUAL TRANSMISSION ZJ (4) Remove speed sensor and speedometer adapter as assembly. (5) Remove speed sensor retaining screw and re- move sensor from adapter. (6) Remove speedometer pinion from adapter. (7) Inspect sensor and adapter O-rings (Fig. 6). Re- move and discard O-rings if worn or damaged. (8) Inspect terminal pins in speed sensor. Clean pins with Mopar electrical spray cleaner if dirty or oxidized. Replace sensor if faulty, or pins are loose, severely corroded, or damaged. SPEEDOMETER INSTALLATION AND INDEXING (1) Thoroughly clean adapter flange and adapter mounting surface in housing. Surfaces must be clean for proper adapter alignment and speedometer oper- Fig. 7 Location Of Index Numbers On Speedometer ation. Adapter (2) Install new O-rings on speed sensor and speed- ometer adapter if necessary (Fig. 6). (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 N⅐m (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. 7). 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- Fig. 8 Marking Propeller Shaft And Axle Yoke bers correspond to number of teeth on pinion gear. (9) Disconnect wires at transfer case electrical (10) Install speedometer adapter clamp and retain- switch. ing screw. Tighten clamp screw to 10-12 N⅐m (90-110 (10) Support transmission with transmission jack. in. lbs.) torque. Secure transmission on jack with safety chains. (11) Connect wires to vehicle speed sensor. (11) Support engine with jack positioned under (12) Lower vehicle and top off transmission fluid clutch housing or oil pan flange. level if necessary. (12) Remove bolts/nuts attaching rear mount to crossmember (Fig. 9). TRANSMISSION REMOVAL (13) Remove rear crossmember. (1) Shift transmission into Neutral. (14) Remove transfer case attaching nuts and re- (2) Raise vehicle on hoist. move transfer case from transmission. (3) Remove skid plate. (15) Lower transmission enough to provide access (4) Mark front and rear propeller shafts for instal- to shift lever. lation alignment (Fig. 8). Then remove shafts. (5) Disconnect transfer case shift linkage from (16) Reach up and around transmission case and shift lever, or range lever. unseat shift lever dust boot from transmission shift (6) Disconnect harness wires at vehicle speed sen- tower (Fig. 10). Move boot upward on shift lever for sor (Fig. 6). access to lever retainer. (7) Remove harness wires from clips on transmis- (17) Disengage transmission shift lever as follows: sion case. (a) Reach up and around transmission case and (8) Disconnect transmission and transfer case vent press shift lever retainer downward with your fin- hoses. gers.
  • 5. ZJ AX 15 MANUAL TRANSMISSION 21 - 5 Fig. 9 Transmission Rear Mounting Fig. 10 Shift Lever Attachment (b) Turn retainer counterclockwise to release it. (6) Reach up and around transmission and insert (c) Lift lever and retainer out of shift tower (Fig. shift lever in shift tower. Press lever retainer down- 10). It is not necessary to remove shift lever ward and turn it clockwise to lock it in place. Then from floorpan boot. Simply leave lever in install lever dust boot on shift tower. place for later installation. (7) Align transfer case and transmission shafts and (18) Disconnect and remove engine timing sensor. install transfer case. Tighten transfer attaching nuts Retain sensor attaching screws. to 35 N⅐m (26 ft. lbs.) torque. (19) Remove clutch slave cylinder from clutch (8) Move adjustable support stand from under en- housing. Move cylinder aside for working clearance gine and reposition it under transmission. Then re- and access to other components. move transmission jack. (20) Remove bolts attaching clutch housing to en- (9) Install rear crossmember. Tighten crossmem- gine. ber-to-frame bolts to 41 N⅐m (30 ft. lbs.) torque. (21) Pull transmission rearward until clutch hous- Tighten transmission-to-rear support bolts/nuts to 45 ing is clear of engine. Then remove transmission N⅐m (33 ft. lbs.) torque. from under vehicle. (10) Install slave cylinder in clutch housing. Tighten cylinder attaching nuts securely. TRANSMISSION INSTALLATION (11) Connect or install engine timing sensor, if re- (1) Mount transmission and clutch housing assem- moved. bly on transmission jack. Secure assembly with (12) Connect transfer case electrical switch wires. safety chains. (13) Connect transfer case shift rod to range lever. (2) Lubricate pilot bearing and transmission input (14) Connect transmission and transfer case vent shaft splines with Mopar high temperature grease. hoses and indicator switch wires. (3) Align transmission input shaft and clutch disc (15) Connect backup light switch wires. splines and seat clutch housing on engine. (16) Connect vehicle speed sensor wires. (4) Install and tighten bolts that clutch housing to (17) Align and install front/rear propeller shafts. engine. Tighten bolts to 61 N⅐m (45 ft. lbs.) torque. Tighten shaft U-joint clamp bolts to 19 N⅐m (170 in. (5) Lower transmission for access to transmission shift tower. lbs.) torque.
  • 6. 21 - 6 AX 15 MANUAL TRANSMISSION ZJ (18) Install skid plate if removed. Tighten bolts to (4) Remove gasket from shift tower (Fig. 3). 42 N⅐m (31 ft. lbs.) torque. Tighten stud nuts to 17 N⅐m (150 in. lbs.) torque. (19) Top off transmission and transfer lubricant levels. (20) Lower vehicle. TRANSMISSION DISASSEMBLY AND OVERHAUL ADAPTER HOUSING REMOVAL (1) Remove release bearing, release lever and re- lease fork from clutch housing. Then remove clutch housing from transmission. (2) Remove backup light switch. Then remove drain plug (Fig. 1) and drain transmission lubricant into pan. Fig. 3 Shift Tower Gasket Removal/Installation (5) Remove shift arm retainer bolt (Fig. 4). Fig. 1 Drain Plug And Backup Light Switch Location (3) Remove shift tower bolts and remove tower from adapter or extension housing (Fig. 2). Fig. 4 Shift Arm Retainer Bolt Removal/Installation (6) Loosen and remove restrictor pins (Fig. 5). Fig. 2 Shift Tower Removal/Installation Fig. 5 Removing/Installing Restrictor Pins
  • 7. ZJ AX 15 MANUAL TRANSMISSION 21 - 7 (7) Remove shift arm shaft plug (Fig. 6). (10) Remove plug for reverse shift head lock ball. Plug is at right side of adapter housing near backup light switch (Fig. 9). Fig. 6 Removing/Installing Shift Arm Shaft Plug (4WD) Fig. 9 Removing/Installing Lock Ball Plug (8) Remove shift arm shaft with large magnet (Fig. (11) Remove lock ball spring with pencil magnet 7). (Fig. 10). Fig. 10 Removing/Installing Lock Ball Spring Fig. 7 Removing/Installing Shift Arm Shaft (4WD) (12) Remove shift head lock ball with pencil mag- (9) Remove shift arm (Fig. 8). net (Fig. 11). Fig. 11 Removing/Installing Shift Head Lock Ball Fig. 8 Shift Arm Removal/Installation
  • 8. 21 - 8 AX 15 MANUAL TRANSMISSION ZJ (13) Remove adapter housing bolts (Fig. 12). (14) Loosen adapter/extension housing with rubber mallet (Fig. 13). Fig. 13 Loosening Adapter Housing (15) Remove housing after loosening it (Fig. 14) Fig. 14 Adapter Housing Removal (16) Remove adapter housing oil seal with a pry tool (Fig. 15). Fig. 15 Removing Adapter Housing Seal Fig. 12 Adapter Housing Bolt Locations
  • 9. ZJ AX 15 MANUAL TRANSMISSION 21 - 9 GEAR CASE REMOVAL (1) Remove bearing retainer bolts and remove re- tainer (Fig. 16). Fig. 18 Removing Input Shaft Bearing Snap Ring Fig. 16 Front Bearing Retainer Removal (2) Remove retainer oil seal with pry tool (Fig. 17). Fig. 19 Removing Cluster Gear Front Bearing Snap Ring Fig. 17 Front Bearing Retainer Seal Location (3) Remove input shaft bearing snap ring (Fig. 18). (4) Remove cluster gear front bearing snap ring (Fig. 19). (5) Loosen gear case by tapping it away from inter- mediate plate with rubber mallet (Fig. 20). Fig. 20 Loosening Gear Case
  • 10. 21 - 10 AX 15 MANUAL TRANSMISSION ZJ (6) Remove gear case from geartrain and interme- (2) Remove three lock ball springs and lock balls diate plate (Fig. 21). from intermediate plate with pencil magnet (Fig. 23). (7) Remove speedometer gear snap ring and re- move speedometer gear and spacer from output shaft. Fig. 21 Gear Case Removal FIFTH GEAR AND SYNCHRO ASSEMBLY REMOVAL (1) Remove three lock ball plugs from intermediate plate (Fig. 22). Fig. 23 Removing/Installing Lock Ball And Spring Fig. 22 Lock Ball Plug Locations
  • 11. ZJ AX 15 MANUAL TRANSMISSION 21 - 11 Fig. 24 Mounting Intermediate Plate And Geartrain In Vise (3) Mount intermediate plate and geartrain assem- (5) Remove E-ring that secures reverse shift arm bly in vise as follows: to fork (Fig. 26). (a) Insert two spare bolts in one bottom bolt hole in intermediate plate. Insert bolts from opposite sides of plates (Fig. 24). (b) Install enough flat washers under each bolt head to prevent bolts from touching (Fig. 24). (c) Tape bolts and washers in place and mount intermediate plate in vise (Fig. 24). (d) Clamp vise jaws securely against bolt heads (Fig. 24). Do not clamp vise jaws on intermedi- ate plate. Clamp only on bolt heads. (4) Remove fifth gear snap ring (Fig. 25). Retain snap ring for assembly reference. It is a select fit component. Fig. 26 Reverse Shift Arm E-Ring Removal Fig. 25 Fifth Gear Snap Ring Removal
  • 12. 21 - 12 AX 15 MANUAL TRANSMISSION ZJ (6) Remove bolts attaching reverse shift arm bracket to intermediate plate. Then remove bracket (Fig. 27). Fig. 29 Fifth Gear Fork Set Screw Removal Fig. 27 Reverse Shift Arm Bracket Removal (7) Remove reverse shift arm and shoe (Fig. 28). Fig. 30 Fifth Gear Shift Fork Removal Fig. 28 Reverse Shift Arm And Shoe Removal (8) Remove fifth gear shift fork set screw (Fig. 29). (9) Move fifth gear shift rail forward until it clears shift fork. (10) Remove fifth gear shift fork from synchro sleeve (Fig. 30). (11) Remove reverse shift rail and reverse shift head as assembly (Fig. 31). (12) Measure thrust clearance between counter fifth gear and thrust ring with feeler gauge. Clear- ance should be 0.10 to 0.40 mm (0.003 to 0.019 in.). If clearance exceeds limits, gear and/or ring will have to be replaced. Fig. 31 Reverse Shift Head And Rail Removal
  • 13. ZJ AX 15 MANUAL TRANSMISSION 21 - 13 (13) Loosen fifth spline gear with standard two-jaw puller (Fig. 32). Position puller jaws behind fifth counter gear as shown. Fig. 34 Fifth Gear Synchro Ring Removal Fig. 32 Loosening Fifth Spline Gear (14) Remove fifth spline gear (Fig. 33). Fig. 35 Counter Fifth Gear And Synchro Assembly Removal Fig. 33 Fifth Spline Gear Removal (15) Remove fifth gear synchro ring (Fig. 34). (16) Remove fifth gear synchro and sleeve assem- bly (Fig. 35). (17) Remove counter fifth gear thrust ring (Fig. 36). Fig. 36 Fifth Gear Thrust Ring Removal
  • 14. 21 - 14 AX 15 MANUAL TRANSMISSION ZJ (18) Remove thrust ring lock ball with pencil mag- net (Fig. 37). Fig. 39 Output Shaft Rear Bearing Retainer Removal Fig. 37 Thrust Ring Lock Ball Removal (19) Remove bolts attaching output shaft rear bearing retainer to intermediate plate (Fig. 38). Fig. 40 Reverse Idler Gear And Shaft Removal Fig. 38 Output Shaft Rear Bearing Retainer Bolt Removal (20) Remove rear bearing retainer (Fig. 39). (21) Remove reverse idler gear and shaft (Fig. 40).
  • 15. ZJ AX 15 MANUAL TRANSMISSION 21 - 15 Fig. 41 Shift Rail Identification SHIFT RAIL AND FORK REMOVAL There are a total of five shift rails in the AX 15 transmission. The 1-2, 3-4, fifth gear and front re- verse shift rails are shown in Figure 41. Two shift rails are used for reverse gear range. The front reverse rail is at the forward side of the inter- mediate plate (Fig. 41). The short rear reverse rail and reverse shift head are at the rear side of the in- termediate plate. It is not necessary to remove the shift rails if they are in good condition. Only the shift forks need be removed for access to the shafts and gears. (1) Remove fifth gear shift rail (Fig. 41). Catch lock ball in your hand as rail comes out of intermediate plate. (2) Remove 1-2 and 3-4 shift rail C-rings with two screwdrivers of equal size and length (Fig. 42). Fig. 42 Shift Rail C-Ring Removal
  • 16. 21 - 16 AX 15 MANUAL TRANSMISSION ZJ (3) Remove shift fork set screws (Fig. 43). (6) Remove 1-2 shift rail from shift fork and inter- mediate plate (Fig. 46). Fig. 43 Shift Fork Set Screw Removal Fig. 46 Removing 1-2 Shift Rail (4) Remove 3-4 shift rail from shift fork and inter- (7) Remove 1-2 shift rail interlock pin from shift mediate plate (Fig. 44). rail (Fig. 47). Fig. 47 Removing 1-2 Shift Rail Interlock Pin Fig. 44 Removing 3-4 Shift Rail (8) Remove 1-2 shift rail interlock plug from inter- (5) Remove 3-4 shift rail interlock plug from inter- mediate plate (Fig. 48). mediate plate with magnet (Fig. 45). Fig. 48 Removing 1-2 Shift Rail Interlock Plug Fig. 45 Removing 3-4 Shift Rail Interlock Plug
  • 17. ZJ AX 15 MANUAL TRANSMISSION 21 - 17 (9) Lift reverse shift fork upward and remove fifth gear shift rail lock ball (Fig. 49). Fig. 49 Fifth Gear Shift Rail Lock Ball Removal (10) Remove 3-4 shift fork (Fig. 50). (11) Remove 1-2 shift fork (Fig. 50). Fig. 51 Reverse Shift Rail C-Ring Removal Fig. 52 Reverse Shift Rail And Fork Removal Fig. 50 Shift Fork Removal (12) Remove reverse shift rail C-ring with two equal length and size screwdrivers (Fig. 51). (13) Remove reverse shift rail and fork (Fig. 52).
  • 18. 21 - 18 AX 15 MANUAL TRANSMISSION ZJ (14) Remove interlock pin from reverse shift rail (3) Tap end of output shaft with mallet to unseat and (Fig. 53). start rear bearing out of intermediate plate (Fig. 55). (15) Position shift rails, shift forks, lock balls, in- terlock plugs and interlock pins on the workbench in order of removal. This will help in identifying compo- nents during inspection and assembly. Fig. 55 Unseating Output Shaft Rear Bearing (4) Remove output shaft by rocking it lightly until rear bearing comes out of intermediate plate (Fig. 56). Fig. 53 Reverse Shift Rail Interlock Pin Removal OUTPUT SHAFT AND CLUSTER GEAR REMOVAL (1) Remove output shaft rear bearing snap ring (Fig. 54). (2) Remove cluster gear rear bearing snap ring (Fig. 54). Fig. 56 Input And Output Shaft Removal (5) Remove cluster gear by pulling it straight out of rear bearing (Fig. 57). Fig. 57 Cluster Gear Removal Fig. 54 Removing Bearing Snap Rings
  • 19. ZJ AX 15 MANUAL TRANSMISSION 21 - 19 (6) Remove cluster gear rear bearing from interme- (9) Remove synchro ring from input shaft (Fig. 61). diate plate (Fig. 58). (10) Remove bearing snap ring and press bearing off input shaft (Fig. 61). Fig. 58 Removing Cluster Gear Rear Bearing Fig. 61 Input Shaft Components (7) Remove input shaft from output shaft (Fig. 59). OUTPUT SHAFT DISASSEMBLY (1) Measure thrust clearance of output shaft first, second and third gears with feeler gauge (Fig. 62). • First gear clearance should be 0.10 to 0.40 mm (0.003 to 0.0197 in). • Second-third gear clearance should be 0.10 to 0.30 mm (0.003 to 0.0118 in.). (2) If first gear thrust clearance is incorrect, re- place gear and thrust washer. If second or third gear clearance is incorrect, either gear and bearing, or output shaft flange is worn. Refer to output shaft inspection in Cleaning and Inspec- tion section. Fig. 59 Input Shaft Removal (8) Remove output shaft pilot bearing from input shaft (Fig. 60). Fig. 62 Checking Output Shaft Gear Thrust Fig. 60 Input Shaft Pilot Bearing Removal Clearance
  • 20. 21 - 20 AX 15 MANUAL TRANSMISSION ZJ Fig. 63 Output Shaft And Gears (3) Press fifth gear and rear bearing off rear of Inspect the transmission case. Replace the case if output shaft. cracked or porous or if any of the bearing and gear (4) Remove thrust washer, pin, and first gear and bores are damaged. bearing (Fig. 62). (5) Remove first/reverse hub snap ring (Fig. 63). Output Shaft Inspection (6) Remove synchro ring. Measure thickness of the output shaft flange with (7) Press reverse gear and first/reverse hub off a micrometer (Fig. 64). Minimum allowable flange shaft as assembly. thickness is 4.70 mm (0.185 in). (8) Remove remaining synchro ring and second If shaft flange thickness is OK but previously gear and bearing (Fig. 63). measured second/third gear thrust clearance (9) Remove snap ring at front of output shaft (Fig. was incorrect (Fig. 62), replace the necessary 63). gear and needle bearing as an assembly. (10) Press 3-4 hub and sleeve off output shaft as Check diameter of the first, second and third gear assembly (Fig. 63). bearing surfaces of the output shaft (Fig. 64). Mini- (11) Remove synchro ring. mum allowable diameters are: (12) Remove third gear and needle bearing (Fig. • 38.86 mm (1.529 in.) for first gear surface 63). • 46.86 mm (1.844 in.) for second gear surface • 37.86 mm (1.490 in.) for third gear surface TRANSMISSION CLEANING AND INSPECTION Check output shaft runout with V-blocks and a dial Clean the transmission components in solvent. indicator (Fig. 64). Maximum allowable runout is Then dry the cases, gears, shift mechanism and 0.06 mm (0.0024 in.). shafts with compressed air. Dry the bearings with Replace the output shaft if any surface measured clean, dry shop towels only. Never use com- fails to meet stated tolerance. pressed air on the bearings. This could damage the bearing rollers. Cluster Gear Inspection Replace components that are obviously worn, Inspect the cluster gear teeth. Replace the gear if cracked, chipped or damaged. any teeth are worn or damaged or if the bearing sur- faces are damaged.
  • 21. ZJ AX 15 MANUAL TRANSMISSION 21 - 21 GEAR AND SYNCHRO INSPECTION Install the synchro rings on their respective gears. Rotate each ring on the gear and note synchro action. Replace any synchro ring that exhibits a lack of braking action or binds on the gear. Also replace any ring that is worn or has chipped or broken teeth. Measure end clearance between the synchro ring and the gear with a feeler gauge (Fig. 66). Clearance should be 0.06 mm to 1.6 mm (0.024 to 0.063 in.). Fig. 66 Checking Synchro Ring End Clearance Install the needle bearings in the first, second and third gears. Then install the gears on the output shaft and check shaft-to-gear clearance with a dial indicator (Fig. 67). Fig. 64 Checking Output Shaft Tolerances Check diameter of the cluster gear journal with a micrometer (Fig. 65). Minimum allowable diameter is 27.860 mm (1.096 in.). Fig. 65 Checking Cluster Gear Journal Diameter Check condition of the cluster gear front bearing. Replace the bearing if worn, noisy, or damaged. Fig. 67 Checking Gear-To-Shaft Clearance
  • 22. 21 - 22 AX 15 MANUAL TRANSMISSION ZJ Maximum allowable clearance is 0.16 mm (0.0063 Inspect the threads in the case, housing and plate. in.). If any gear exhibits excessive clearance, replace Minor thread damage can be repaired with steel the gear and needle bearing. thread inserts if necessary. However, do not attempt Check clearance between the shift forks and syn- to repair if the cracks are evident around any chro sleeves with a feeler gauge (Fig. 68). Clearance threaded hole. should not exceed 1.0 mm (0.039 in.). Replace the Inspect the reverse pin in the adapter/extension synchro sleeve (and matching hub) if clearance ex- housing. Replace the pin if worn or damaged. Refer ceeds the stated limit. to the replacement procedure in the Transmission As- sembly section. TRANSMISSION ASSEMBLY AND ADJUSTMENT Lubricate the transmission components with gear lubricant during assembly. Use petroleum jelly to lu- bricate seal lips and/or hold parts in place during in- stallation. FRONT BEARING/BEARING SEAL/REVERSE SHAFT PIN INSTALLATION (1) Press front bearing on input shaft. Then secure bearing with thickest snap ring that will fit in shaft groove (Fig. 70). Fig. 68 Checking Shift Fork-To-Sleeve Clearance Check condition of the reverse idler gear bushing (Fig. 69). Replace the gear if the bushing is scored or worn. Fig. 70 Selecting Input Shaft Front Bearing Snap Ring (2) Press front bearing on cluster gear. Then se- cure bearing with thickest snap ring that will fit in ring groove on gear (Fig. 71). (3) Install new oil seals in front bearing retainer and adapter housing (Fig. 72). Installation depth for Fig. 69 Reverse Idler Gear Bushing bearing retainer seal is 10.5 to 11.5 mm (0.414 to Gear Case, Housing And Intermediate Plate 0.453 in.). (4) Install reverse shaft and shaft retaining pin in Clean the case, housing and plate with solvent and adapter housing. Then install access hole plug with dry with compressed air. Replace any component that torx bit (Fig. 73). is cracked, warped or damaged in any way.
  • 23. ZJ AX 15 MANUAL TRANSMISSION 21 - 23 Fig. 71 Selecting Cluster Gear Front Bearing Snap Fig. 73 Installing Reverse Shaft Pin Ring OUTPUT SHAFT ASSEMBLY (1) Lubricate output shaft journals, gears and nee- dle bearings with recommended gear lubricant. (2) Install third gear and needle bearing on shaft (Fig. 63) (3) Install synchro ring on third gear (Fig. 63). (4) Assemble 1-2 and 3-4 synchro hubs and sleeves (Fig.74). Fig. 74 Synchro Sleeve And Hub Identification Fig. 72 Oil Seal Installation (5) Lubricate reverse shaft and gear components with Mopar 75W-90 gear lubricant.
  • 24. 21 - 24 AX 15 MANUAL TRANSMISSION ZJ (5) Install inserts and springs in synchro sleeves. Position open ends of springs 180° apart as shown (Fig. 75). Fig. 77 Checking Third Gear Clearance Fig. 75 Insert Spring Position (12) Assemble first/reverse hub, insert springs, in- serts, reverse gear and 1-2 sleeve (Fig. 78). Be sure (6) Install 3-4 synchro hub and sleeve on output spring ends are 180° apart. Note that splines in shaft. Press hub onto shaft if necessary. hub bore are chamfered on one side. Install (7) Install 3-4 synchro hub snap ring (Fig. 76). Use hub so chamfered side faces front of output thickest snap ring that will fit in shaft groove. shaft. (13) Press assembled hub and sleeve on output shaft. (14) Install selective snap ring (Fig. 78). Use thick- est snap ring that will fit in output shaft groove. Fig. 76 Installing 3-4 Synchro Hub Snap Ring (8) Verify third gear thrust clearance with feeler gauge (Fig. 56). Clearance should be 0.10 to 0.25 mm (0.004 to 0.010 in.). (9) Lubricate remaining output shaft gears and Fig. 78 Second Gear And Synchro Assembly bearings with gear lubricant. (15) Install synchro ring on first gear (Fig. 79). (10) Install second gear and needle bearing on (16) Install first gear spacer on shaft and against shaft (Fig. 78). selective fit snap ring (Fig. 79). (11) Install synchro ring on second gear (Fig. 78). (17) Install first gear and needle bearing (Fig. 79) on output shaft.
  • 25. ZJ AX 15 MANUAL TRANSMISSION 21 - 25 (18) Install locating pin and thrust washer on (22) Lubricate input shaft pilot bearing with petro- shaft (Fig. 79). leum jelly and install bearing in shaft (Fig. 60). (23) Install input shaft on output shaft (Fig. 59). Be sure output shaft hub is fully seated in pilot bearing. OUTPUT SHAFT AND CLUSTER GEAR INSTALLATION (1) Mount intermediate plate in vise (Fig. 24). (2) Lubricate cluster gear journal and rear bearing with petroleum jelly or gear lubricant. (3) Install cluster gear rear bearing in intermedi- ate plate (Fig. 81). Be sure snap ring groove in bear- ing is rearward as shown. Fig. 79 First And Fifth Gear Components (19) Press rear bearing on shaft. Position bearing snap ring groove so it is closest to end of output shaft. (20) Check first and second gear thrust clearance with feeler gauge (Fig. 62). • First gear clearance should be 0.10 to 0.40 mm (0.003 to 0.0197 in.) • Second gear clearance should be 0.10 to 0.30 mm (0.003 to 0.0118 in.) (21) Press fifth gear onto output shaft. Then install select fit snap ring (Fig. 80). Use thickest snap ring that will fit in shaft groove. Fig. 81 Installing Cluster Gear Rear Bearing (4) Start cluster gear into bearing (Fig. 57). Then hold bearing and push gear into place. Use plastic or rawhide mallet to seat bearing if necessary. (5) Start output shaft rear bearing in intermediate plate. Push shaft rearward and tap intermediate plate with mallet to seat bearing. (6) Install snap rings on cluster and output shaft rear bearings only (Fig. 82). Do not install front bearing snap rings at this time. Fig. 80 Selecting Fifth Gear Snap Ring Fig. 82 Installing Rear Bearing Snap Rings
  • 26. 21 - 26 AX 15 MANUAL TRANSMISSION ZJ Fig. 83 Installing Reverse Idler Gear And Shaft Fig. 84 Installing Rear Bearing Retainer (7) Install reverse idler gear and shaft (Fig. 83). SHIFT RAIL AND FORK INSTALLATION (8) Position rear bearing retainer over output shaft The shift rail interlock pins, balls and plugs must and rear bearing. Be sure bearing retainer tab is be installed in the correct sequence for proper shift- engaged in reverse idler shaft notch (Fig. 84). ing. Refer to the installation diagram (Fig. 85) during (9) Install and tighten rear bearing retainer bolts assembly. to 18 N⅐m (13 ft-lbs). Coat the intermediate plate shift rail bores and the interlock balls, pins and plugs with a thick covering of petroleum jelly before assem- Fig. 85 Shift Rail Ball-Plug-Pin Position
  • 27. ZJ AX 15 MANUAL TRANSMISSION 21 - 27 bly. The jelly will hold the interlock compo- nents in place making installation easier. Use a pencil magnet to hold and insert the interlocks. Then use a small screwdriver to push the inter- lock components into place. (1) Coat reverse rail interlock pin with petroleum jelly and install pin in rail (Fig. 86). (2) Install reverse shift rail in intermediate plate (Fig. 87). (3) Install reverse shift rail C-ring (Fig. 51). Fig. 86 Installing Reverse Shift Rail Interlock Pin Fig. 88 Shift Fork Installation Fig. 87 Installing Reverse Shift Rail And Fork (4) Position 1-2 and 3-4 shift forks in synchro Fig. 89 Installing Reverse Shift Rail Lock Ball sleeves (Fig. 88). (9) Coat 3-4 shift rail interlock plug with petro- (5) Coat reverse rail lock ball with petroleum jelly. leum jelly and install plug in intermediate plate (Fig. Then tilt reverse shift fork upward and insert ball in 93). intermediate plate (Fig. 89). (10) Install 3-4 shift rail in intermediate plate and (6) Coat 1-2 shift rail interlock plug with petro- in both shift forks (Fig. 94). leum jelly and install it in intermediate plate bore (11) Verify that none of the interlock balls, plugs, (Fig. 90). or pins were displaced during shift rail installation. (7) Coat 1-2 shift rail interlock pin with petroleum (12) Install and tighten shift fork setscrews to 20 jelly and insert it in shift rail (Fig. 91). N⅐m (14 ft. lbs.) torque (Fig. 95). (8) Install 1-2 shift rail in intermediate plate and 1-2 fork (Fig. 92).
  • 28. 21 - 28 AX 15 MANUAL TRANSMISSION ZJ Fig. 90 Installing 1-2 Shift Rail Interlock Plug Fig. 93 Installing 3-4 Shift Rail Interlock Plug Fig. 91 Installing 1-2 Shift Rail Interlock Pin Fig. 94 Installing 3-4 Shift Rail Fig. 92 Installing 1-2 Shift Rail Fig. 95 Installing Shift Fork Set Screws
  • 29. ZJ AX 15 MANUAL TRANSMISSION 21 - 29 (13) Install 1-2 and 3-4 shift rail C-rings (Fig. 96). (14) Insert fifth gear shift rail through reverse shift fork. Then slide rail into intermediate plate just far enough to secure interlock ball. Do not fully install shift rail at this time. Fig. 98 Installing Fifth Gear Thrust Ring Fig. 96 Installing Shift Rail C-Rings FIFTH-REVERSE GEAR AND SHIFT COMPONENT INSTALLATION (1) Install thrust ring lock ball in cluster gear jour- nal (Fig. 97). Use petroleum jelly to hold ball in place. (2) Install fifth gear thrust ring (Fig. 98). Be sure thrust ring notch fits over lock ball. Fig. 99 Assembling Fifth Gear And Synchro Assembly Fig. 97 Installing Thrust Ring Lock Ball (3) Assemble counter fifth gear, synchro sleeve, in- serts and insert springs (Fig. 99). (4) Lubricate two-piece bearing with petroleum jelly and install it in counter fifth gear (Fig. 100). Fig. 100 Installing Counter Fifth Gear Bearing
  • 30. 21 - 30 AX 15 MANUAL TRANSMISSION ZJ (5) Install counter fifth gear and synchro assembly (8) Install fifth gear selective snap ring (Fig. 104). on cluster gear journal (Fig. 101). Use thickest snap ring that will fit in shaft groove. Fig. 101 Installing Counter Fifth Gear And Sleeve (6) Install synchro ring in synchro sleeve (Fig. 102). Fig. 104 Installing Fifth Gear Snap Ring (9) Install reverse shift head and rail (Fig. 105). Then install lock ball in shift head. Fig. 102 Installing Fifth Gear Synchro Ring (7) Install fifth spline gear on cluster journal (Fig. 103). Tap spline gear into place with plastic mallet if necessary. Fig. 105 Installing Reverse Shift Head And Rail (10) Position fifth gear shift fork in synchro sleeve (Fig. 106). (11) Install fifth gear shift rail (Fig. 107). Slide rail through fork, shift head, intermediate plate and re- verse shift fork. Be sure interlock ball is not dis- Fig. 103 Installing Fifth Spline Gear placed during installation.
  • 31. ZJ AX 15 MANUAL TRANSMISSION 21 - 31 Fig. 106 Fifth Gear Shift Fork Installation Fig. 109 Detent Ball And Spring Installation (14) Install reverse shift arm bracket (Fig. 110). Tighten bracket bolts to 18 N⅐m (13 ft. lbs.) torque. (15) Install reverse shift arm (Fig. 110). Position Fig. 107 Fifth Gear Shift Rail Installation arm on reverse fork pin and engage it with pin on shift arm bracket. (12) Align screw holes in shift fork and rail and in- (16) Verify that shift arm shoe is engaged in re- stall set screw (Fig. 108). Tighten screw to 20 N⅐m verse idler gear. Then secure shift arm to pin on re- (15 ft. lbs.) torque. verse fork with new E-clip. Fig. 108 Shift Fork Set Screw Installation (13) Install lock balls and springs in intermediate Fig. 110 Reverse Shift Arm And Bracket Installation plate (Fig. 109). Then install and tighten lock ball GEAR CASE AND ADAPTER INSTALLATION plugs to 19 N⅐m (14 ft. lbs.) torque. (1) Dismount intermediate plate and gear assem- blies from vise.
  • 32. 21 - 32 AX 15 MANUAL TRANSMISSION ZJ (2) Clean mating surfaces of intermediate plate and transmission gear case with wax and grease re- mover. Then wipe dry with a clean cloth. (3) Apply 3 mm (1/8 in.) wide bead of Mopar Gas- ket Maker, or Loctite 518 to mating surface of gear case. Keep sealer bead inside bolt holes as shown (Fig. 111). Fig. 113 Front Bearing Snap Ring Installation Fig. 111 Applying Sealer To Gear Case (10) Align and install front bearing retainer (Fig. (4) Install gear case (Fig. 112). Align shift rails and 114). Be sure retainer is properly seated on case and bearings in case and tap case into position. bearings. (5) Verify that gear case is seated on intermediate plate dowel pins. Fig. 114 Installing Front Bearing Retainer (11) Install and tighten front bearing retainer bolts Fig. 112 Gear Case Installation to 17 N⅐m (12 ft. lbs.) torque. (6) Install front bearing snap rings (Fig. 113). (12) On models with extension housing, install (7) Clean gear case and front bearing retainer seal- speedometer gear, lock ball and retaining rings (Fig. ing surfaces with wax and grease remover. Then 115). Be sure lock ball is engaged in gear. wipe dry with a clean cloth. (13) Inspect condition of reverse pin in adapter/ex- (8) Install new seal in front bearing retainer. Then tension housing (Fig. 116). If pin is worn or damaged, lubricate seal lip with petroleum jelly. Installation replace it as follows: depth for seal is 10.5 to 11.5 mm (0.413 to 0.453 (a) Remove roll pin access plug (Fig. 117). in.). (b) Tap roll pin out of housing with pin punch (9) Apply a 3 mm (1/8 in.) wide bead of Mopar (Fig. 118). Then remove old reverse pin. Gasket Maker, or Loctite 518 to front bearing re- tainer sealing surface.
  • 33. ZJ AX 15 MANUAL TRANSMISSION 21 - 33 Fig. 115 Speedometer Gear Installation (2WD Fig. 118 Roll Pin Removal/Installation Models) (14) Clean sealing surfaces of adapter or extension housing and intermediate plate with wax and grease remover. Then wipe dry with a clean cloth. (15) Apply 3 mm (1/8 in.) wide bead of Mopar Gas- ket Maker, or Loctite 518 to sealing surface of adapter or extension housing. Keep sealer bead in- side bolt holes as shown in Figure 111. (16) Align and install adapter or extension housing on intermediate plate (Fig. 119). Be sure housing is seated on intermediate plate dowel pins. (17) Coat threads of housing attaching bolts with Mopar silicone sealer. Then install and tighten bolts to 37 N⅐m (27 ft. lbs.) torque. Fig. 116 Reverse Pin Position Fig. 119 Adapter/Extension Housing Installation (18) Install detent ball (Fig. 120). (19) Install detent spring (Fig. 121). (20) Install detent access plug (Fig. 122). Tighten plug to 19 N⅐m (14 ft. lbs.) torque. Fig. 117 Access Plug Removal/Installation (21) Lubricate shift arm shaft and install it in (c) Install new reverse pin and secure it with roll adapter housing (Fig. 123). pin. Then install and tighten access plug to 19 N⅐m (22) Position shift arm in adapter housing (Fig. (14 ft. lbs.) torque. 124). Be sure arm is engaged in shift rails. (23) Align shift arm with shaft and push shaft into arm.
  • 34. 21 - 34 AX 15 MANUAL TRANSMISSION ZJ Fig. 120 Installing Detent Ball Fig. 123 Installing Shift Arm Shaft Fig. 121 Installing Detent Spring Fig. 124 Shift Arm Installation (26) Install and tighten restrictor pins to 19 N⅐m (14 ft. lbs.) torque (Fig. 125). Fig. 122 Installing Detent Access Plug (24) Rotate shift arm shaft until set screw holes in shaft and arm are aligned. Fig. 125 Set Screw And Restrictor Pin Installation (25) Install and tighten shift arm set screw to 38 N⅐m (28 ft. lbs.) torque (Fig. 125).
  • 35. ZJ AX 15 MANUAL TRANSMISSION 21 - 35 (27) Install and tighten shift arm shaft access plug to 19 N⅐m (14 ft. lbs.) torque (Fig. 126). Fig. 127 Shift Tower Gasket Installation Fig. 126 Access Plug Installation (28) Position new shift tower gasket on adapter housing (Fig 127). (29) Install shift tower (Fig. 128). Tighten tower attaching bolts to 18 N⅐m (13 ft. lbs.) torque. (30) Install new gasket on backup light switch and install switch. Tighten switch to 37 N⅐m (27 ft. lbs.) torque. (31) Install new washer on drain plug. Then install and tighten plug to 37 N⅐m (27 ft. lbs.) torque. (32) If transmission will be filled with gear lubri- cant before installation, place transmission in a level position. Then fill with Mopar 75W-90, grade GL-5 gear lubricant. Fig. 128 Shift Tower Installation (33) Install new washer on fill plug. Then install and tighten plug to 37 N⅐m (27 ft. lbs.) torque. (34) Install clutch housing and hydraulic concen- tric bearing. (35) On models with extension housing, install new seal in housing with suitable size installer tool (Fig. 129). Lubricate seal lips with petroleum jelly before installation. (36) On models with extension housing, install speedometer driven gear, speedometer adapter and speed sensor. Fig. 129 Installing Extension Housing Seal
  • 36. 21 - 36 42RE AUTOMATIC TRANSMISSION ZJ 42RE AUTOMATIC TRANSMISSION CONTENTS page page GENERAL INFORMATION . . . . . . . . . . . . . . . . . 36 42RE TRANSMISSION OVERHAUL . . . . . . . . . . 98 42RE TRANSMISSION DIAGNOSIS . . . . . . . . . . 42 42RE TRANSMISSION/OVERDRIVE 42RE OVERDRIVE UNIT OVERHAUL . . . . . . . . 146 REMOVAL AND INSTALLATION . . . . . . . . . . . 89 42RE IN-VEHICLE SERVICE . . . . . . . . . . . . . . . 77 GENERAL INFORMATION INDEX page page Converter Clutch Engagement . . ... . . . . . . . . . . . 40 Recommended Fluid . . . . . . . . . . . . . . . . . . . . . . . 38 Converter Drainback Valve . . . . ... . . . . . . . . . . . 40 Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . 38 Electronic Governor Components .. . . . . . . . . . . . 38 Transmission Changes and Parts Gear Ratios . . . . . . . . . . . . . . . ... . . . . . . . . . . . 38 Interchangeability . . . . . . . . . . . . . . . . . . . . . . . . 41 Governor Pressure Curves . . . . ... . . . . . . . . . . . 40 Transmission Description . . . . . . . . . . . . . . . . . . . . 36 Overdrive Off Switch . . . . . . . . . ... . . . . . . . . . . . 40 Transmission Identification . . . . . . . . . . . . . . . . . . 38 Quick Fill Valve . . . . . . . . . . . . . ... . . . . . . . . . . . 40 Transmission Shifting . . . . . . . . . . . . . . . . . . . . . . 40 TRANSMISSION DESCRIPTION The overdrive clutch is applied in fourth gear only. The Chrysler 42RE is a 4-speed, fully automatic The direct clutch is applied in all ranges except transmission with an electronic governor. It is used fourth gear. with 4.0L engines. The 42RE valve body transfer plate is different. It Mechanical and hydraulic components in the 42RE is designed to accept a governor body and different are similar to those in RH series transmissions. The hydraulic circuitry. The governor pressure solenoid main difference involves the method of producing valve and sensor are mounted in this body. The governor pressure for shift control. The 42RE uses transfer plate channels line pressure to the solenoid electronic components to develop governor pressure. valve through the governor body. It also channels A mechanical governor is used to generate governor governor pressure from the solenoid valve to the gov- pressure in the RH series. ernor circuit. It is the solenoid valve that develops First through third gear ranges are provided by the necessary governor pressure. clutches, bands, overrunning clutch and planetary The 42RE overdrive unit is different from previous gear sets in the transmission unit. Fourth gear range overdrive units. It is shorter in length as a result of is provided by the overdrive unit which contains an eliminating the mechanical governor assembly in- overdrive clutch, direct clutch, planetary gear set and cluding the governor tubes and governor support. overrunning clutch.
  • 37. ZJ 42RE AUTOMATIC TRANSMISSION Fig. 1 42RE Automatic Transmission (4 x 2 Model) 21 - 37
  • 38. 21 - 38 42RE AUTOMATIC TRANSMISSION ZJ TORQUE CONVERTER A three element torque converter is used for all ap- plications (Fig. 1). Converter elements consist of the turbine, stator and impeller. The converter also con- tains an overrunning clutch and a converter clutch mechanism. The converter clutch is an electronically controlled mechanism. The clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmis- sion fluid temperatures. The converter clutch is engaged in fourth gear and in third gear when the overdrive control switch is in the OFF position. An overrunning clutch is mounted in the stator hub. This one-way clutch prevents the stator from Fig. 2 Transmission Identification Number And turning in a direction opposite to engine rotation. Code Location This retains the torque multiplication feature of the converter. • governor pressure sensor The torque converter is not a serviceable compo- • fluid temperature thermister nent. It should be replaced as an assembly when di- • transmission speed sensor agnosis indicates a malfunction has occurred, or • throttle position sensor when a major malfunction causes debris to enter the • transmission control module (TCM) converter. Governor Pressure Solenoid Valve GEAR RATIOS The solenoid valve generates the governor pressure Forward Gear ratios for the 42RE transmission needed for upshifts and downshifts. It is an electro- are: hydraulic device and is located in the governor body • First gear = 2.74:1 on the valve body transfer plate (Fig. 3). • Second gear = 1.54:1 The inlet side of the solenoid valve is exposed to • Third gear = 1.00:1 normal transmission line pressure. The outlet side of • Fourth gear = 0.69:1. the valve leads to the valve body governor circuit. The solenoid valve regulates line pressure to pro- RECOMMENDED FLUID duce governor pressure. The average current sup- The only fluid recommended for the 42RE trans- plied to the solenoid controls governor pressure. One mission is Mopar ATF Plus, type 7176. amp current produces zero kPa/psi governor pres- Dexron II is not really recommended and should sure. Zero amps sets the maximum governor pres- only be used when ATF Plus is not available. sure. The transmission control module (TCM) supplies TRANSMISSION IDENTIFICATION electrical power to the solenoid valve. Operating volt- The transmission part/identification numbers and codes are stamped on the left side of the case just age is 12 volts (DC) and is provided through the bat- above the oil pan gasket surface (Fig. 2). tery terminal on the module. The first letter/number group is the assembly part The solenoid is polarity sensitive. The TCM ener- number. The next number group the transmission gizes the solenoid by grounding it through the power build date. The last number group is the transmis- ground terminal on the transmission control module. sion serial number. Refer to this information when ordering replacement parts. Governor Pressure Sensor The governor pressure sensor measures output ELECTRONIC GOVERNOR COMPONENTS pressure of the governor pressure solenoid valve (Fig. Governor pressure is developed and controlled elec- 4). tronically in the 42RE transmission. Components The sensor output signal provides the necessary used for development and control of governor pres- feedback to the transmission control module. This sure include: feedback is needed to adequately control governor • governor body pressure. • new design valve body transfer plate • governor pressure solenoid valve
  • 39. ZJ 42RE AUTOMATIC TRANSMISSION 21 - 39 clutch, when fluid temperature is below approxi- mately 1°C (30°F). If fluid temperature exceeds 126°C (260°F), the transmission control module will cause a 4-3 down- shift and engage the converter clutch. Engagement is according to the third gear converter clutch engage- ment schedule. The overdrive OFF lamp in the instrument panel, also illuminates when the shift back to third occurs. The transmission will not allow fourth gear operation until fluid temperature decreases to approximately Fig. 3 Governor Pressure Solenoid Valve 110°C (230°F). The thermistor is mounted on the solenoid assem- bly (Fig. 6). It is immersed in transmission fluid at all times. Fig. 4 Governor Pressure Sensor Governor Body And Transfer Plate A different transfer plate is used with the 42RE Fig. 6 Thermister Location valve body. The transfer plate is designed to supply transmission line pressure to the governor pressure Transmission Speed Sensor solenoid valve and to return governor pressure. The The speed sensor (Fig. 7), is located in the over- governor pressure solenoid valve is mounted in the drive gear case. The sensor is positioned over the governor body. The body is bolted to the lower side of park gear and monitors transmission output shaft ro- the transfer plate (Fig. 5). tating speed. The sensor used with the 42RE trans- mission is the same as is used in Chrysler 41TE and 42LE front drive automatic transmissions. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The vehicle speed sensor also serves as backup to the transmission speed sensor. Signals from this sen- sor are shared with the powertrain control module. Fig. 5 Governor Body Transmission Fluid Temperature Thermister Transmission fluid temperature readings are sup- plied to the transmission control module by the ther- mister (Fig. 6). The temperature readings are used to control engagement of the fourth gear overdrive clutch, the converter clutch, and governor pressure. Normal resistance value for the thermister at room temperature is approximately 1000 ohms. The transmission control module (TCM) prevents Fig. 7 Transmission Speed Sensor engagement of the converter clutch and overdrive
  • 40. 21 - 40 42RE AUTOMATIC TRANSMISSION ZJ Throttle Position Sensor (TPS) CONVERTER CLUTCH ENGAGEMENT The TPS provides throttle position input signals to The torque converter clutch is engaged by the both the transmission control module and powertrain clutch solenoid on the valve body. The clutch can be controller. This input signal is used to determine engaged in third and fourth gear ranges depending overdrive and converter clutch shift schedule and to on overdrive control switch position. select the proper governor curve. If the overdrive control switch is in the normal ON position, the clutch will engage after the shift to Transmission Control Module (TCM) fourth gear, and above approximately 72 km/h (45 The TCM controls operation of the converter clutch, mph). overdrive clutch, and governor pressure solenoid. If the control switch is in the OFF position, the The control module determines transmission shift clutch will engage after the shift to third gear, at ap- points based on input signals from the transmission proximately 56 km/h (35 mph) at light throttle. thermistor, transmission output shaft speed sensor, crankshaft position sensor, vehicle speed sensor and OVERDRIVE OFF SWITCH throttle position sensor. The overdrive Off switch is located in the instru- Operating voltage is supplied through the battery ment panel. The switch is a momentary contact de- terminal on the control module. The ignition voltage vice that signals the TCM to toggle current status of signal is supplied through a terminal on the ABS the overdrive function. At key-on, overdrive operation control module. is allowed. The DRB scan tool can be used to check operation Pressing the switch once causes the overdrive Off of the control module and transmission electrical mode to be entered and the overdrive Off switch components. The diagnostic connector (for the scan lamp to be illuminated. Pressing the switch a second tool) is located under the driver side of the instru- time causes normal overdrive operation to be re- ment panel. The connector has a 6-way terminal and stored and the overdrive lamp to be turned off. is blue in color. The normal position for the control switch is the ON position. The switch must be in this position to GOVERNOR PRESSURE CURVES energize the solenoid and allow a fourth gear upshift. There are four governor pressure curves pro- The control switch has an indicator light. The light grammed into the transmission control module. The illuminates when the overdrive switch is turned to different curves allow the control module to adjust the OFF position, or when illuminated by the trans- governor pressure for varying conditions. mission control module. One curve is used for operation when fluid temper- The control switch indicator light is also used to ature is at, or below 10°C (50°F). A second curve is used when fluid temperature is signal fault flash codes for diagnostic purposes. at, or above 10°C (50°F) during normal city, or high- way driving. QUICK FILL VALVE A third curve is used during wide open throttle op- The 3-4 quick fill valve provides faster engagement eration. The fourth curve is used when driving with of the overdrive clutch during 3-4 upshifts. The valve the transfer case in low range. temporarily bypasses the clutch piston feed orifice at the start of a 3-4 upshift. This exposes a larger pas- TRANSMISSION SHIFTING sage into the piston retainer resulting in a much Shift valve operation with the electronic governor faster clutch fill and apply sequence. is basically unchanged. The 1-2 and 2-3 upshift se- The quick fill valve does not bypass the regular quence occurs exactly the same as in non-electronic clutch feed orifice throughout the 3-4 upshift. In- governor transmissions. stead, once a predetermined pressure develops within The shift valves are still moved by a combination of the clutch, the valve closes the bypass. Clutch fill is throttle and governor pressure. The only real differ- then completed through the regular feed orifice. ence is that governor pressure is generated by elec- trical components instead of a mechanical valve and CONVERTER DRAINBACK VALVE weight assembly. The drainback valve is located in the transmission The conditions under which a shift to fourth will cooler outlet (pressure) line. The valve prevents fluid not occur, also remain the same. These being: from draining from the converter into the cooler and • shift to third not yet completed lines when the vehicle is shut down for lengthy peri- • overdrive switch is in OFF position ods. • vehicle speed too low for 3-4 shift to occur Production valves have a hose nipple at one end, • transmission fluid temperature is below 10°C while the opposite end is threaded for a flare fitting. (50°F) or above 121°C (250°F). Some early valves have hose nipples at both ends. All
  • 41. ZJ 42RE AUTOMATIC TRANSMISSION 21 - 41 valves have an arrow mark (or similar mark) to in- annulus support hub has been remachined to accom- dicate direction of flow through the valve. modate the new plate tabs. Plastic check balls are now used in some valve bod- TRANSMISSION CHANGES AND PARTS ies. The new check balls entered production as a run- INTERCHANGEABILITY ning change. The plastic and steel check balls are not 1995 transmissions are similar to previous models interchangeable. but only in appearance. Current transmissions are A converter drainback check valve has been added dimensionally different and have different hydraulic to the fluid cooler system. The one-way valve is lo- circuitry. Do not interchange parts. cated in the transmission outlet (pressure) line. The Transmission changes affect the governor weight valve prevents fluid drainback when the vehicle is assembly, low-reverse drum, front annulus, boost parked for lengthy periods. valve tube retainer, fluid cooling system, and valve The boost valve tube retainer has been lengthened body check balls. and an extra tab added to better secure the tube. The thrust plate and front annulus have changed. The thrust plate now has two locating tabs and the
  • 42. 21 - 42 42RE TRANSMISSION DIAGNOSIS ZJ 42RE TRANSMISSION DIAGNOSIS INDEX page page Air Testing Transmission Clutch and Band Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Effects of Incorrect Fluid Level . . . . . . . . . . . . . . . 43 Analyzing the Road Test . . . . . . . . . . . . . . . . . . . . 44 Fluid Contamination . . . . . . . . . . . . . . . . . . . . . . . 43 Causes of Burned Fluid . . . . . . . . . . . . . . . . . . . . . 43 Hydraulic Pressure Test . . . . . . . . . . . . . . . . . . . . 45 Checking Fluid Level and Condition . . . . . . . . . . . . 42 Overdrive Electrical Controls . . . . . . . . . . . . . . . . . 43 Converter Housing Fluid Leak Diagnosis . . . . . . . . 49 Preliminary Diagnosis . . . . . . . . . . . . . . . . . . . . . . 42 Converter Stall Test . . . . . . . . . . . . . . . . . . . . . . . . 47 Road Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Diagnosis and Hydraulic Flow Charts . . . . . . . . . . . 51 Stall Test Analysis . . . . . . . . . . . . . . . . . . . . . . . . . 48 Diagnosis Procedures . . . . . . . . . . . . . . . . . . . . . . 42 Transmission Throttle Valve and Shift Cables . . . . . 44 Diagnostic Trouble Flash Codes . . . . . . . . . . . . . . 44 DIAGNOSIS PROCEDURES (7) Perform air pressure test to check clutch-band Begin diagnosis by checking the easily accessible operation. items such as fluid level, fluid condition and throttle cable/shift linkage adjustments. A road test will de- VEHICLE IS DISABLED termine if further diagnosis is necessary. (1) Check fluid level and condition. Procedures outlined in this section should be per- (2) Check for broken, disconnected, binding throt- formed in the following sequence to realize the most tle valve cable, or lever. accurate results: (3) Check for cracked, leaking cooler lines, or loose, (1) Preliminary diagnosis missing pressure port plugs. (2) Fluid Level and condition (4) Raise vehicle, start engine, shift transmission (3) Leak tests (if fluid level is low) into gear and note following: (4) Linkage Adjustment (a) If propeller shafts turn but wheels do not, (5) Overdrive control switch test problem is with differential or axle shafts. (6) Road test (b) If propeller shafts do not turn and transmis- (7) Stall test sion is noisy, stop engine. Remove oil pan, and (8) Hydraulic pressure test check for debris. If pan is clear, remove transmis- (9) Air pressure tests sion and check for damaged drive plate, converter, (10) Analyze test results and consult diagnosis oil pump or input shaft. charts (c) If propeller shafts do not turn and transmis- sion is not PRELIMINARY DIAGNOSIS noisy, perform hydraulic pressure test to deter- Two basic procedures are required. One procedure mine if problem is a hydraulic or mechanical. for vehicles that are driveable and an alternate pro- cedure for disabled vehicles (will not back up or move CHECKING FLUID LEVEL AND CONDITION forward). (1) Place vehicle on level surface. This is important for an accurate reading. VEHICLE IS DRIVEABLE (2) Do not check level until fluid is at normal hot (1) Check for TCM fault codes with DRB scan tool, operating temperature of approximately 180°F. This or with fault flash codes at lamp in overdrive Off is necessary to avoid false readings which could pro- switch. duce under or over fill condition. (2) Check fluid level and condition. (3) Start and run engine at curb idle speed and ap- (3) Adjust throttle and gearshift linkage if com- ply parking brakes. plaint was based on delayed, erratic, or harsh shifts. (4) Shift transmission through all gear ranges and (4) Road test and note how transmission upshifts, back to Neutral. downshifts and engages. (5) Clean top of filler tube and dipstick to keep dirt (5) Perform stall test if complaint is based on slug- out of tube. gish acceleration. Or, if abnormal throttle opening is (6) Remove dipstick and check fluid level as fol- needed to maintain normal speeds with a properly lows: tuned engine. (a) Dipstick has three fluid level indicating (6) Perform hydraulic pressure test if shift prob- marks which are a MIN dot mark, an OK mark lems were noted during road test. and a MAX fill arrow mark:
  • 43. ZJ 42RE TRANSMISSION DIAGNOSIS 21 - 43 (b) Correct level is to Full, or MAX arrow mark an auxiliary transmission fluid cooler, a heavy duty on dipstick. This is correct maximum hot fluid cooling system, and the engine/axle ratio combination level. Acceptable level is between OK mark and needed to handle heavy loads. max arrow mark on dipstick. (c) If level is at, or below MIN/ADD level, add FLUID CONTAMINATION only enough fluid to restore correct level. Mopar Fluid contamination is generally a result of: ATF Plus, type 7176 is the required fluid. • adding incorrect fluid • failure to clean dipstick and fill tube when check- CAUTION: Do not overfill the transmission. Overfill- ing level ing may cause leakage out the pump vent which • engine coolant entering fluid can be mistaken for a pump seal leak. In addition, • internal failure that generates debris overfilling will also cause fluid aeration and foam- • overheat that generates sludge (fluid breakdown) ing as the excess fluid is picked up and churned by • failure to reverse flush cooler and lines after re- the gear train. This will reduce the life of the fluid pair significantly. • failure to replace contaminated converter during (7) Check fluid condition. Fluid color should range repair from dark rad to pink and be free of particles and The use of non-recommended fluids can result in sludge. transmission failure. The usual results are erratic (a) If fluid is discolored, or smells burned but shifts, slippage, abnormal wear and eventual failure transmission operation was OK, flush cooler and due to fluid breakdown and sludge formation. Avoid lines and change fluid and filter. Then road test this condition by using recommended fluids only. again to confirm proper operation. The dipstick cap and fill tube should be wiped (b) If fluid is black, dark brown, turned to clean before checking fluid level. Dirt, grease and sludge, contains extensive amount of metal or fric- other foreign material on the cap and tube could fall tion material particles, transmission will need over- into the tube if not removed beforehand. Take the haul (especially if shift problems were evident time to wipe the cap and tube clean before withdraw- during road test). ing the dipstick. Engine coolant in the transmission fluid is gener- EFFECTS OF INCORRECT FLUID LEVEL ally caused by a cooler malfunction. The only remedy A low fluid level allows the pump to take in air is to replace the radiator as the cooler in the radiator along with the fluid. Air in the fluid will cause fluid is not a serviceable part. If coolant has circulated pressures to be low and develop slower than normal. through the transmission for some time, an overhaul If the transmission is overfilled, the gears churn may also be necessary; especially if shift problems the fluid into foam, aerating the fluid and causing had developed. the same conditions that occur with a low level. In The transmission cooler and lines should be reverse either case, air bubbles cause fluid overheating, oxi- flushed whenever a malfunction generates sludge dation and varnish buildup which interferes with valve, clutch and servo operation. and/or debris. The torque converter should also be re- Foaming also causes fluid expansion which can re- placed at the same time. sult in fluid overflow from the transmission vent or Failure to flush the cooler and lines will result in fill tube. Fluid overflow can easily be mistaken for a re-contamination and a shop comeback. Flushing ap- leak if inspection is not careful. plies to auxiliary coolers as well. The torque con- verter and drainback valve should also be replaced CAUSES OF BURNED FLUID whenever a failure generates sludge and debris. This Burned, discolored fluid is a result of overheating is necessary because converter flushing procedures which has two primary causes. will not remove all of the contaminants. The first cause is a result of restricted fluid flow through the main and/or auxiliary cooler. This condi- OVERDRIVE ELECTRICAL CONTROLS tion is usually the result of a faulty or improperly in- The electrical controls governing the shift into stalled drainback valve, a damaged main cooler, or fourth gear consist of the overdrive off switch in the severe restrictions in the coolers and lines caused by instrument panel and the overdrive solenoid on the debris. valve body. The second primary cause is heavy duty operation The overdrive off switch, valve body solenoid, case with a vehicle not properly equipped for this type of connectors and related wiring can all be tested with operation. Trailer towing or similar high load opera- a 12 volt test lamp or a volt/ohmmeter. Check conti- tion will overheat the transmission fluid if the vehi- nuity of each component when diagnosis indicates cle is improperly equipped. Such vehicles should have this is necessary.