JEEP CHEROKEE 1995 Service Repair Manual

(6) Install hub in planetary ring gear and install
snap ring.
(7) Coat race and bearing with petroleum jelly and
install in planetary ring gear (Fig. 22).
(8) Verify bearing/race size. Outside diameter of race
is 47.8 mm (1.882 in.) and inside diameter is 24.2 mm
(0.953 in.). Outside diameter of bearing is 46.8 mm
(1.843 in.) and inside diameter is 26 mm (1.024 in.).
(9) Lubricate and install new O-rings on clutch pis-
ton. Then install piston in clutch drum.
(10) Install piston return springs in clutch piston
(Fig. 23).(11) Install piston snap ring. Compress piston re-
turn springs with Tool 7538 and shop press (Fig. 24).
(12) Install clutch pack in drum. Install steel plate
first, then a disc (Fig. 25). Continue installation se-
quence until required number of discs and plates
have been installed.
(13) Install clutch pack retainer with flat side fac-
ing downward. Then install retainer snap ring (Fig.
26). Compress springs with suitable tool.
Fig. 22 Install Ring Gear Bearing And Race
Fig. 23 Installing Piston Return Springs
Fig. 24 Installing Clutch Piston Snap Ring
Fig. 25 Installing Overdrive Clutch Discs And Plates
21 - 224 AW-4 TRANSMISSION OVERHAULJ

(14) Install clutch drum bearing and race assembly
(Fig. 27). Be sure bearing rollers face upward as
shown. Outside diameter of assembled bearing and
race is 50.2 mm (1.976 in.). Inside diameter is 28.9
mm (1.138 in.).(15) Install clutch on planetary gear.
(16) Verify one-way clutch operation. Hold drum
and turn planetary shaft clockwise and counterclock-
wise. Shaft should turn clockwise freely but lock
when turned counterclockwise.
Fig. 1 Overdrive Support Components
Fig. 26 Installing Retainer And Snap Ring
Fig. 27 Installing Clutch Drum Bearing And Race
Assembly
JAW-4 TRANSMISSION OVERHAUL 21 - 225

OVERDRIVE SUPPORT OVERHAUL
SUPPORT DISASSEMBLY
(1) Check brake piston operation. Mount support
on clutch (Fig. 2).
(2) Apply compressed air through support feed hole
and observe brake piston movement (Fig. 2). Piston
should move smoothly and not bind or stick. If oper-
ation is incorrect, replace piston and support.
(3) Remove thrust bearing front race, thrust bear-
ing and rear race (Fig. 3).(4) Turn overdrive support over and remove bear-
ing race and clutch drum thrust washer (Fig. 4).
(5) Compress piston return spring with Spring Com-
pressor 7537 and remove piston snap ring (Fig. 5).
(6) Mount support in direct clutch and remove
brake piston with compressed air. Apply air to same
feed hole used when checking piston operation.
(7) Remove and discard support O-rings (Fig. 1).
Fig. 2 Checking Brake Piston Movement
Fig. 3 Removing Support Thrust Bearing And Races
Fig. 4 Removing Clutch Drum Thrust Washer And
Race
Fig. 5 Removing/Installing Piston Snap Ring
21 - 226 AW-4 TRANSMISSION OVERHAULJ

(8) Remove support seal rings (Fig. 6).
(9) Measure free length of piston return springs
with springs mounted in retainer (Fig. 7). Length
should be 17.23 mm (0.678 in.).
(10) Clean support components and dry them with
compressed air.
(11) Inspect overdrive support and brake piston.
Replace support and piston if either part is worn or
damaged.
ASSEMBLING OVERDRIVE SUPPORT
(1) Lubricate new support seal rings. Then com-
press rings and install them on support (Fig. 8).(2) Lubricate and install new O-rings on brake pis-
ton. Then carefully seat piston in support.
(3) Install return springs on brake piston.
(4) Compress return springs with Spring Compres-
sor 7537 (Fig. 5) and install piston snap ring.
(5) Install support bearing race and clutch drum
thrust washer (Fig. 4).
(6) Install thrust bearing and front and rear bear-
ing races. Thrust bearing rollers should face upward
as shown (Fig. 9).
(7) Verify thrust bearing/race sizes (Fig. 9).
²Front race outer diameter is 47.8 mm (1.882 in.)
and inside diameter is 30.7 mm (1.209 in.).
Fig. 6 Removing Support Seal Rings
Fig. 7 Checking Piston Return Spring Length
Fig. 8 Installing Support Seal Rings
Fig. 9 Installing Support Thrust Bearing And Races
JAW-4 TRANSMISSION OVERHAUL 21 - 227

²Rear race outer diameter is 47.8 mm (1.882 in.)
and inside diameter is 34.3 mm (1.350 in.).
²Bearing outer diameter is 47.7 mm (1.878 in.) and
inside diameter is 32.7 mm (1.287 in.).
(8) Verify brake piston operation. Use same proce-
dure described at beginning of disassembly. Piston
should operate smoothly and not bind or stick.
DIRECT CLUTCH OVERHAUL
CLUTCH DISASSEMBLY
(1) Remove direct clutch from forward clutch (Fig. 1).
(2) Remove clutch drum thrust washer (Fig. 2).(3) Check clutch piston stroke length as outlined in
following steps.
(4) Mount direct clutch on overdrive support as-
sembly (Fig. 3).
(5) Mount dial indicator on clutch and position in-
dicator plunger on clutch piston (Fig. 4).
(6) Apply 57-114 psi air pressure through feed hole
in overdrive support and note piston stroke length
(Fig. 4). Check stroke at least twice.
(7) Piston stroke length should be 1.37 mm - 1.67
mm (0.054 -0.065 in.). If stroke length is incorrect, ei-
ther the clutch pack retainer or clutch discs will have
to be replaced.
Fig. 1 Separate Direct Clutch From Forward Clutch
Fig. 2 Removing Clutch Drum Thrust Washer
Fig. 3 Mount Direct Clutch On Overdrive Support
Fig. 4 Checking Direct Clutch Piston Stroke Length
21 - 228 AW-4 TRANSMISSION OVERHAULJ

(8) Remove clutch pack snap ring and remove re-
tainer and clutch pack from drum (Fig. 5).
(9) Compress clutch piston return springs with tool
7538 and remove clutch piston snap ring (Fig. 6).
(10) Remove compressor tool and return spring.
(11) Remove clutch piston. Remount clutch on
overdrive support (Fig. 7). Apply compressed air
through piston feed hole in support to remove piston.
Use only enough air to ease piston out.
(12) Remove and discard clutch piston O-rings.(13) Measure clutch disc thickness. Minimum al-
lowable thickness is 1.84 mm (0.0724 in). Replace
clutch pack if necessary.
(14) Measure free length of piston return springs
with springs in retainer (Fig. 8). Length should be
21.32 mm (0.839 in.). Replace return springs if not
within specification.
(15) Check clutch piston check ball (Fig. 9). Shake
piston to see if ball moves freely. Then check ball
seating by applying low pressure compressed air to
ball inlet as shown. Air should not leak past check
ball.
Fig. 5 Removing Clutch Pack Snap Ring
Fig. 6 Removing Piston Return Spring
Fig. 7 Removing Direct Clutch Piston
Fig. 8 Checking Piston Return Spring Length
JAW-4 TRANSMISSION OVERHAUL 21 - 229

(16) Measure inside diameter of clutch drum bush-
ing. Inside diameter should be no more than 53.97mm (2.1248 in.). Replace drum if bushing inside di-
ameter is greater than specified.
DIRECT CLUTCH ASSEMBLY
(1) Lubricate and install replacement O-rings on
clutch piston (Fig. 10).
(2) Install clutch piston in drum and install return
springs on piston.
(3) Compress piston return springs with Tool 7538
and install snap ring (Fig. 6). Be sure snap ring end
gap is not aligned with spring retainer tab.
(4) Install clutch discs and plates (Fig. 11). Install
plate then disc until all plates and discs are in-
stalled. Four plates and discs are required.
(5) Install clutch pack retainer in drum (Fig. 12).
(6) Install clutch pack snap ring (Fig. 12).
(7) Check snap ring position. If necessary, shift
snap ring until end gap isnotaligned with any
notches in clutch drum (Fig. 12).
Fig. 10 Direct Clutch Components
Fig. 9 Testing Piston Check Ball Seating
21 - 230 AW-4 TRANSMISSION OVERHAULJ

(8) Lubricate clutch drum thrust washer with pe-
troleum jelly and install it in drum (Fig. 3).
(9) Mount direct clutch assembly on forward clutch
assembly and check assembled height (Fig. 14).
Height should be 70.3 to 71.5 mm (2.767 to 2.815
in.).
(10) If assembled height is incorrect, clutches are
not seated.
(11) If clutch height is OK, remove direct clutch
from forward clutch and proceed to forward clutch
overhaul.
Fig. 11 Installing Direct Clutch Discs And Plates
Fig. 12 Install Clutch Pack Retainer
Fig. 13 Adjusting Clutch Pack Snap Ring Position
Fig. 14 Checking Direct Clutch Assembled Height
JAW-4 TRANSMISSION OVERHAUL 21 - 231

FORWARD CLUTCH OVERHAUL
FORWARD CLUTCH DISASSEMBLY (FIG. 1)
(1) Check clutch piston stroke as outlined in fol-
lowing steps (2) through (7).
(2) Position overdrive support on wood blocks and
mount forward clutch drum on support (Fig. 2).
(3) Remove bearing and race from forward clutch
drum (Fig. 2).
(4) Mount dial indicator on clutch drum. Position
dial indicator plunger against clutch piston (Fig. 3).(5) Apply compressed air through right side feed
hole in support and note piston stroke length on dial
indicator.
(6) Stroke length should be 3.55 - 3.73 mm (0.1348
- 0.1469 in.).
(7) Replace clutch discs if stroke length is incor-
rect.
(8) Remove clutch pack snap ring and remove re-
tainer and clutch pack (Fig. 4).
(9) Remove clutch pack cushion plate (Fig. 5).
(10) Compress clutch springs with Tool 7538 and
remove piston snap ring.
Fig. 1 Forward Clutch Components
21 - 232 AW-4 TRANSMISSION OVERHAULJ

Fig. 2 Positioning Drum And Support On Wood
Blocks
Fig. 3 Checking Forward Clutch Piston Stroke
Length
Fig. 4 Removing Retainer And Clutch Pack
Fig. 5 Removing Cushion Plate
JAW-4 TRANSMISSION OVERHAUL 21 - 233