INDEX

Copyright © ATSG 2006

JEEPAW-4

2

GENERAL INFORMATION................................................ ............................................................................... 3

DIAGNOSIS........................................................................................................................................................... 7

TROUBLESHOOTING.......................................................................................................................................... 10

TRANSMISSION SERVICE................................................................................................................................... 13

TRANSMISSION REMOVAL................... ............................................................................................................ 26

TRANSMISSION OVERHAUL............................................................................................................................. 28

SUB ASSEMBLY OVERHAUL............................................................................................................................... 41

VALVE BODY .......................................................................................................................................................... 79

BEARING LOCATIONS......................................................................................................................................... 95

UNIT RE-ASSEMBLY............................................................................................................................................. 96

ACCUMULATOR SPRING LOCATIONS........................................................................................................... 109

CHECKBALL , ORIFICE AND FILTER LOCATIONS...................................................................................... 113

AUTOMATIC TRANSMISSION SERVICE GROUP18639 S.W. 107TH AVENUEMIAMI, FLORIDA 33157

(305) 670-4161

INTRODUCTIONJEEP AW-4

1

No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without written permission of Automatic Transmission Service Group. This includes all text illustrations, tables and charts.

The information and part numbers contained in this booklet havebeen carefully compiled from industry sources known for their

reliability, but ATSG does not guarantee its accuracy.

Copyright © ATSG 2003

UpdatedJanuary, 2004

DALE ENGLANDFIELD SERVICE CONSULTANT

ED KRUSETECHNICAL CONSULTANT

WAYNE COLONNATECHNICAL SUPERVISOR

PETER LUBANTECHNICAL CONSULTANT

JIM DIALTECHNICAL CONSULTANT

GREGORY LIPNICKTECHNICAL CONSULTANT

JERRY GOTTTECHNICAL CONSULTANT

JON GLATSTEINTECHNICAL CONSULTANT

DAVID CHALKERTECHNICAL CONSULTANT

ROLAND ALVAREZTECHNICAL CONSULTANT

MIKE SOUZATECHNICAL CONSULTANT

GERALD CAMPBELLTECHNICAL CONSULTANT

We wish to thank Chrysler Corporationfor the information and illustrationsthat have made this booklet possible.

The AW-4 is a four speed, electronically controlled automatic transmission. Running gear consists of a lock-up converter, oil pump, three planetary sets, clutch and brake units, hydraulic accumulators, valve body withsolenoids and a transmission control unit (TCU). Cables are used for shift and throttle pressure control. A neutral safety switch permits engine starting in Park and Neutral ranges only. The valve body solenoids are controlled by signals from the TCU. Signal sequence is determined by vehicle speed and throttle position. A seperate planetary gear set provides overdrive operation in 4th gear at 0.70:1 ratio.

AUTOMATIC TRANSMISSION SERVICE GROUP18639 S.W. 107TH AVENUEMIAMI, FLORIDA 33157

(305) 670-4161

109

Service Information AW-4

113

Service Information AW-4

JEEP CHEROKEE WITH AW-4 TRANSMISSIONCHECKBALL LOCATIONS, 87-89 MODELS ONLY

OVERDRIVE CLUTCHEXHAUST CHECKBALL

5.5mm (.217") STEEL

INTERMEDIATE CLUTCHORIFICE CHECKBALL

5.5mm (.217") STEEL

DIRECT CLUTCHORIFICE CHECKBALL

5.5mm (.217") STEEL

DIRECT CLUTCHSHUTTLE CHECKBALL

7.1mm (.281") STEEL

T.C. CHARGE ONE-WAYCHECK VALVE BALL6.3mm (.250") RUBBER

INTERMEDIATE CLUTCHEXHAUST CHECKBALL

5.5mm (.217") STEEL

OVERDRIVE CLUTCHORIFICE CHECKBALL

5.5mm (.217") STEEL

SOLENOID OIL SCREEN11.6 X 8.3mm

OVERRUN CLUTCHORIFICE CHECKBALL

5.5mm (.217") STEEL

INTERMEDIATE CLUTCHORIFICE CHECKBALL

5.5mm (.217") STEEL

114

Service Information AW-4

JEEP CHEROKEE WITH AW-4 TRANSMISSIONCHECKBALL LOCATIONS, 90-95 MODELS ONLY

INTERMEDIATE CLUTCHORIFICE CHECKBALL5.5mm (.217") RUBBER

DIRECT CLUTCHORIFICE CHECKBALL5.5mm (.217") RUBBER

T.C. CHARGE ONE-WAYCHECK VALVE BALL6.3mm (.250") RUBBER

INTERMEDIATE CLUTCHEXHAUST CHECKBALL

5.5mm (.217") STEEL

DIRECT CLUTCHEXHAUST CHECKBALL

5.5mm (.217") STEEL

OVERDRIVE CLUTCHORIFICE CHECKBALL

5.5mm (.217") STEEL

SOLENOID OIL SCREEN11.6 X 8.3mm

OVERRUN CLUTCHORIFICE CHECKBALL

5.5mm (.217") STEEL

INTERMEDIATE CLUTCHORIFICE CHECKBALL

5.5mm (.217") STEEL

115

Service Information AW-4

JEEP CHEROKEE WITH AW-4 TRANSMISSIONCHECKBALL LOCATIONS, 96-UP MODELS ONLY

INTERMEDIATE CLUTCHORIFICE CHECKBALL5.5mm (.217") RUBBER

DIRECT CLUTCHORIFICE CHECKBALL5.5mm (.217") RUBBER

T.C. CHARGE ONE-WAYCHECK VALVE BALL6.3mm (.250") RUBBER

DIRECT CLUTCHEXHAUST CHECKBALL

6.35mm (.250") STEELOVERDRIVE CLUTCHORIFICE CHECKBALL

5.5mm (.217") STEEL

SOLENOID OIL SCREEN11.6 X 8.3mm

OVERRUN CLUTCHORIFICE CHECKBALL

5.5mm (.217") STEEL

INTERMEDIATE CLUTCHORIFICE CHECKBALL

5.5mm (.217") STEEL

OVERDRIVE CLUTCHEXHAUST CHECKBALL

5.5mm (.217") STEEL