Jeep 1996 Grand Cherokee Service Manual - page 1215
(45) Carefully withdraw alignment tool from over-
drive unit.
(46) Lubricate
intermediate
shaft
splines
and
bushing surfaces with transmission fluid or petro-
leum jelly.
(47) Install overdrive unit. Note that intermediate
shaft is snug fit in overdrive planetary gear and
overrunning clutch. If overdrive unit will not seat,
gear and clutch splines are probably misaligned.
(48) Apply 1-2 drops of Mopar thread adhesive (or
Loctite 242) to overdrive unit attaching bolts. Then
install and tighten bolts to 34 N·m (25 ft. lbs.)
torque. Be sure wire harness clips are placed on
appropriate overdrive bolts beforehand.
(49) Measure and if necessary, correct input shaft
end play as follows (Fig. 183):
(a) Be sure overdrive unit is installed on trans-
mission. End play cannot be properly checked
with overdrive unit off transmission.
(b) Attach dial indicator to converter housing.
(c) Position indicator plunger against input shaft
and zero indicator.
(d) Move input shaft in and out and record read-
ing. End play should be 0.56 - 2.31 mm (0.022 -
0.091 in.). Proceed to next step if end play is not
within specified limits.
(e) Intermediate shaft thrust washer (in hub of
rear clutch retainer) controls end play. Washer is a
select fit part and can be changed to adjust end
play. If end play turns out to be incorrect, remove
oil pump, and clutches. Then install thinner/
thicker thrust washer as necessary.
(50) Install accumulator piston and inner and
outer springs (Fig. 184).
(51) Verify that park/neutral position switch has
not been installed in case. Valve body can not be
installed if switch is in position.
(52) Verify that valve body solenoid harness is
secured in 3-4 accumulator housing cover plate.
(53) Install valve body as follows:
(a) Align and carefully insert park rod into pawl.
Rod will make click noise as it enters pawl. Move
rod slightly to check engagement.
(b) Align and seat valve body on case. Be sure
manual lever shaft and overdrive connector are
fully seated in case. Also be sure valve body wiring
is not pinched or kinked.
(c) Install and start all valve body attaching
bolts by hand. Then tighten bolts evenly, in a diag-
onal pattern to 12 N·m (105 in. lbs.) torque. Do
not overtighten valve body bolts. This could
result in distortion and cross leakage after
installation..
CAUTION:
It is possible for the park rod to dis-
place into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged
in the pawl and has not displaced into the cavity. If
the rod enters the cavity during installation, it will
become bent when the overdrive bolts are tight-
ened. If this occurs, the rod will have to be removed
and replaced.
(54) Install new filter on valve body. Tighten filter
screws to 4 N·m (35 in. lbs.).
(55) Adjust front and rear bands as follows:
(a) Loosen band adjusting screw locknuts.
(b) Tighten each band adjusting screw to 5 N·m
(72 in. lbs.) with torque wrench.
(c) Back off front band adjusting screw 3-5/8
turns.
(d) Back off rear band screw 4 turns.
Fig. 183 Measuring Input Shaft End Play
Fig. 184 Accumulator Piston And Springs
21 - 76
TRANSMISSION AND TRANSFER CASE
ZJ
DISASSEMBLY AND ASSEMBLY (Continued)