JEEP CHEROKEE 1994 Service Repair Manual

(37) Disassemble second coast brake piston (Fig.
29).
(38) Remove direct and forward clutch assembly
(Fig. 30).
(39) Remove thrust bearing and race from clutch
hub (Fig. 31).
(40) Remove second coast brake band E-ring from
band pin and remove brake band (Fig. 32).
(41) Remove front planetary ring gear front bear-
ing race and remove front planetary ring gear (Fig.
33).(42) Remove thrust bearing and rear race from
ring gear (Fig. 34).
(43) Remove planetary thrust race (Fig. 35).
(44) Relieve load on planetary snap ring as follows:
Loosen transmission holding fixture. Turn transmis-
Fig. 29 Second Coast Brake Piston Components
Fig. 30 Removing Direct And Forward Clutch
Assembly
Fig. 31 Remove Bearing And Race From Clutch Hub
Fig. 32 Removing Second Coast Brake Band
21 - 200 AW-4 TRANSMISSION OVERHAULJ

sion over and allow output shaft to support transmis-
sion weight. Place wood blocks under shaft to protect
splines (Fig. 35).
(45) Remove planetary snap ring and remove plan-
etary gear (Fig. 36).
(46) Remove sun gear, input drum and one-way
Fig. 33 Removing Front Planetary Ring Gear
Fig. 34 Removing Ring Gear Bearing And Rear Race
Fig. 35 Relieving Load On Planetary Snap Ring
Fig. 36 Removing Planetary Snap Ring And Gear
JAW-4 TRANSMISSION OVERHAUL 21 - 201

clutch as assembly (Fig. 37).
(47) Measure second brake clutch pack clearance
(Fig. 38). Clearance should be 0.62 - 1.98 mm (0.0244
- 0.0780 in.). Replace discs if clearance is not within
specifications.(48) Remove second brake clutch pack snap ring
(Fig. 39).
(49) Remove second brake clutch pack (Fig. 40).
Measure disc thickness with micrometer. Minimum
thickness should be 1.84 mm (0.0724 in.). Replace
discs if not within specifications.
Fig. 37 Removing Sun Gear, Input Drum And
One-Way Clutch
Fig. 38 Checking Second Brake Clutch Pack
Clearance
Fig. 39 Removing Second Brake Clutch Pack Snap
Ring
Fig. 40 Remove/Measure Second Brake Clutch Disc
Thickness
21 - 202 AW-4 TRANSMISSION OVERHAULJ

(50) Remove bolts attaching park rod bracket to
case. Then disconnect park rod from manual shaft le-
ver and remove rod and bracket (Fig. 41).
(51) Remove park pawl spring, pin and pawl (Fig. 42).
(52) Measure clearance of first-reverse brake
clutch pack (Fig. 43). Clearance should be: 0.70 - 1.2
mm (0.028 - 0.047 in.). Replace discs if clearance is
not as specified.
(53) Remove second brake piston sleeve (Fig. 44).
Cover remover tool with tape to avoid damaging case.
(54) Remove rear planetary gear, second brake
drum and output shaft as an assembly (Fig. 45).
(55) Remove planetary and brake drum thrust
bearing and race assembly (Fig. 46).
Fig. 41 Removing Park Rod And Bracket
Fig. 42 Removing Park Pawl, Pin And Spring
Fig. 43 Checking First-Reverse Brake Clutch Pack
Clearance
Fig. 44 Removing Second Brake Piston Sleeve
JAW-4 TRANSMISSION OVERHAUL 21 - 203

(56) Remove second brake drum gasket from case
with gasket scraper or screwdriver (Fig. 47). Retain
tube shaped gasket if condition is OK.
(57) Measure inside diameter of transmission case
rear bushing with bore gauge or inside micrometer
(Fig. 48). Maximum allowable diameter is 38.18 mm
(1.5031 in.).Replace transmission case if bush-
ing I.D. is greater than specified. Bushing is not
serviceable.
CLEANING AND INSPECTION
Clean the transmission components with solvent
and dry them with compressed air only. Do not use
shop towels or rags.
Blow compressed air through all oil feed passages
and channels to be sure they are clear. Inspect the
transmission components for wear and damage. Re-
place components that are damaged or worn beyond
the limits specified in the individual overhaul proce-
dures.
Replace all O-rings, gaskets and seals. These com-
ponents are not reusable. Also replace any snap ring
that is distorted or damaged.
Fig. 45 Removing Rear Planetary, Second Brake
Drum And Output Shaft
Fig. 46 Removing Planetary And Brake Drum Thrust
Bearing And Race Assembly
Fig. 47 Removing Brake Drum Gasket
Fig. 48 Checking Rear Bushing Inside Diameter
21 - 204 AW-4 TRANSMISSION OVERHAULJ

During overhaul assembly operations, lubricate the
transmission components with Jeep or Mopar Mer-
conŸ automatic transmission fluid or petroleum jelly
as indicated. Petroleum jelly should be used to prelu-
bricate thrust bearings, washers and races. It can
also be used to hold parts in position during assem-
bly.
Soak replacement clutch and brake pack com-
ponents in transmission fluid for at least 30
minutes before installation.
MANUAL VALVE SHAFT OVERHAUL
(1) Cut shaft spacer sleeve in half with chisel and
remove it from lever and shaft (Fig. 2).
(2) Remove shift sector retaining pin with pin
punch (Fig. 3).
(3) Pull shaft out of case and remove manual lever.
(4) Carefully pry shaft seals from case.
(5) Lubricate new seals with petroleum jelly and
install them in case (Fig. 4).
(6) Install new spacer sleeve on shift sector (Fig.
5).
(7) Install sector and sleeve on shaft and install
shaft in case.
(8) Align sector and sleeve and install new retain-
ing pin.
(9) Align notch in sleeve with depression in sector
and stake sleeve in two places. Be sure lever and
shaft rotate smoothly.
Fig. 1 Manual Valve Shaft Components
Fig. 2 Cutting Shaft Spacer Sleeve
Fig. 3 Removing/Installing Sector Retaining Pin
JAW-4 TRANSMISSION OVERHAUL 21 - 205

OIL PUMP OVERHAUL
(1) Remove pump body O-ring (Fig. 1).
(2) Remove pump seal rings (Fig. 1).
(3) Remove bolts attaching stator shaft to pump
body and separate components.
(4) Remove drive gear and driven gear from pump
body (Fig. 1).
(5) Measure inside diameter of pump body bushing
with bore gauge or inside micrometer (Fig. 2). Diam-
eter should be maximum of 38.19 mm (1.5035 in.).
Replace pump body if bushing I.D. is greater than
specified.
Fig. 1 Oil Pump Components
Fig. 4 Installing Manual Shaft Seals
Fig. 5 Installing Manual Shaft And Sector
21 - 206 AW-4 TRANSMISSION OVERHAULJ

(6) Measure inside diameter of stator shaft bush-
ing (Fig. 2). Take measurements at front and rear of
bushing. Diameter should be maximum of 21.58 mm
(0.08496 in.) at front and 27.08 mm (1.0661 in.) at
rear. Replace stator shaft if bushing diameter is
greater than specified.
(7) Measure oil pump clearances (Fig. 3).
²Clearance between pump driven gear and pump
body should be maximum of 0.3 mm (0.012 in).
²Clearance between tips of pump gear teeth should
be maximum of 0.3 mm (0.012 in).
²Clearance between rear surface of pump housing
and pump gears should be maximum of 0.1 mm
(0.004 in.).
(8) Replace pump body and gears if any clearance
is greater than specified.
Fig. 2 Checking Pump/Stator Shaft Bushings
Fig. 3 Checking Pump Gear Clearances
JAW-4 TRANSMISSION OVERHAUL 21 - 207

(9) Remove old pump seal. Install new seal with
Seal Installer 7549 (Fig. 4).
(10) Lubricate and install gears in pump body.
(11) Assemble stator shaft and pump body. Tighten
shaft-to-body bolts to 10 Nzm (7 ft. lbs.) torque.
(12) Install new O-ring on pump body and new
seal rings on stator shaft.
(13) Install pump in torque converter and check
pump gear rotation. Gears must rotate smoothly
when turned clockwise and counterclockwise.
(14) Lubricate pump O-ring and seal rings with pe-
troleum jelly.
Fig. 5 Checking Pump Gear Rotation
Fig. 4 Installing Pump Seal
21 - 208 AW-4 TRANSMISSION OVERHAULJ

OVERDRIVE PLANETARY GEAR AND CLUTCH
OVERHAUL
GEAR AND CLUTCH DISASSEMBLY
(1) Check operation of one-way clutch in clutch
drum. Hold drum and turn planetary shaft clockwise
and counterclockwise. Shaft should turn clockwise
freely but lock when turned counterclockwise. Re-
place one-way clutch if necessary.
(2) Remove overdrive clutch from planetary gear
(Fig. 3).
(3) Remove thrust bearing and race assembly from
clutch drum (Fig. 4).
Fig. 1 Overdrive Planetary Gear And Clutch Components
JAW-4 TRANSMISSION OVERHAUL 21 - 209