Throttle Cable Adjustment

102. Turn ignition switch to Off position.

103. Fully retract cable plunger. Press cable button all
     the way down. Then push cable plunger inward (Fig.
     29).

104. Rotate primary throttle lever to wide open throttle
     position (Fig. 30).

105. Hold primary throttle lever in wide open position
     and let cable plunger extend. Release lever when
     plunger is fully extended. Cable is now adjusted.

Fig. 24 Installing Manual Valve Shaft Seals

Fig. 26 Installing Park Rod Bracket

Fig. 25 Installing Spacer Sleeve On Sector

Fig. 27 Removing/Installing Throttle Cable

ACCUMULATOR PISTONS AND SPRINGS

Accumulator Piston and Spring Removal

102. Remove valve body .Refer to procedure in this sec­
     tion.

103. Remove accumulator pistons with compressed air
     (Fig. 31). Apply air through small feed hole next to each
     piston bore. Catch each piston in a shop towel as it exits
     the bore.

CABLE BRACKET

CAUTION: Use only enough air pressure to ease each piston out of the bore. In addition, remove the pistons

one at a time and tag the pistons and springs for assembly reference. Do not intermix them.

*CYl. PRIMARY

THROTTLE

LEVER

102. Remove and discard piston O-ring seals. Then
     clean the pistons and springs with solvent.

103. Inspect the pistons and springs and the piston
     bores in the case. Replace worn damaged pistons. Re­
     place broken, collapsed or distorted springs. Replace the
     case if the piston bores are damaged.

Fig. 28 Removing/Installing Cable And Bracket

Fig. 30 Rotate Primary Throttle Lever To Wide Open Position

Fig. 31 Removing Accumulator Pistons

102. Install new O-ring seals on pistons. Lubricate seals
     and pistons and piston bores with transmission fluid.

103. Install pistons and springs (Fig. 32).

104. Install valve body, oil screen and oil pan.

SECOND COAST BRAKE SERVO

Servo Overhaul

102. Remove valve body as outlined in this section.

103. Remove servo piston cover snap ring with snap
     ring pliers (Fig. 33).

104. Remove servo piston and cover with compressed
     air. Apply compressed air through oil hole in servo boss
     to ease piston out of bore (Fig. 34).

105. Remove and discard seal and O-rings from cover
     and piston (Fig. 35). Inspect E-ring, piston, spring and
     retainer, piston rod and piston spring. Replace worn or
     damaged parts.

106. Install new seals on cover and piston.

107. Lubricate servo components with transmission
     fluid.

108. Assemble and install servo components in case. Be
     sure servo piston rod is properly engaged in the second
     coast brake band.

109. Compress cover and piston and install cover snap
     ring.

110. Install valve body, oil screen and oil pan.

A. OVERDRIVE CLUTCH ACCUMULATOR PISTON AND SPRINGS

B. OVERDRIVE BRAKE ACCUMULATOR PISTON AND SPRINGS
Ñ SECOND CLUTCH ACCUMULATOR PISTON, SPRINGS AND

SPACER

D. SECOND CLUTCH ACCUMULATOR PISTON, SPRINGS AND SPACER

NOTE: PISTON HEIGHT AND DIAMETER ARE OUTLINED IN THE SPECIFICATIONS SECTION.

PARK ROD AND PAWL

Park Rod and Pawl Removal

102. Remove valve body as outlined in this section.

103. Remove bolts attaching park rod bracket to case
     (Fig. 36).

104. Remove park rod from manual valve shaft sector
     (Fig. 37).

105. Remove park rod.

Fig. 33 Removing/Installing Servo Piston Cover Snap Ring

Fig. 32 Accumulator Piston-Springs-Spacers

21 Fig. 34 Removing Servo Cover And Piston

,

102. Remove park pawl, pin and spring (Fig. 38).

103. Examine park rod, pawl, pin and spring. Replace
     any component that is worn or damaged.

104. Install pawl in case. Insert pin and install spring.
     Be sure spring is positioned as shown in Figure 38.

105. Install park rod and bracket (Fig. 36). Tighten
     bracket bolts to 10 N-m (7 ft-lbs) torque.

106. Install valve body, oil screen and oil pan as out­
     lined in this section.

EXTENSION/ADAPTOR HOUSING SEAL REPLACEMENT

(1) Raise vehicle.

SNAP RING

Fig. 35 Second Coast Brake Servo Components

Fig. 37 Removing/Installing Park Rod

102. On 2WD or 4WD models, disconnect or remove
     components necessary to gain access to the seal (e.g.
     propeller shaft, crossmember, shift linkage, transfer
     case, exhaust components, hoses, wires).

103. On 2WD models, remove seal from adaptor hous­
     ing (Fig. 39).

104. On 4WD model, remove dust shield and remove
     seal from extension housing (Fig. 39).

105. Install new seal with appropriate size seal install­
     er. On 4WD models, also install dust shield.

106. Reinstall components removed to gain access to
     seal.

107. Top off transmission fluid if necessary.

Fig. 36 Removing/Installing Park Rod Bracket 22 Fig. 38 Removing/Installing Park Pawl-Pin-Spring

SPEH)SENSOR

Speed Sensor Testing

Test the speed sensor with an ohmmeter. Place the ohmmeter leads on the terminals in the sensor connec­tor (Fig. 40).

Rotate the transmission output shaft and observe the ohmmeter needle. The needle should deflect indicating the switch is opening/closing as the rotor moves past the sensor (Fig. 40). Replace the sensor if the ohmmeter does not display any kind of reading.

If a digital ohmmeter is being used, the sensor should generate an ohmmeter readout each time the switch opens and closes.

Speed Sensor Replacement

102. Disconnect sensor wire harness connector.

103. Remove sensor retainer bolt and remove sensor
     (Fig. 41).

104. Remove and discard speed sensor O-ring.

105. Install new O-ring on speed sensor and install
     sensor in transmission case.

106. Install sensor bracket and retainer bolt. Tighten
     bolt to 7.4 N-m (65 in-lbs) torque.

107. Connect sensor wire harness connector.

SPEED SENSOR ROTOR-SPEEDOMETER DRIVE GEAR

Rotor-Drive Gear Removal

102. Raise vehicle.

103. Remove components necessary to gain access to
     rotor and drive gear (e.g. propeller shaft, transfer case,
     crossmember, shift linkage).

102. Disconnect speedometer cable and/or speed sensor.

103. Remove extension or adaptor housing.

     Fig. 40 Speed Sensor Testing

     
     

104. Remove speedometer drive gear snap ring (Fig.
     42).

105. Remove the speedometer drive gear and spacer (if
     equipped).

106. Remove rotor by carefully prying it off output shaft
     with wood dowel or hammer handle (Fig. 43).

107. Clean sealing surfaces of transmission case and
     extension/adaptor housing.

Fig. 39 Adaptor/Extension Housing Seals

23 Fig. 41 Speed Sensor Removal/Installation

Rotor-Drive Gear Installation

102. Install rotor, spacer (if equipped) and drive gear on
     output shaft. Then install drive gear snap ring (Fig. 42).

103. Apply bead of RTV sealer, to transmission case
     sealing surface and install extension/adaptor housing
     on case.

104. Tighten extension/adaptor housing bolts to 34 ¹m
     (25 ft-lbs) torque.

105. Install components removed to gain access to rotor
     and drive gear.

Fig. 42 Removing/Installation Speedometer Drive Gear

TPS SERVICE

A separate throttle position sensor is used for auto­matic transmission applications. The sensor is attached to the base of the throttle body. Refer to Group 14 for TPS service and adjustment.

SHIFT CABLE ADJUSTMENT

102. Shift transmission into Park.

103. Raise vehicle.

104. Release cable adjuster clamp to unlock cable (Fig.
     47).

105. Unsnap cable from cable bracket (Fig. 47).

106. Move transmission shift lever all the way rear­
     ward into Park detent. Lever is on manual valve shaft
     at left side of case.

107. Verify positive engagement of park lock by at­
     tempting tn rotate propeller shaft. Shaft will not rotate
     when park lock is engaged.

108. Snap cable into cable bracket.

109. Lock shaft cable by pressing cable adjuster clamp
     down until it snaps into place.

110. Check engine starting. Engine should start only in
     Park and Neutral.

(10) Lower automobile.

PARK LOCK CABLE ADJUSTMENT

102. Shift transmission into Park.

103. Turn ignition switch to Lock position.

104. Remove shift lever bezel and console screws. Raise
     bezel and console for access to cable.

105. Pull cable lock button up to release cable (Fig. 48).

106. Pull cable forward. Then release cable and press
     cable lock button down until it snaps in place.

107. Check adjustment as follows:

Fig. 43 Removing Speed Sensor Rotor

Fig. 47 Shift Cable Adjustment

102. Check movement of release shift handle but­
     ton (floor shift) or release lever (column shift). You
     should not be able to press button inward or move
     column lever.

103. Turn ignition switch to On position.

(e) Press floor shift lever release button or move column lever. Then shift into Neutral. If cable ad­justment is correct, ignition switch can not be turned to Lock position. Perform same check with transmis­sion in D range.

(7) Move shift lever back to Park and check ignition switch operation. You should be able to turn switch to Lock position and shift lever release button/lever should not move.

25

Fig. 48 Park Lock Cable

TRANSMISSION AND TORQUE CONVERTER REMOVAL

102. Raise vehicle.

103. Drain transmission fluid and reinstall oil pan
     drain plug.

104. Remove upper half of transmission fill tube (Fig.
     49).

105. Disconnect cooler lines at transmission. Cooler
     lines have quick-disconnect fittings. Press fitting re­
     lease tabs and pull cooler line and fitting out of case.

106. Support engine with safety stand and support
     transmission with jack.

102. Disconnect or remove following: transmission/
     transfer case shift linkage; necessary exhaust compo­
     nents; speedometer cable; front/rear propeller shaft;
     transmission wire harnesses; transfer case vacuum and
     wire harnesses.

103. Remove rear crossmember.

104. Disconnect transmission throttle cable at engine.

105. Disconnect necessary vacuum and fluid hoses.

     Fig. 49 Two-Piece Transmission Fill Tube

     
     
     

106. Remove starter motor.

107. Remove converter-to-drive plate bolts.

108. Remove converter housing-to-engine bolts.

102. Secure transmission (and transfer case assembly
     on 4WD models) to transmission jack with safety
     chains. Then remove transmission.

103. Remove torque converter if converter or oil pump
     seal are to be serviced.

(15) Remove transfer case if transmission is to be
overhauled.

TORQUE CONVERTER STATOR CLUTCH INSPECTION

102. Insert rotating tool B.Vi. FM. 36 into converter
     hub and seat tool in one-way clutch (Fig. 50).

103. Insert stopper tool B.Vi. FM. 37 in one converter
     hub notch and into outer race of rotating tool.

104. Turn rotating tool clockwise. Converter clutch
     should rotate freely and smoothly. Less than 2.5 N*m
     (22 in-lbs) of torque should be required to rotate clutch
     in clockwise direction.

105. Turn rotating tool in counterclockwise direction.
     Converter clutch should lock.

106. Replace converter if clutch binds or will not lock.

OIL PUMP SEAL REPLACEMENT

102. Remove converter.

103. Remove old seal. Use blunt punch to collapse seal
     and pry seal out of pump housing. Do not scratch or
     damage seal bore.

104. Lubricate lip of new seal with petroleum jelly and
     install seal in pump (Fig. 511.

105. Align and install torque converter.

TRANSMISSION AND TORQUE CONVERTER INSTALLATION

102. Mount transmission on transmission jack.

103. Install torque converter on transmission.

104. On 4WD models, install transfer case on trans­
     mission.

(41 Secure transmission (and transfer case assembly on 4WD models) to jack with safety chains.

(5) Align and position transmission and converter on
engine.

(6) Install converter housing-to-engine bolts.
(71 Install converter-to-drive plate bolts.

102. Install and connect starter motor.

103. On 4WD models, connect transfer case shift link­
     age and vacuum hoses.

(10) Connect exhaust components.

102. Install rear crossmember.

103. Connect speedometer cable and neutral switch
     wires.

104. Align and connect front and rear propeller shafts.

105. Connect transmission wire harnesses and trans­
     fer case vacuum and wire harnesses.

106. Connect transmission cooler lines.

107. Connect transmission throttle valve cable at en­
     gine.

108. Install new O-ring seal on upper half of trans­
     mission fill tube. Then connect upper and lower tube
     halves.

109. Lower vehicle.

Fig. 51 Installing Oil Pump Seal

(19) Fill transmission with Mopar Mercon™ auto­
matic transmission fluid.

Fig. 50 Checking Converter Clutch Operation