2000 Jeep Truck Cherokee 4WD L6-4.0L VIN S

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1 2000 Jeep Truck Cherokee 4WD L6-4.0L VIN S Vehicle» Transmission and Drivetrain» Automatic Transmission/Transaxle» Service and Repair» 30-40LE (AW4) 4 Speed» Overhaul (Transmission)» Disassembly DISASSEMBLY 1. Remove torque converter. Fig Remove clamps attaching wire harness and throttle cable (Fig. 95) to transmission. 3. Remove shift lever from manual valve shaft at left side of transmission. 4. Remove park/neutral position switch. 5. Remove speed sensor. Fig. 96

2 6. Remove converter housing bolts and remove housing (Fig. 96) from case. 7. Remove adapter housing, speedometer drive gear, and speed sensor rotor. Fig. 97

3 8. Remove transmission oil pan, oil screen and screen gaskets (Fig. 97). Fig Remove valve body oil feed tubes (Fig. 98). Fig. 99

4 10. Disconnect valve body solenoid wires (Fig. 99). Fig. 100

5 11. Remove harness bracket bolt and remove harness and bracket (Fig. 100). Fig Remove valve body bolts (Fig. 101). Fig. 102

6 13. Disconnect throttle cable from throttle cam (Fig. 102). Fig. 103

7 14. Remove valve body from case. Then remove accumulator springs, check ball, and spring (Fig. 103). Fig Remove second brake and clutch accumulator pistons with compressed air (Fig. 104). Apply air

8 pressure through feed port and ease the pistons and springs out of the bore. Note and identify the original location of all springs. 16. Remove overdrive brake accumulator piston with compressed air (Fig. 104). Note and identify the original location of all springs. 17. Remove overdrive clutch accumulator piston with compressed air (Fig. 104). 18. Remove throttle cable. Fig Remove oil pump bolts and remove pump with bridge-type Puller 7536 (Fig. 105). Fig. 106

9 20. Remove race from oil pump (Fig. 106). Fig. 107

10 21. Remove overdrive planetary gear and clutch assembly (Fig. 107). Fig. 108

11 22. Remove race from overdrive planetary (Fig. 108). Fig. 109

12 23. Remove thrust bearing, race and overdrive planetary ring gear (Fig. 109). 24. Measure stroke length of overdrive brake piston as follows: a. Mount dial indicator on case using Miller Tool C-3339 and a suitable bolt threaded into the transmission case. b. Verify that the dial indicator is mounted solidly and square to the direction of the piston travel. c. Apply psi air pressure through piston apply port and note piston stroke on dial indicator. Stroke length should be: mm ( inch). d. Record the reading for use during re-assembly. e. Remove the dial indicator set-up from the transmission. 25. Measure stroke length of second coast brake piston rod as follows: a. Install a small wire tie strap around the second coast brake piston rod tight against the transmission case. b. Apply psi air pressure through piston feed hole and check stroke length with Gauge Tool c. Stroke length should be mm ( inch). d. Record the reading for use during re-assembly. 26. Remove the bolt holding the input speed sensor to the transmission case. 27. Remove the input speed sensor from the transmission case.

13 Fig Remove overdrive brake pack snap ring (Fig. 110). 29. Remove overdrive brake pack discs and plates. Inspect and replace as necessary. Fig. 111

14 30. Remove overdrive support lower race and upper bearing and race assembly (Fig. 111). Fig. 112

15 31. Remove overdrive support snap ring with Snap Ring Plier Tool 7540 (Fig. 112). Fig. 113

16 32. Remove overdrive support bolts (Fig. 113). Fig Remove overdrive support (Fig. 114) with bridge-type Puller Fig. 115

17 34. Remove race from hub of overdrive support (Fig. 115). 35. Remove second coast brake piston snap ring with Snap Ring Plier Tool Then remove piston cover and piston assembly. Fig. 116

18 36. Disassemble second coast brake piston (Fig. 116), if necessary. Fig. 117

19 37. Remove direct and forward clutch assembly (Fig. 117). Fig. 118

20 38. Remove thrust bearing and race from clutch hub (Fig. 118). Fig Remove second coast brake band E-ring from band pin and remove pin and brake band (Fig. 119). Fig. 120

21 40. Remove front planetary bearing race and remove front planetary ring gear (Fig. 120). Fig. 121

22 41. Remove thrust bearing and rear race from ring gear (Fig. 121). 42. Remove planetary thrust race. 43. Push forward on output shaft to relieve the load on the planetary snap ring. Fig. 122

23 44. Remove planetary snap ring and remove planetary gear (Fig. 122). Fig. 123

24 45. Remove sun gear, input drum, one-way clutch, and thrust washer as assembly (Fig. 123). Fig. 124

25 46. Measure second brake clutch pack clearance (Fig. 124). Clearance should be mm ( inch). Record measurement for use during re-assembly. Fig Remove second brake clutch pack snap ring (Fig. 125). Fig. 126

26 48. Remove second brake clutch pack (Fig. 126). Inspect and replace as necessary. Fig. 127

27 49. Remove bolts attaching park rod bracket to case. Then disconnect park rod from manual shaft lever and remove rod and bracket (Fig. 127). Fig. 128

28 50. Remove park pawl spring, pin and pawl (Fig. 128). Fig. 129

29 51. Measure clearance of first-reverse brake clutch pack (Fig. 129). Clearance should be: mm ( inch). Record measurement for use during re-assembly. Fig. 130

30 52. Remove second brake piston sleeve (Fig. 130). 53. Remove second brake snap-ring. Fig. 131

31 54. Remove rear planetary gear, second brake drum and output shaft as an assembly (Fig. 131). Fig. 132

32 55. Remove planetary and brake drum thrust bearing and race assembly (Fig. 132). 56. Remove second brake drum gasket from case with screwdriver. Fig. 133

33 57. Measure inside diameter of transmission case rear bushing with bore gauge or inside micrometer (Fig. 133). Maximum allowable diameter is mm ( inch). Replace transmission case if bushing I.D. is greater than specified. Bushing is not serviceable. Fig. 134

34 58. Check first/reverse brake piston operation. With compressed air (Fig. 134). Piston should move smoothly and not bind or stick. If piston operation is incorrect, case or piston may require replacement. Fig. 135

35 59. Compress piston return springs with Tool 7539 and remove piston snap ring (Fig. 135). 60. Remove Tool 7539 and remove piston return springs. 61. Remove No. 2 first-reverse brake piston with compressed air. Apply air through same transmission feed hole used for checking piston operation. Fig. 136

36 62. Remove reaction sleeve with Sleeve Remover Tool 7542 (Fig. 136). Insert tool flanges under sleeve and lift tool and sleeve out of case. Fig. 137

37 63. Remove No. 1 first/reverse brake piston with Piston Puller 7543 (Fig. 137). Slip tool under piston and lift tool and piston out of case.

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