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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
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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
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Service Information AW-4
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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
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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
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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