NOTE: This flushes the main oil cooler core pas-
sages only.
(16) Turn pump OFF.
(17) Remove the thermostat cover from the oil
cooler.
(18) Remove Special Tool Cooler Plug 8414 from
the transmission oil cooler.
(19) Install a new thermostat spring, thermostat,
cover, and snap-ring into the transmission oil cooler.
(20) Install the transmission oil cooler onto the
vehicle.
(21) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(22) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(23) Place CLEAR suction line into a one quart
container of Mopar
t
ATF Plus 3, type 7176 automatic
transmission fluid.
(24) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(25) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum trans-
mission case and valve body can be repaired by the
use of Heli-Coils, or equivalent. This repair consists
of drilling out the worn-out damaged threads. Then
tap the hole with a special Heli-Coil tap, or equiva-
lent, and installing a Heli-Coil insert, or equivalent,
into the hole. This brings the hole back to its original
thread size.
Heli-Coil, or equivalent, tools and inserts are readily
available from most automotive parts suppliers.
REMOVAL AND INSTALLATION
TRANSMISSION
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid component
damage. The converter drive plate, pump bushing, or
oil seal can be damaged if the converter is left
attached to the driveplate during removal.
REMOVAL
(1) Disconnect battery negative cable.
(2) Disconnect and lower or remove necessary
exhaust components.
(3) Remove engine-to-transmission bending braces.
(4) Disconnect fluid cooler lines at transmission.
(5) Remove starter motor.
(6) Disconnect and remove crankshaft position sen-
sor (Fig. 67). Retain sensor attaching bolts.
CAUTION: The crankshaft position sensor can be
damaged during transmission removal (or installa-
tion) if the sensor is left in place. To avoid damage,
remove the sensor before removing the transmis-
sion.
(7) Remove torque converter access cover.
(8) If transmission is being removed for overhaul,
remove transmission oil pan, drain fluid and reinstall
pan.
(9) Remove skid plate for access.
(10) Remove the fill tube bracket bolts and pull tube
out of transmission. Retain fill tube seal. On 4 x 4 mod-
els, it will also be necessary to remove bolt attaching
transfer case vent tube to converter housing.
(11) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.
(12) Mark propeller shaft and axle yokes for
assembly alignment. Then disconnect and remove
propeller shafts.
(13) Disconnect wires from park/neutral position
switch and vehicle speed sensor.
(14) Disconnect gearshift cable from transmission
manual valve lever.
(15) Disconnect throttle valve cable from transmis-
sion bracket and throttle valve lever.
(16) Disconnect shift rod from transfer case shift
lever or remove shift lever from transfer case.
Fig. 67 Crankshaft Position Sensor—2.5L Engine
1 – EXHAUST DOWN PIPE
2 – TRANSMISSION HOUSING
3 – CRANKSHAFT POSITION SENSOR
21 - 144
AUTOMATIC TRANSMISSION—30RH
XJ
SERVICE PROCEDURES (Continued)
Summary of Contents for 200 Cherokee
Page 5: ...FASTENER IDENTIFICATION 4 INTRODUCTION XJ DESCRIPTION AND OPERATION Continued ...
Page 6: ...FASTENER STRENGTH XJ INTRODUCTION 5 DESCRIPTION AND OPERATION Continued ...
Page 8: ...METRIC CONVERSION CHART XJ INTRODUCTION 7 DESCRIPTION AND OPERATION Continued ...
Page 9: ...TORQUE SPECIFICATIONS 8 INTRODUCTION XJ DESCRIPTION AND OPERATION Continued ...
Page 47: ......
Page 107: ...Fig 105 Gear Tooth Contact Patterns 3 60 TUBE 181 AND 186 FBI AXLE XJ ADJUSTMENTS Continued ...
Page 111: ...Installer D 144 Installer W 262 3 64 TUBE 181 AND 186 FBI AXLE XJ SPECIAL TOOLS Continued ...
Page 145: ...Fig 79 Gear Tooth Contact Patterns 3 98 194 RBI AXLE XJ ADJUSTMENTS Continued ...
Page 177: ...Fig 59 Gear Tooth Contact Patterns 3 130 8 1 4 REAR AXLE XJ ADJUSTMENTS Continued ...
Page 230: ...Fig 8 Clutch Components And Inspection XJ CLUTCH 6 5 DIAGNOSIS AND TESTING Continued ...
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Page 484: ...SPECIAL TOOLS HEADLAMP ALIGNMENT Headlamp Aiming Kit C 4466 A XJ LAMPS 8L 9 ...
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Page 1072: ...Fig 16 2 5L Engine XJ 8W 90 CONNECTOR LOCATIONS 8W 90 25 DESCRIPTION AND OPERATION Continued ...
Page 1073: ...Fig 17 4 0L Engine 8W 90 26 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...
Page 1074: ...Fig 18 4 0L Engine XJ 8W 90 CONNECTOR LOCATIONS 8W 90 27 DESCRIPTION AND OPERATION Continued ...
Page 1087: ...Fig 31 Liftgate 8W 90 40 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...
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Page 1331: ...Fig 6 Frame Dimensions 13 8 FRAME AND BUMPERS XJ SPECIFICATIONS Continued ...
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Page 1912: ...Fig 3 Hood Components XJ BODY 23 25 REMOVAL AND INSTALLATION Continued ...
Page 1955: ...WELD LOCATIONS UPPER COWL 23 68 BODY XJ SPECIFICATIONS Continued ...
Page 1956: ...UPPER COWL XJ BODY 23 69 SPECIFICATIONS Continued ...
Page 1957: ...COWL 23 70 BODY XJ SPECIFICATIONS Continued ...
Page 1958: ...A PILLAR XJ BODY 23 71 SPECIFICATIONS Continued ...
Page 1959: ...A PILLAR 23 72 BODY XJ SPECIFICATIONS Continued ...
Page 1960: ...A PILLAR XJ BODY 23 73 SPECIFICATIONS Continued ...
Page 1961: ...A PILLAR 23 74 BODY XJ SPECIFICATIONS Continued ...
Page 1962: ...B PILLAR XJ BODY 23 75 SPECIFICATIONS Continued ...
Page 1963: ...D PILLAR 23 76 BODY XJ SPECIFICATIONS Continued ...
Page 1964: ...FUEL FILLER OPENING XJ BODY 23 77 SPECIFICATIONS Continued ...
Page 1965: ...CARGO AREA FLOOR PAN 23 78 BODY XJ SPECIFICATIONS Continued ...
Page 1966: ...ROOF AND D PILLAR XJ BODY 23 79 SPECIFICATIONS Continued ...
Page 1967: ...LIFTGATE OPENING 23 80 BODY XJ SPECIFICATIONS Continued ...
Page 1968: ...ROOF XJ BODY 23 81 SPECIFICATIONS Continued ...
Page 1969: ...ROOF 23 82 BODY XJ SPECIFICATIONS Continued ...
Page 1970: ...FRAME RAIL XJ BODY 23 83 SPECIFICATIONS Continued ...
Page 1971: ...FRAME RAIL 23 84 BODY XJ SPECIFICATIONS Continued ...
Page 1972: ...FRAME RAIL XJ BODY 23 85 SPECIFICATIONS Continued ...
Page 1973: ...FRAME RAIL 23 86 BODY XJ SPECIFICATIONS Continued ...
Page 1974: ...REINFORCEMENT XJ BODY 23 87 SPECIFICATIONS Continued ...
Page 1975: ...FRONT INNER FENDER 23 88 BODY XJ SPECIFICATIONS Continued ...
Page 1976: ...FRONT INNER FENDER AND RADIATOR CLOSURE PANEL XJ BODY 23 89 SPECIFICATIONS Continued ...
Page 1977: ...REINFORCEMENT 23 90 BODY XJ SPECIFICATIONS Continued ...
Page 1978: ...FRONT FENDER XJ BODY 23 91 SPECIFICATIONS Continued ...
Page 1979: ...BODY SIDE 23 92 BODY XJ SPECIFICATIONS Continued ...
Page 1980: ...REAR WHEELHOUSE XJ BODY 23 93 SPECIFICATIONS Continued ...
Page 1981: ...REAR INNER WHEELHOUSE 23 94 BODY XJ SPECIFICATIONS Continued ...
Page 1982: ...BODY SIDE XJ BODY 23 95 SPECIFICATIONS Continued ...
Page 1983: ...BODY SIDE 23 96 BODY XJ SPECIFICATIONS Continued ...
Page 1984: ...BODY SIDE XJ BODY 23 97 SPECIFICATIONS Continued ...
Page 1985: ...BODY SIDE 23 98 BODY XJ SPECIFICATIONS Continued ...
Page 1986: ...BODY SIDE XJ BODY 23 99 SPECIFICATIONS Continued ...
Page 1987: ...BODY SIDE 23 100 BODY XJ SPECIFICATIONS Continued ...
Page 1988: ...UNDERBODY XJ BODY 23 101 SPECIFICATIONS Continued ...
Page 1989: ...UNDERBODY 23 102 BODY XJ SPECIFICATIONS Continued ...
Page 1990: ...UNDERBODY XJ BODY 23 103 SPECIFICATIONS Continued ...
Page 1991: ...UNDERBODY 23 104 BODY XJ SPECIFICATIONS Continued ...
Page 1992: ...UNDERBODY XJ BODY 23 105 SPECIFICATIONS Continued ...
Page 1993: ...UNDERBODY 23 106 BODY XJ SPECIFICATIONS Continued ...
Page 1994: ...UNDERBODY XJ BODY 23 107 SPECIFICATIONS Continued ...
Page 1995: ...UNDERBODY 23 108 BODY XJ SPECIFICATIONS Continued ...
Page 1996: ...UNDERBODY XJ BODY 23 109 SPECIFICATIONS Continued ...
Page 1997: ...UNDERBODY 23 110 BODY XJ SPECIFICATIONS Continued ...
Page 1998: ...UNDERBODY XJ BODY 23 111 SPECIFICATIONS Continued ...
Page 1999: ...BODY SEALING LOCATIONS APPLICATION METHODS 23 112 BODY XJ SPECIFICATIONS Continued ...
Page 2000: ...COWL AND DASH PANEL XJ BODY 23 113 SPECIFICATIONS Continued ...
Page 2001: ...DASH PANEL AND FLOOR PAN 23 114 BODY XJ SPECIFICATIONS Continued ...
Page 2002: ...FLOOR PAN XJ BODY 23 115 SPECIFICATIONS Continued ...
Page 2003: ...REAR INNER WHEELHOUSE 23 116 BODY XJ SPECIFICATIONS Continued ...
Page 2004: ...FRONT INNER WHEELHOUSE XJ BODY 23 117 SPECIFICATIONS Continued ...
Page 2005: ...BODY SIDE 23 118 BODY XJ SPECIFICATIONS Continued ...
Page 2006: ...BODY SIDE XJ BODY 23 119 SPECIFICATIONS Continued ...
Page 2007: ...BODY SIDE 23 120 BODY XJ SPECIFICATIONS Continued ...
Page 2008: ...ROOF PANEL XJ BODY 23 121 SPECIFICATIONS Continued ...
Page 2009: ...FUEL FILLER HOUSING 23 122 BODY XJ SPECIFICATIONS Continued ...
Page 2010: ...LIFTGATE OPENING XJ BODY 23 123 SPECIFICATIONS Continued ...
Page 2011: ...STRUCTURAL ADHESIVE LOCATIONS LEFT QUARTER PANEL 23 124 BODY XJ SPECIFICATIONS Continued ...
Page 2012: ...REAR WHEELHOUSE XJ BODY 23 125 SPECIFICATIONS Continued ...
Page 2013: ...ROOF BOWS 23 126 BODY XJ SPECIFICATIONS Continued ...
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