Jeep Wagoneer/Commando/Cherokee 1984-1998

Transmission Assembly

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Removal & Installation



See Figures 1, 2, 3 and 4



Click image to see an enlarged view

Fig. Fig. 1: Rear engine mount used on 4.0L Cherokee/Wagoneer and Comanche models

1984-91 Models
2WD MODELS
  1. Disconnect the negative battery cable. Raise and support the vehicle on jackstands.
  2.  
  3. Matchmark the rear driveshaft and yoke for reassembly. Disconnect and remove the rear driveshaft.
  4.  
  5. Remove the torque converter inspection cover. Mark the converter driveplate and converter assembly for reassembly.
  6.  
  7. Remove the bolts attaching the torque converter to the flexplate. Support the transmission assembly on a floor jack.
  8.  
  9. Remove the bolts attaching the rear crossmember to the transmission side rail. Disconnect the exhaust pipe at the catalytic converter.
  10.  
  11. Lower the transmission slightly in order to disconnect the fluid cooler lines.
  12.  
  13. Disconnect the backup light switch wire and the speedometer cable. Disconnect the transmission linkage.
  14.  
  15. Remove the bolts attaching the transmission assembly to the engine. Move the transmission assembly and the torque converter rearward to clear the crankshaft.
  16.  
  17. Carefully lower the transmission assembly from the vehicle.
  18.  

To install:
  1. Carefully raise the transmission into position.
  2.  
  3. Install the bolts attaching the transmission assembly to the engine. Tighten the bolts to 25 ft. lbs. (34 Nm) for the 904. On the AW-4, tighten the 10mm bolts to 25 ft. lbs. (34 Nm); the 12mm bolts to 42 ft. lbs. (57 Nm).
  4.  
  5. Connect the backup light switch wire.
  6.  
  7. Connect the speedometer cable.
  8.  
  9. Connect the transmission linkage.
  10.  
  11. Connect the fluid cooler lines.
  12.  
  13. Install the rear crossmember. Tighten the crossmember bolts to 30 ft. lbs. (41 Nm); the transmission-to-crossmember bolts to 33 ft. lbs. (48 Nm).
  14.  
  15. Connect the exhaust pipe at the catalytic converter.
  16.  
  17. Install the bolts attaching the torque converter to the flexplate. Tighten the bolts to 40 ft. lbs. (54 Nm).
  18.  
  19. Remove the floor jack.
  20.  
  21. Install the torque converter inspection cover.
  22.  
  23. Install the driveshaft. Tighten the nuts to 14 ft. lbs. (19 Nm).
  24.  

New strap bolts must be used every time the driveshaft is disconnected.

  1. Lower the truck.
  2.  
  3. Connect the negative battery cable.
  4.  

4WD MODELS
  1. Disconnect the negative battery cable. Raise and support the vehicle safely.
  2.  
  3. Matchmark the rear driveshaft and yoke for reassembly. Disconnect and remove the rear driveshaft.
  4.  
  5. Remove the torque converter inspection cover. Mark the converter driveplate and converter assembly for reassembly.
  6.  
  7. Remove the bolts attaching the torque converter to the flexplate. Support the transmission assembly with a floor jack.
  8.  

If the vehicle is equipped with a diesel engine, support the engine with a jack under the crankshaft damper, and remove the left motor mount and starter in order to gain access to the torque converter driveplate bolts through the starter opening.

  1. Remove the rear crossmember-to-side rail attaching bolts. Disconnect the exhaust pipe at the catalytic converter.
  2.  
  3. Lower the transmission slightly in order to disconnect the fluid cooler lines. Matchmark the front driveshaft assembly for installation. Disconnect the driveshaft at the transfer case and secure the assembly out of the way.
  4.  
  5. Disconnect the backup light switch wire and the speedometer cable. Disconnect the transfer case and the transmission linkage. Disconnect the vacuum lines and the vent hose.
  6.  
  7. Remove the bolts attaching the transmission assembly to the engine. Move the transmission assembly and the torque converter rearward to clear the crankshaft.
  8.  
  9. Carefully lower the transmission assembly from the vehicle. Separate the transfer case from the transmission assembly.
  10.  

To install:
  1. If the transmission and transfer case were separated, reassemble the components and tighten the bolts to 26 ft. lbs. (35 Nm).
  2.  
  3. Carefully raise the transmission into position.
  4.  
  5. Install the bolts attaching the transmission assembly to the engine. Tighten the bolts to 25 ft. lbs. (34 Nm) for the 904. On the AW-4, tighten the 10mm bolts to 25 ft. lbs. (34 Nm); the 12mm bolts to 42 ft. lbs. (57 Nm).
  6.  
  7. Connect the backup light switch wire and the speedometer cable.
  8.  
  9. Connect the transfer case and the transmission linkage.
  10.  
  11. Connect the vacuum lines and the vent hose.
  12.  
  13. Connect the fluid cooler lines.
  14.  
  15. Connect the rear driveshaft to the transfer case. Tighten the strap bolt nuts to 14 ft. lbs. (19 Nm); the flange-to-case bolts to 35 ft. lbs. (47 Nm).
  16.  

New strap bolts must be used everytime the driveshaft is disconnected.

  1. Install the rear crossmember. Tighten the crossmember attaching bolts to 30 ft. lbs. (41 Nm); the transmission-to-crossmember bolts to 33 ft. lbs. (45 Nm).
  2.  
  3. Connect the exhaust pipe at the catalytic converter.
  4.  
  5. Install the bolts attaching the torque converter to the flexplate. Tighten the bolts to 40 ft. lbs. (54 Nm)
  6.  
  7. Remove the floor jack.
  8.  
  9. Install the torque converter inspection cover.
  10.  
  11. If the vehicle is equipped with a diesel engine, install the left motor mount and starter.
  12.  
  13. Lower the truck.
  14.  
  15. Connect the negative battery cable.
  16.  

1992-98 Cherokee and Comanche
2WD MODELS
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Matchmark the rear driveshaft and yoke for reassembly.
  6.  
  7. Disconnect and remove the rear driveshaft.
  8.  
  9. Remove the torque converter inspection cover.
  10.  
  11. Matchmark the converter driveplate and converter assembly for reassembly.
  12.  
  13. Remove the bolts attaching the torque converter to the flexplate.
  14.  
  15. Remove the starter.
  16.  
  17. Support the transmission assembly using a jack.
  18.  
  19. Remove the bolts attaching the rear crossmember to the transmission side rail.
  20.  
  21. Disconnect the exhaust pipe at the catalytic converter.
  22.  
  23. Lower the transmission slightly in order to disconnect the fluid cooler lines.
  24.  
  25. Disconnect the backup light switch wire and speedometer cable.
  26.  
  27. Disconnect the transmission linkage.
  28.  
  29. Remove the bolts attaching the transmission assembly to the engine.
  30.  
  31. Move the transmission assembly and the torque converter rearward to clear the crankshaft.
  32.  
  33. Carefully lower the transmission assembly from the vehicle.
  34.  

To install:
  1. Carefully raise the transmission into position.
  2.  
  3. Install the bolts attaching the transmission assembly to the engine. Tighten the bolts to:

    10mm bolts: 25 ft. lbs. (34 Nm)
     
    12mm bolts: 42 ft. lbs. (57 Nm)
     

  4.  
  5. Connect the backup light switch wire.
  6.  
  7. Connect the speedometer cable.
  8.  
  9. Connect the transmission linkage.
  10.  
  11. Connect the fluid cooler lines.
  12.  
  13. Install the rear crossmember. Tighten the crossmember bolts to 30 ft. lbs. (41 Nm); the transmission-to-crossmember bolts to 33 ft. lbs. (45 Nm).
  14.  
  15. Connect the exhaust pipe at the catalytic converter.
  16.  
  17. Install the bolts attaching the torque converter to the flexplate. Tighten the bolts to 40 ft. lbs. (54 Nm).
  18.  
  19. Install the starter.
  20.  
  21. Remove the transmission jack.
  22.  
  23. Install the torque converter inspection cover.
  24.  
  25. Install the driveshaft. New strap bolts should be used every time the driveshaft is disconnected. Tighten the nuts to 14 ft. lbs. (19 Nm).
  26.  
  27. Lower the vehicle.
  28.  
  29. Connect the negative battery cable.
  30.  

4WD MODELS
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Matchmark the rear driveshaft and yoke for reassembly. Disconnect and remove the rear driveshaft.
  6.  
  7. Remove the torque converter inspection cover.
  8.  
  9. Matchmark the converter driveplate and converter assembly for reassembly.
  10.  
  11. Remove the bolts attaching the torque converter to the flexplate.
  12.  
  13. Support the transmission assembly with a jack.
  14.  
  15. Remove the bolts attaching the rear crossmember to the transmission side rail.
  16.  
  17. Disconnect the exhaust pipe at the catalytic converter.
  18.  
  19. Lower the transmission slightly in order to disconnect the fluid cooler lines.
  20.  
  21. Matchmark the front driveshaft assembly for installation.
  22.  
  23. Disconnect the driveshaft at the transfer case and secure the assembly aside.
  24.  
  25. Disconnect the backup light switch wire and speedometer cable.
  26.  
  27. Disconnect the transfer case and transmission linkage.
  28.  
  29. Disconnect the vacuum lines and vent hose.
  30.  
  31. Remove the bolts attaching the transmission assembly to the engine.
  32.  
  33. Move the transmission assembly and torque converter rearward to clear the crankshaft.
  34.  
  35. Carefully lower the transmission assembly from the vehicle.
  36.  
  37. Remove the transfer case retaining bolts from the transmission assembly.
  38.  

To install:
  1. If the transmission and transfer case were separated, re-attach them and tighten the bolts to 26 ft. lbs. (35 Nm).
  2.  
  3. Carefully raise the transmission into position.
  4.  
  5. Install the bolts attaching the transmission assembly to the engine. Tighten the bolts to:

    10mm bolts: 25 ft. lbs. (34 Nm)
     
    12mm bolts: 42 ft. lbs. (57 Nm)
     

  6.  
  7. Connect the backup light switch wire and speedometer cable.
  8.  
  9. Connect the transfer case and transmission linkage.
  10.  
  11. Connect the vacuum lines and the vent hose.
  12.  
  13. Connect the fluid cooler lines.
  14.  
  15. Connect the driveshaft at the transfer case. New strap bolts should be used whenever the driveshaft is disconnected. Tighten the strap bolt nuts to 14 ft. lbs (19 Nm); the flange-to-case bolts to 35 ft. lbs. (48 Nm).
  16.  
  17. Install the rear crossmember. Tighten the crossmember attaching bolts to 30 ft. lbs. (41 Nm); the transmission-to-crossmember bolts to 33 ft. lbs. (45 Nm).
  18.  
  19. Connect the exhaust pipe at the catalytic converter.
  20.  
  21. Install the bolts attaching the torque converter to the flexplate. Tighten the bolts to 40 ft. lbs. (61 Nm).
  22.  
  23. Remove the floor jack.
  24.  
  25. Install the torque converter inspection cover.
  26.  
  27. Install the rear driveshaft. Use new strap bolts. Tighten the strap bolt nuts to 14 ft. lbs. (19 Nm); the flange bolts to 35 ft. lbs. (48 Nm).
  28.  
  29. Lower the vehicle.
  30.  
  31. Connect the negative battery cable.
  32.  

1993-98 Grand Cherokee/Wagoneer
2WD MODELS
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. If equipped, remove the skid plate.
  6.  
  7. If the transmission is being removed for repair, drain the fluid and reinstall the pan.
  8.  
  9. Matchmark the driveshaft yoke and remove the driveshaft.
  10.  
  11. Disconnect the vehicle speed wires, transmission solenoid wires and park-neutral position switch wires.
  12.  
  13. Disconnect the wires from the transmission speed sensor at the rear of the overdrive unit.
  14.  
  15. Remove the exhaust Y-pipe.
  16.  
  17. Unclip the wire harness from the transmission clips.
  18.  
  19. Disconnect the throttle valve and gearshift cables from the levers on the valve body manual shaft. Position the cables aside and secure them to the underbody.
  20.  
  21. Remove the dust cover from the transmission converter housing.
  22.  
  23. Remove the starter.
  24.  
  25. Remove the bolts attaching the converter to the driveplate.
  26.  
  27. Disconnect the cooler fluid lines from the transmission.
  28.  
  29. Support the transmission with a jack.
  30.  
  31. Remove the nuts and bolts securing the rear crossmember to the insulator and remove the crossmember.
  32.  
  33. Lower the jack to gain access to the upper portion of the transmission.
  34.  
  35. Remove the crankshaft position sensor.
  36.  
  37. Remove the transmission fill tube and discard the O-ring.
  38.  
  39. Remove the bolts attaching the transmission to the engine.
  40.  
  41. Slide the transmission back and secure a C-clamp to the converter.
  42.  
  43. Remove the transmission.
  44.  

To install:
  1. Ensure the torque converter hub and hub drive are free from sharp edges, scratches or nicks. Polish with 400 grit sandpaper if necessary.
  2.  
  3. Lubricate the converter hub and pump seal with high temperature grease.
  4.  
  5. Secure the C-clamp to the converter.
  6.  
  7. Ensure the dowel pins are seated in the engine block and protrude far enough to align the transmission.
  8.  
  9. Align the transmission with the engine dowels and converter with the driveplate. Install 2 transmission bolts to keep it in place.
  10.  
  11. Remove the C-clamp and install the torque converter bolts. Tighten the bolts to:

    3 lug converter-40 ft. lbs. (54 Nm)
     
    4 lug converter-270 inch lbs. (31 Nm)
     

  12.  
  13. Install and tighten the remaining transmission-to-engine bolts.
  14.  
  15. Install the crankshaft position sensor.
  16.  
  17. Install the dust cover on the converter housing.
  18.  
  19. Install the starter.
  20.  
  21. Connect the transmission shift and throttle valve cables to the transmission.
  22.  
  23. Fasten the wire harness to the transmission.
  24.  
  25. Engage the harness connectors unplugged during removal.
  26.  
  27. Install the transmission filler tube with a new O-ring.
  28.  
  29. Install the rear crossmember.
  30.  
  31. Connect the fluid cooler lines to the transmission.
  32.  
  33. Align and install the driveshaft.
  34.  
  35. Install the exhaust system components.
  36.  
  37. Lower the vehicle.
  38.  
  39. Connect the negative battery cable.
  40.  
  41. Check the transmission control cables; adjust if necessary.
  42.  
  43. If the transmission fluid was drained, fill the transmission with fluid to the proper level.
  44.  

4WD MODELS
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. If equipped, remove the skid plate.
  6.  
  7. If the transmission is being removed for repair, drain the fluid and reinstall the pan.
  8.  
  9. Matchmark the driveshaft yokes and remove both driveshafts.
  10.  
  11. Disconnect the vehicle speed wires, transmission solenoid wires and park-neutral position switch wires.
  12.  
  13. Unclip the wire harness from the transmission clips.
  14.  
  15. Disconnect the transfer case shift linkage from the lever. Remove the linkage and bracket from the transfer case. Position the linkage aside.
  16.  
  17. Remove the nuts attaching the transfer case to the overdrive unit gear case.
  18.  
  19. Place a jack under the transfer case and remove the case.
  20.  
  21. Support the transmission with the jack.
  22.  
  23. Remove the rear transmission crossmember.
  24.  
  25. Remove the exhaust Y-pipe.
  26.  
  27. Remove the crankshaft position sensor.
  28.  
  29. Disconnect the gearshift linkage from the lever on the transmission.
  30.  
  31. Remove the transmission shift linkage torque shaft assembly from the transmission and frame rail. Position it aside.
  32.  
  33. Remove the transmission-to-engine brackets.
  34.  
  35. Remove the dust cover from the transmission converter housing.
  36.  
  37. Remove the starter.
  38.  
  39. Remove the bolts attaching the converter to the driveplate.
  40.  
  41. Disconnect the cooler fluid lines from the transmission.
  42.  
  43. Disconnect the solenoid and park/neutral position switch wires.
  44.  
  45. Remove the transmission fill tube and discard the O-ring.
  46.  
  47. Lower the jack to gain access to the upper portion of the transmission.
  48.  
  49. Remove the bolts attaching the transmission to the engine.
  50.  
  51. Slide the transmission back and secure a C-clamp to the converter.
  52.  
  53. Move the transmission rearward until it clears the engine block dowels.
  54.  

On some models, part of the flange joining the vehicle cab and dash panel may interfere with transmission removal. If necessary peen this part of the flange over with a mallet.

  1. Remove the transmission.
  2.  

To install:
  1. Ensure the torque converter hub and hub drive are free from sharp edges, scratches or nicks. Polish with 400 grit sandpaper if necessary.
  2.  
  3. Lubricate the converter hub and pump seal with high temperature grease.
  4.  
  5. Secure the C-clamp to the converter.
  6.  
  7. Ensure the dowel pins are seated in the engine block and protrude far enough to align the transmission.
  8.  
  9. Align the transmission with the engine dowels and converter with the driveplate. Install 2 transmission bolts to keep it in place.
  10.  
  11. Remove the C-clamp and install the torque converter bolts. Tighten the bolts as follows:

    3 lug converter-40 ft. lbs. (54 Nm)
     
    4 lug, except 10.75 inch converter-55 ft. lbs. (74 Nm)
     
    4 lug, 10.75 inch converter-270 inch lbs. (31 Nm)
     

  12.  
  13. Install the starter.
  14.  
  15. Install the strut brackets securing the transmission to the engine and front axle.
  16.  
  17. Install and tighten the remaining transmission-to-engine bolts.
  18.  
  19. Install the crankshaft position sensor.
  20.  
  21. Install the transmission filler tube with a new O-ring.
  22.  
  23. Install the exhaust system components.
  24.  
  25. Install the shift linkage torque bracket.
  26.  
  27. Connect the shift linkage to the transmission.
  28.  
  29. Connect the harness connectors disconnected during removal.
  30.  
  31. Install the rear crossmember.
  32.  
  33. Install the transfer case. Tighten the nuts as follows:

    3 / 8 stud nuts-35 ft. lbs. (47 Nm)
     
    5 / 16 stud nuts-26 ft. lbs. (35 Nm)
     

  34.  
  35. Install the damper on the transfer case rear retainer if removed. Tighten the nuts to 40 ft. lbs. (54 Nm).
  36.  
  37. Connect the transfer case shift linkage.
  38.  
  39. Connect the fluid cooler lines to the transmission.
  40.  
  41. Align and install the driveshafts. Tighten the U-joint clamp bolts to 170 inch lbs. (19 Nm).
  42.  
  43. Fill the transfer case to the proper level with fluid.
  44.  
  45. Lower the vehicle.
  46.  
  47. Connect the negative battery cable.
  48.  
  49. Fill the transmission to the proper level with the appropriate fluid.
  50.  
  51. Check the transmission control cables, adjust if necessary.
  52.  
  53. Check and adjust the transmission and transfer case shift linkage.
  54.  

adjustments

Shift Linkage/Cable
EXCEPT 30RH/32RH, 42RE/44RE and AW4 MODELS

See Figure 2

  1. Raise and support the truck on jackstands.
  2.  
  3. Loosen the shift rod trunnion locknuts.
  4.  
  5. Remove the lockpin retaining the shift rod trunnion to the bellcrank and disengage the trunnion and shift rod from the bellcrank.
  6.  



Click image to see an enlarged view

Fig. Fig. 2: Loosen the locknut (1). Remove the lockpin retaining the shift rod. Disengage the trunnion (2) and shift rod (3) at the bellcrank (4)

  1. Place the shift lever in P and lock the steering column.
  2.  
  3. Move the lever on the transmission rearward to the P detent. Park is the last possible rearward position.
  4.  
  5. Check to make sure that P is engaged, by trying to rotate the driveshaft by hand.
  6.  
  7. Adjust the shift rod trunnion so that the pin fits freely in the bellcrank arm and tighten the trunnion locknuts. Prevent the shift rod from turning while tightening the locknuts.
  8.  

All lash in the linkage must be eliminated to provide for proper adjustment. Lash can be eliminated by pulling downward on the shift rod and pressing upward on the bellcrank.

  1. Check that the engine starts in only the P and N positions, and that all shift ranges work properly.
  2.  
  3. Lower the truck.
  4.  

30RH/32RH, 42RE/44RE and AW4 MODELS

See Figures 3 and 4

  1. Place gearshift lever in P .
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Unlock the transmission shift control cable by prying upward on the T-shaped adjuster clamp to release.
  6.  



Click image to see an enlarged view

Fig. Fig. 3: Unlock transmission shift control cable by prying upward on the T-shaped adjuster clamp to release

  1. Move the valve body manual lever rearward into P detent (last rearward detent). Ensure that vehicle is in P by attempting to rotate the driveshaft. The driveshaft should NOT rotate.
  2.  



Click image to see an enlarged view

Fig. Fig. 4: With the valve body manual lever in the P position, snap the cable into the lower reaction bracket

  1. With the valve body manual lever in the P position, snap the cable into the lower reaction bracket.
  2.  
  3. Lock the cable by pressing the T-shaped adjuster clamp down until it snaps into place.
  4.  
  5. Check engine starting procedure to ensure engine will only start in P or N .
  6.  
  7. Lower vehicle.
  8.  

Park Lock Cable
EXCEPT 42RE/44RE

See Figure 5

  1. Shift the transmission into P .
  2.  
  3. Turn the ignition switch to the LOCK position.
  4.  
  5. Remove the shifter lever bezel and console screws. Raise the console for access to the cable.
  6.  
  7. Pull the cable lock button up to the release cable.
  8.  
  9. Pull the cable forward. Then release the cable and press the lock button down until it snaps in place.
  10.  
  11. Check the movement of the release shift handle button (floor shift) or release lever (column shift). You should not be able to press the button inward or move the column lever.
  12.  
  13. Turn the ignition to the ON position. Move the shift or column lever into N . If the cable adjustment is correct, ignition should not return to LOCK position. Recheck with the shift or column lever in the D position.
  14.  
  15. Move the shift or column lever to the P position. Ignition should now return to the LOCK position. With the ignition in the LOCK position, the shift or column lever should not move.
  16.  



Click image to see an enlarged view

Fig. Fig. 5: Park lock cable assembly

42RE/44RE MODELS
  1. Shift the transmission into P .
  2.  
  3. Turn ignition switch to the ACC position.
  4.  
  5. Remove the shifter lever bezel and console screws. Raise console for access to cable.
  6.  
  7. Pull the cable lock button up to release cable.
  8.  
  9. Pull the cable forward. Then release the cable and press the lock button down until it snaps in place.
  10.  
  11. With the shift lever in P , the ignition lock cylinder should move from OFF to LOCK . Cylinder should not rotate in any other position.
  12.  
  13. Turn the ignition to the RUN position. Press and hold the brake pedal. Check that the lever can be moved out of P .
  14.  

Throttle Cable
AW-4 AND 30RH/32RH MODELS

See Figure 6

  1. Turn the ignition switch to OFF .
  2.  
  3. Press the throttle cable button all the way down, then, push the cable plunger inward.
  4.  



Click image to see an enlarged view

Fig. Fig. 6: AW-4 and 30RH/32RH adjusting mechanism

  1. Rotate the primary throttle lever to the wide open throttle position.
  2.  
  3. Hold the primary throttle lever in this position and let the cable plunger extend.
  4.  
  5. Release the lever when the plunger is fully extended.
  6.  
  7. The cable is now adjusted.
  8.  

42RE/44RE MODELS
  1. Turn the ignition switch to OFF .
  2.  
  3. Disconnect the cable from the stud.
  4.  
  5. Press the cable lock button inward to release the cable.
  6.  
  7. Center the end of the cable to the stud within 0.039 in. (1mm).
  8.  
  9. Install the cable onto the stud.
  10.  

46RH MODELS
  1. Turn the ignition switch to OFF .
  2.  
  3. Remove the air cleaner.
  4.  
  5. Position a 0.110-0.120 in. (2.8-3.0mm) feeler gauge between the idle stop and throttle lever.
  6.  
  7. Press the cable lock button to release the cable.
  8.  
  9. Raise the vehicle for access to the throttle valve lever.
  10.  
  11. Rotate the lever towards the front of the vehicle until the ratcheting sound stops.
  12.  
  13. Remove the feeler gauges and check the cable adjustment. The throttle lever should begin to move at the same time the lever on the throttle body moves off idle.
  14.  
  15. Lower the vehicle and install the air cleaner.
  16.  

Throttle Valve Lever and Cable
2.1L DIESEL ENGINES

See Figures 7, 8 and 9

Special tool J-35514 and gauge J-35591 are necessary for this procedure.

  1. Disconnect the throttle valve cable from the pin on the throttle valve lever.
  2.  
  3. Disconnect the cable from the transmission throttle lever. Remove and discard the cable.
  4.  
  5. Set the injection pump automatic advance lever at the curb idle position (seated against the stop).
  6.  



Click image to see an enlarged view

Fig. Fig. 7: Throttle valve lever and cable adjusting tool

  1. Loosen the set screw and turn the cable clevis 1 / 4 turn counterclockwise. Tighten the set screw.
  2.  
  3. Install the special tool as shown.
  4.  
  5. Loosen the thumbscrew on the tool and move the sliding legs rearward.
  6.  
  7. Place the notched leg of the tool on the cable bracket. Then, rest the sliding legs on the lever.
  8.  



Click image to see an enlarged view

Fig. Fig. 8: Throttle valve cable adjustment points

  1. Move the sliding legs forward until the rear leg lightly touches the cable attaching pin. Tighten the thumbscrew.
  2.  
  3. Move the lever to the wide open throttle position. The cable attaching pin should now lightly touch the forward leg of the sliding legs.
  4.  
  5. If the cable attaching pin does not touch the forward leg, or if the pin tends to move the special tool, hold the lever in the wide open throttle position, loosen the two lever adjusting screws and move the lever to adjust the travel. Tighten the screws to 66 inch lbs. Return the lever to the curb idle position and verify that the pin is, again, lightly touching the rear leg of the sliding legs. If the pin doesn't touch the rear leg at curb idle, loosen the thumbscrew and adjust the tool so that it does, and repeat the adjustment.
  6.  
  7. Install a new throttle valve cable, part number 8953 001 796.
  8.  
  9. The new cable should be supplied with a cable stop, or one can be obtained from a lawn mower shop, motorcycle repair shop or small engines outlet. The throttle stop should have an inside diameter of 1.07mm.
  10.  
  11. The new cable has a factory installed cable stop crimped onto the end of the cable. Cut this off and slide the inner cable stop off the cable. Slide the new cable stop into place and hand tighten the set screw.
  12.  
  13. Connect the new cable to the throttle valve lever pin.
  14.  
  15. Obtain a small coil spring and use it to hold the throttle valve lever against its stop.
  16.  
  17. Loosen the cable stop and install gauge J-35591 between the cable stop and the retainer.
  18.  



Click image to see an enlarged view

Fig. Fig. 9: Gauge attached to the cable (A), between the cable stop (N) and retainer (S)

  1. Remove all slack from the cable.
  2.  
  3. Slide the cable stop rearward against the gauge and retainer. Securely tighten the set screw and remove the gauge. Remove the spring that you used on the throttle lever. Loosen the clevis set screw and turn the clevis screw back 1 / 4 turn.
  4.  

Front Band
42RE/44RE, 46RH AND 30RH/32RH MODELS

See Figure 10

  1. Raise and support the truck on jackstands. The front band adjusting screw is located on the left side of the case, just above the control levers.
  2.  
  3. Loosen the locknut and back it off about five turns.
  4.  



Click image to see an enlarged view

Fig. Fig. 10: Front band adjustment

  1. Make sure that the screw turns freely. Use penetrating oil if it binds.
  2.  
  3. Tighten the screw to 72 inch lbs. (8 Nm).
  4.  
  5. Back off the screw 2 1 / 2 turns on 42RE/44RE, 46RH and 30RH. On the 32RH, back it off 2 1 / 4 turns. On the 42RE/44RE back it off 2 7 / 8 turns.
  6.  
  7. Tighten the locknut to 30 ft. lbs. (41 Nm). Hold the screw still while tightening the locknut.
  8.  
  9. Lower the truck.
  10.  

Rear Band
42RE/44RE, 46RH AND 30RH/32RH MODELS

See Figure 11

  1. Raise and support the truck on jackstands.
  2.  
  3. Drain the fluid and remove the pan.
  4.  
  5. Remove the adjusting screw locknut.
  6.  



Click image to see an enlarged view

Fig. Fig. 11: Rear band adjustment

  1. Tighten the adjusting screw to 41 inch lbs. (5 Nm) on 42RE/44RE and 30RH. On the 32RH and 46RH, tighten it to 72 inch lbs. (8 Nm).
  2.  
  3. Back off the adjusting screw 7 turns on 30RH. On the 32RH back it off 4 turns. On the 42RE/44RE and 46RH, back it off 2 turns.
  4.  
  5. Hold the adjusting screw still and tighten the locknut to 150 inch lbs. (17 Nm) on the 30RH/32RH. On the 42RE/44RE and 46RH, tighten it to 25 ft. lbs. (34 Nm).
  6.  
  7. Install the pan and fill the unit with the appropriate fluid.
  8.  

 
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