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AW-4 Transmission Swap


The AW4 transmission, like most others, uses a throttle valve (TV) cable.  The TV cable helps control shift speed, quality, and part-throttle downshift sensitivity.  If the cable is too loose, early shifts may occur.  If the cable is too tight, delayed shifts may occur and part-throttle down shifts may be too sensitive. 


The cable bracket for the throttle body comes setup for the TV cable.  The spring shown in the above photo must be removed to make room for the TV cable.  Unhook it from the bracket.  The other end can be pushed off of the throttle linkage. 

 

With the spring removed, the end of the TV cable is inserted into the bracket and similar to the shifter cable, locking tabs secure it in place.  If you look at the top of the valve cover, you should see some clips where the throttle cable is secured.  Mine had an extra slot available for the TV cable.  The other end of the TV cable is attached to the AW4 and is not intended to be removed (unlike this end). 

 

There is a spring loaded plunger on the top of the TV cable (where it locks into the bracket near the throttle body).  By pushing the plunger (my thumb is on it in the above photo), you can adjust the tension on the TV cable.  You want to set the cable tension so that the TV cable is in sync with the throttle body.  In other words, just as the throttle body begins to move, any slack in the TV cable is gone and it too begins to move.  To put it another way, you don't want any pre-load nor any slop in the cable.



And since you are under the hood hooking things up, don't forget to install the CPS (crank shaft position sensor) into the AW4's housing.  It is located slightly to the driver's side on the top of the AW4 housing.  Looking down past the end of the manifold will get you lined up on where it goes.  While the stock 3 speed TJ auto tranny's CPS relied on an air gap for proper operation, you can install the CPS from the manual tranny by simply bolting it into position.  I found it easier to get to the mounting bolts by reaching up from the bottom rather than down from the top.  Your results may vary. 
 

More AW-4 Tranny Swap

 

 

 

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