JEEP CHEROKEE 1994 Service Repair Manual

²Race outer diameter is 48.9 mm (1.925 in.) and in-
side diameter is 26.0 mm (1.024 in.).
²Bearing outer diameter is 46.7 mm (1.839 in.) and
inside diameter is 26.0 mm (1.024 in.).
(31) Coat front planetary ring gear race with pe-
troleum jelly and install it in ring gear (Fig. 25).
(32) Verify ring gear race size. Outer diameter is
47.0 mm (1.850 in.) and inside diameter is 26.5 mm
(1.045 in.).
(33) Align forward-direct clutch disc splines with
screwdriver (Fig. 26).
(34) Align and install front planetary ring gear in
forward-direct clutch (Fig. 27).
Fig. 24 Installing Forward-Direct Clutch Thrust Bearing
And Race
Fig. 21 Installing Planetary Thrust Race
Fig. 22 Installing Second Coast Brake Band
Fig. 23 Installing Second Coast Brake Band Retaining Pin
21 - 260 AW-4 TRANSMISSION OVERHAULJ

(35) Coat bearing and race with petroleum jelly
and install them in ring gear (Fig. 28). Verify bear-
ing/race size.
²Bearing outer diameter is 47.7 mm (1.878 in.) and
inside diameter is 32.6 mm (1.283 in.).
²Race outer diameter is 53.6 mm (2.110 in.) and in-
side diameter is 30.6 mm (1.205 in.).
(36) Rotate front of transmission case downward
and install assembled planetary gear/forward-direct
clutch (Fig. 29).
Fig. 25 Installing Planetary Ring Gear Race
Fig. 26 Aligning Forward-Direct Clutch Splines
Fig. 27 Installing Front Planetary Ring Gear
Fig. 28 Installing Ring Gear Bearing And Race
ART: j8921-696; SIZE (3) = 3-1/2h x 3-1/2w
Fig. 29 Installing Front Planetary And Forward-
Direct Clutch Assembly
JAW-4 TRANSMISSION OVERHAUL 21 - 261

(37) Check clearance between sun gear input drum
and direct clutch drum (Fig. 30). Clearance should be
9.8 - 11.8 mm (0.386 - 0.465 in.). If clearance is in-
correct, planetary gear/forward-direct clutch assem-
bly is not seated or is improperly assembled. Remove,
and correct if necessary.
(38) Coat thrust bearing and race assembly with
petroleum jelly and install it on clutch shaft. Bearing
faces up and toward case front as shown (Fig. 31).
Verify bearing/race size. Bearing and race outer di-
ameter is 47.8 mm (1.882 in.) and inside diameter is
33.6 mm (1.301 in.).
(39) Assemble second coast brake piston compo-
nents (Fig. 32).(40) Install assembled second coast brake piston in
case.
(41) Install replacement seals on second coast
brake piston cover and install cover in case.
(42) Install second coast brake piston snap ring
with snap ring plier tool (Fig. 33).
(43) Check second coast brake piston stroke as fol-
lows:
(a) Make reference mark on brake piston rod
(Fig. 34).
(b) Apply 57-114 psi air pressure through feed
hole (Fig. 34). Alternately apply and release air
pressure to operate piston.
(c) Check stroke with gauge 7552 (Fig. 35).
(d) If stroke length is incorrect, piston, cover or
snap ring is not seated. Reassemble and check
stroke again if necessary.
(44) Coat thrust race and tabbed washer with pe-
troleum jelly and install them on overdrive support
(Fig. 36). Verify race size. Race outer diameter is 50.9
mm (2.004 in.) and inside diameter is 36.2 mm (1.426
in.).
Fig. 30 Checking Input Drum-To-Direct Clutch Drum
Clearance
Fig. 31 Installing Clutch Shaft Thrust Bearing And
Race Assembly
Fig. 32 Assembling Second Coast Brake Piston
Fig. 33 Installing Second Coast Brake Piston Snap
Ring
21 - 262 AW-4 TRANSMISSION OVERHAULJ

(45) Install overdrive support in case. Use two long
bolts to help align and guide support into position
(Fig. 37).
(46) Install overdrive support snap ring with Snap
Ring Plier Tool 7540 (Fig. 38). Chamfered side of
snap ring faces up and toward case front.Snap ring
ends must be aligned with case opening with
ring ends approximately 24 mm (0.94 in.) from
centerline of case opening.
(47) Install and tighten overdrive support bolts to
25 Nzm (19 ft-lbs) torque (Fig. 39).
(48) Check output shaft end play with dial indica-
tor (Fig. 40). End play should be 0.27 - 0.86 mm
(0.0106 - 0.0339 in.).(49) If output shaft end play is incorrect, one or
more of installed components is not seated. Reassem-
ble as necessary and check end play again.
(50) Install overdrive clutch pack (Fig. 41). Install
thickest clutch plate first. Rounded edge of plate
faces up. Install first disc followed by another plate
until correct number of discs-plates are installed. In-
stall four discs and three plates.
(51) Install stepped ring retainer plate with flat
side facing disc. Then install brake pack snap ring
(Fig. 42).
Fig. 36 Installing Overdrive Support Thrust Race
And Washer
Fig. 37 Installing Overdrive Support
Fig. 34 Marking Brake Piston Rod
Fig. 35 Checking Second Coast Brake Piston Stroke
JAW-4 TRANSMISSION OVERHAUL 21 - 263

(52) Check overdrive brake piston stroke as fol-
lows:(a) Mount Gauge 7546 in dial indicator and posi-
tion gauge tool against overdrive brake piston (Fig.
43).
(b) Apply and release overdrive brake piston
with compressed air and note piston stroke length
on dial indicator. Apply air pressure through feed
hole in case (Fig. 44).
(c) Piston stroke length should be 1.40 - 1.70 mm
(0.55 - 0.66 in.).
(d) If stroke is incorrect, brake pack or piston is
installed incorrectly. Check and correct as neces-
sary and measure piston stroke again.
(53) Remove dial indicator and gauge tool.
Fig. 38 Installing Overdrive Support Snap Ring
Fig. 39 Installing Overdrive Support Bolts
Fig. 40 Checking Output Shaft End Play
Fig. 41 Install Overdrive Clutch Pack
Fig. 42 installing Overdrive Brake Snap Ring
21 - 264 AW-4 TRANSMISSION OVERHAULJ

(54) Remove overdrive brake piston snap ring and
remove overdrive clutch pack components.
(55) Coat overdrive lower race, thrust bearing and
upper race with petroleum jelly and install them in
overdrive support (Fig. 45). Be sure races and bear-
ing are assembled and installed as shown.
(56) Verify bearing/race sizes before proceeding.
Bearing-race sizes are:
²Outer diameter of lower race is 47.8 mm (1.882
in.) and inside diameter is 34.3 mm (1.350 in.).
²Outer diameter of bearing is 47.7 mm (1.878 in.)
and inside diameter is 32.7 mm (1.287 in.).
²Outer diameter of upper race is 47.8 mm (1.882
in.) and inside diameter is 30.7 mm (1.209 in.).
(57) Install overdrive planetary ring gear in sup-
port (Fig. 46).(58) Coat ring gear thrust race and thrust bearing
assembly with petroleum jelly and install them in
gear (Fig. 47).
(59) Verify bearing/race size before proceeding.
²Outer diameter of ring gear race-bearing is 47.8
mm (1.882 in.) and inside diameter is 24.2 mm (0.953
in.).
Fig. 43 Positioning Gauge Tool And Dial Indicator
Fig. 44 Checking Overdrive Brake Piston Stroke
Fig. 45 Installing Overdrive Support Thrust Bearing
And Races
Fig. 46 Installing Overdrive Planetary Ring Gear
JAW-4 TRANSMISSION OVERHAUL 21 - 265

²Outer diameter of bearing is 46.8 mm (1.844 in.)
and inside diameter is 26.0 mm (1.024 in.).
(60) Coat tabbed thrust race with petroleum jelly
and install it on planetary gear (Fig. 48). Race outer
diameter is 41.8 mm (1.646 in.) and inside diameter
is 27.1 mm (1.067 in.).
(61) Install assembled overdrive planetary gear
and clutch (Fig. 49).
(62) Coat thrust bearing and race assembly with
petroleum jelly and install it on clutch input shaft
(Fig. 50). Bearing and race outer diameter is 50.2
mm (1.976 in.) and inside diameter is 28.9 mm (1.138
in.).
(63) Install overdrive brake pack as follows:
(a) Install 4.0 mm (0.157 in.) thick plate first.
Rounded edge of plate must face upward.(b) Install a disc followed by a plate until the re-
quired number of discs and plates are installed. Be
sure to install the stepped plate last with the flat
side of the plate facing the disc (Fig. 51).
(c) Confirm that four discs and three plates have
been installed.
(64) Install clutch pack snap ring (Fig. 52).
(65) Coat thrust bearing race with petroleum jelly
and install it in oil pump (Fig. 53). Bearing race
Fig. 47 Installing Ring Gear Thrust Bearing And
Race
Fig. 48 Installing Planetary thrust Race
Fig. 49 Installing Overdrive Planetary And Clutch
Assembly
Fig. 50 Installing Input Shaft Thrust Bearing And
Race Assembly
21 - 266 AW-4 TRANSMISSION OVERHAULJ

outer diameter is 47.2 mm (1.858 in.) and inside di-
ameter is 28.1 mm (1.106 in.).
(66) Lubricate and install replacement O-ring on
oil pump body.
(67) Install oil pump in case. Align pump and case
bolt holes and carefully ease pump into place (Fig.
54).
CAUTION: Do not use force to seat the pump. The
seal rings on the stator shaft could be damaged if
they bind or stick to the direct clutch drum.
(68) Tighten oil pump bolts to 22 Nzm (16 ft. lbs.)
torque.
(69) Verify input shaft rotation. Shaft should rotate
smoothly and not bind.(70) Lubricate and install new O-ring on transmis-
sion throttle cable adapter and install cable in case
(Fig. 55).
(71) Check clutch and brake operation. Operate
clutches and brakes with compressed air applied
through feed holes in case (Fig. 56). Listen for clutch
and brake application. If you do not hear a clutch or
brake apply, disassemble transmission and repair
fault before proceeding.It is necessary to block
the overdrive clutch accumulator feed hole No.
8 (Fig. 56) in order to check direct clutch oper-
ation.
(72) Lubricate and install new O-rings on accumu-
lator pistons (Fig. 57).
(73) Assemble and install accumulator pistons and
springs (Fig. 57).
Fig. 53 Installing Oil Pump Thrust Race
Fig. 54 Installing Oil Pump
Fig. 51 Installing Overdrive Clutch Pack
Fig. 52 Installing Clutch Pack Snap Ring
JAW-4 TRANSMISSION OVERHAUL 21 - 267

(74) Install new check ball body and spring (Fig.
58).
(75) Position valve body on case (Fig. 59).
(76) Install detent spring (Fig. 59).
(77) Align manual valve, detent spring and shift
sector (Fig. 59).
(78) Connect transmission throttle cable to throttle
valve cam (Fig. 60).
(79) Install and tighten valve body-to-case bolts to
10 Nzm (7 ft. lbs.) torque.(80) Connect valve body solenoid wires to solenoids
(Fig. 61).
(81) Install new O-ring on solenoid harness
adapter and secure adapter to case.
Fig. 57 Accumulator Piston And Spring Installation
Fig. 58 Installing Check Ball Body And Spring
Fig. 55 Installing Transmission Throttle Cable
Fig. 56 Clutch And Brake Feed Hole Locations
21 - 268 AW-4 TRANSMISSION OVERHAULJ

(82) Install valve body oil tubes (Fig. 62). Tap
tubes into place with a plastic mallet. Be sure the
flanged tube ends and straight tube ends are in-
stalled as shown.
(83) Install new gaskets on oil screen and install
screen on valve body. Tighten screen bolts to 10 Nzm
(7 ft. lbs.) torque.
(84) Install magnet in oil pan. Be sure magnet
does not interfere with valve body oil tubes.
(85) Apply Mopar or Loctite 599 to sealing surface
of oil pan. Sealer bead should be at least 3 mm (1/8
in.) wide. Install pan on case and tighten pan bolts to
7Nzm (65 in. lbs.) torque.
(86) Install transmission speed sensor rotor and
key on output shaft (Fig. 63).
Fig. 63 Installing Transmission Speed Sensor Rotor
And Key
Fig. 61 Connecting Valve Body Solenoid Wires
Fig. 62 Installing Valve Body Oil Tubes
Fig. 59 Aligning Manual Valve, Shift Sector And
Detent Spring
Fig. 60 Connecting Transmission Throttle Cable
JAW-4 TRANSMISSION OVERHAUL 21 - 269