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  #1  
Old March 6th, 2009, 18:39
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FreemansXJ FreemansXJ is offline
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AW4 Solenoid Replacement write-up (no 56k)

This started off with a friends 1997 Cherokee Sport. His vehicle is equipped with the 4.0, AW4, and 231 case.

While playing around in 4wd, he noticed his CEL light come on and the Jeep was very sluggish on acceleration. It felt as though the Jeep was trying to take off in 3rd gear. When he manually placed it in 1/2 and accelerated, the Jeep accelerated as it should. He also had to manually shift it to 3rd and OD. While driving down the highway, it became obvious that the TQ was also not locking up (running 3k rpm at 70mph). I had him take it to AutoZone and have the codes ran, and it showed codes:

P0700- Transmission Control System Malfunction
P0758- Shift Solenoid B Electrical.

I did some research on here and a few other sites, and found this write up for PRE-97 models.....http://www.transonline.com/transdige...ers/index.html

On the 97 and up, the TCU is located under the dash on the right side of the steering column. I could not find a diagram that showed how to test the TCU on a 97 up Cherokee, so I did the next best thing. I crawled around underneath and checked all the wires coming out of the tranny. I found no lose wires, kinks, or breaks. This lead me to believe it was a Solenoid.

I started by ordering a 2 pack of Solenoids for $98 here:

http://www.bulkpart.com/Merchant2/me...e=A340solenoid

Remember, the AW4 is the same as the Toyota A340, so this is what the parts will say when you get them.

Once the parts arrived, I went to the parts store and picked up a filter/ gasket kit and 3 qts of tranny fluid. Once I had the stuff I needed, it was time to get dirty....

Start off by draining the tranny fluid using the drain plug...



Next, I removed the 10mm bolts holding the transmission pan on (hint: leave 2 on one side in so the pan does not fall to the floor when you break the seal on the gasket...saves on the mess)...



Continued.......
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  #2  
Old March 6th, 2009, 18:53
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FreemansXJ FreemansXJ is offline
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Re: AW4 Solenoid Replacement write-up (no 56k)

I had a heck of a time getting the dipstick tube loose, so I left it attached to the pan. To do this, you will need to remove the bracket that holds the tube to the bellhousing (13mm). This can be easily accessed from the engine compartment...



Once I had the pan dropped, I got a better look at the internals...





Here is a quick MS Paint label job of the solenoids. The front of the Jeep is on your right, so the #2 solenoid (b) is the one all alone.

#1 1/2-3/4 shift solenoid
#2 2/3 shift solenoid.
OD- OD solenoid.



Next, remove the 4 bolts holding on the tranny filter (which holds a suprising amount of fluid...lol)..



Now we use the 10mm again, and remove the #1 and #2 Solenoid bolts. Once you have the bolt out, the Solenoids merely pull straight out.

Here is the old (right) and new (left). Notice the new solenoid has a ground wire. This is attached to the bolt when you re-install the solenoid



Continued...
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  #3  
Old March 6th, 2009, 19:01
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Re: AW4 Solenoid Replacement write-up (no 56k)

To install the new solenoids, you merely push them in to the hole where the old solenoid was. You will then attach the supplied bracket to the solenoid and bolt it down. Remember to attach the ground wire to the bolt!! The new solenoids come with a longer wire, but a little routing can solve the problem.

New B (#2) Solenoid installed...



New #1 Solenoid installed....



You will now install the new Transmission filter, using the original bolts. Once it is installed, you can clean your pan and transmission housing of old gasket. Now you are ready to re-install the transmission pan. Don't forget to put the drain plug back in and re-attach the dipstick bracket.

I started off by putting 2 qts of tranny fluid in. I hooked the battery back up and started the Jeep. I then ran it through the gears, and it worked I took the Jeep for a quick test drive and it solved all the tranny issues. The jeep would take off in 1st, shift on its own, and the TQ would lock-up as it should. After the test drive, I checked the fluid level and added 1 more quart.

I hope this helps and let me know if you have any Questions.

JOhn
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  #4  
Old March 6th, 2009, 20:59
lawsoncl lawsoncl is offline
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Re: AW4 Solenoid Replacement write-up (no 56k)

Quote:
Originally Posted by FreemansXJ View Post
The front of the Jeep is on your right
Nice pics, but em isn't the front of the vehicle to the left?
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  #5  
Old March 6th, 2009, 21:30
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FreemansXJ FreemansXJ is offline
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Re: AW4 Solenoid Replacement write-up (no 56k)

Quote:
Originally Posted by lawsoncl View Post
Nice pics, but em isn't the front of the vehicle to the left?

Good catch...It will not let me edit it....can a mod change that for me?...

The front of the Jeep is to the left for reference.

JOhn

Last edited by FreemansXJ; March 6th, 2009 at 21:36.
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  #6  
Old March 6th, 2009, 21:40
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Re: AW4 Solenoid Replacement write-up (no 56k)

On my 95, the solenoid furthest to the back of the Jeep was hooked up to D16 on the TCM connector. YMMV if you have a different year.
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  #7  
Old March 25th, 2009, 01:44
DravisAR DravisAR is offline
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Re: AW4 Solenoid Replacement write-up (no 56k)

Did you use any RTV when you reinstalled the pan gasket or did you just use the gasket supplied with the filter kit?
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  #8  
Old March 25th, 2009, 05:38
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Re: AW4 Solenoid Replacement write-up (no 56k)

FWIW, I just used the rubber gasket and haven't had leaks yet.
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  #9  
Old March 25th, 2009, 17:16
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Re: AW4 Solenoid Replacement write-up (no 56k)

Quote:
Originally Posted by DravisAR View Post
Did you use any RTV when you reinstalled the pan gasket or did you just use the gasket supplied with the filter kit?
I actually used both. I used a very light skim layer of RTV on the pan to hold the gasket in place while I installed it. I also put a skim layer in the tranny. It hasn't leaked yet

John
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  #10  
Old March 25th, 2009, 19:15
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Re: AW4 Solenoid Replacement write-up (no 56k)

Great write up. I got the same codes with my 97 but never noticed any shift problems. Changed fluid and cleared the codes a few times. Probably only a matter of time until I replace mine. Thanks
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  #11  
Old March 30th, 2009, 16:41
DravisAR DravisAR is offline
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Re: AW4 Solenoid Replacement write-up (no 56k)

I've got everything sitting here to do the exact same thing on my jeep, probably knock it out tomorrow. Ill report back with results/problems
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  #12  
Old March 30th, 2009, 17:05
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Re: AW4 Solenoid Replacement write-up (no 56k)

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Originally Posted by DravisAR View Post
I've got everything sitting here to do the exact same thing on my jeep, probably knock it out tomorrow. Ill report back with results/problems
The hardest part is scraping the 5 lbs of RTV off.
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  #13  
Old March 30th, 2009, 18:52
DravisAR DravisAR is offline
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Re: AW4 Solenoid Replacement write-up (no 56k)

I can NOT get the 13mm on the bracket off, so I bent it out of the way the best I can, and yes the RTV removal is going to SUCK. About to put the new filter in and then the solenoids....
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  #14  
Old March 30th, 2009, 18:58
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Re: AW4 Solenoid Replacement write-up (no 56k)

For that 12mm for the dipstick bracket...

put a socket on it, and a jack handle on the end of the socket. It'll break it free that way. I wrestled with it for like 30 minutes before I did it with the jack handle. Worked like a charm.

Be careful when you remove the solenoids .. I broke all the little tabs off the solenoid wiring harnesses.
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  #15  
Old March 30th, 2009, 21:28
DravisAR DravisAR is offline
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Re: AW4 Solenoid Replacement write-up (no 56k)

Everything worked out fine, thanks again for the write up...I now have 2nd gear and torque back!

Anyone know what the ATF capacity is supposed to be on the AW4? I did 3 quarts.
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