JEEP CHEROKEE 1994 Service Repair Manual

(5) Support sun gear on wood block (Fig. 6). Then
remove first sun gear snap ring and separate drum
from gear.
(6) Remove remaining snap ring from sun gear
(Fig. 7).
(7) Measure inside diameter of sun gear bushings
with bore gauge or inside micrometer (Fig. 8). Maxi-
mum allowable diameter is 27.08 mm (1.0661 in.).
Replace sun gear if bushing inside diameter is
greater than specified.
SUN GEAR AND CLUTCH ASSEMBLY
(1) Install first snap ring on sun gear.
(2) Install sun gear in drum and install remaining
snap ring.(3) Coat replacement seal rings with petroleum
jelly and install them on sun gear.Be sure seal
ring ends are interlocked.
(4) Install thrust washer. Be sure washer tabs are
seated in drum slots.
(5) Install one-way clutch/second brake hub assem-
bly on sun gear. Deep side of hub flange faces up-
ward (Fig. 9).
(6) Check one-way clutch operation again (Fig. 2).
Hold sun gear and turn second brake hub clockwise
and counterclockwise. Hub should turn clockwise
freely, but lock when turned counterclockwise.
Fig. 2 Checking One-Way Clutch Operation
Fig. 3 Removing/Installing Brake Hub And Clutch
Assembly
Fig. 4 Removing/Installing Thrust Washer
Fig. 5 Removing/Installing Sun Gear Seal Rings
21 - 230 AW-4 TRANSMISSION OVERHAULJ

(7) Set sun gear/clutch assembly aside for final as-
sembly.
Fig. 6 Removing/Installing Sun Gear
Fig. 7 Removing/Installing Second Snap Ring
Fig. 8 Checking Sun Gear Bushings
Fig. 9 Installing Clutch And Hub Assembly On Sun
Gear
JAW-4 TRANSMISSION OVERHAUL 21 - 231

SECOND BRAKE OVERHAUL
BRAKE DISASSEMBLY
(1) Remove second brake drum from output shaft
(Fig. 2).
(2) Set output shaft assembly aside for overhaul.
Refer to Rear Planetary Gear and Output Shaft
Overhaul procedures.
(3) Remove thrust washer from second brake drum
(Fig. 3).
(4) Compress piston return springs with shop press
and tool 7538. Then remove piston snap ring (Fig. 4).
(5) Remove compressor tool and remove spring re-
tainer and return springs.
(6) Remove second brake piston and sleeve from
drum with compressed air (Fig. 5). Use only enough
air pressure to ease piston out of drum.
(7) Remove and discard brake piston O-rings.(8) Measure free length of piston return springs
with springs mounted in retainer (Fig. 6). Length
should be approximately 16.05 mm (0.632 in.). Re-
place return springs if length is less than specified.
SECOND BRAKE ASSEMBLY
(1) Lubricate and install new O-rings on brake pis-
ton. Then install brake piston in drum.
(2) Install return springs and retainer on brake
piston.
Fig. 1 Second Brake Components
Fig. 2 Removing/Installing Second Brake Assembly
Fig. 3 Removing/Installing Second Brake Drum
Thrust Washer
21 - 232 AW-4 TRANSMISSION OVERHAULJ

(3) Compress return springs with shop press and
Compressor Tool 7538. Install piston snap ring and
remove brake assembly from press.
(4) Check brake piston operation with low pressure
compressed air (Fig. 7). Apply air pressure through
feed hole in drum. Piston should move smoothly
when applying-releasing air pressure.
(5) Coat thrust washer with petroleum jelly and
install it in drum. Be sure washer notches are
aligned with tabs on spring retainer (Fig. 8).
(6) Set brake components aside for final assembly.
Fig. 6 Measuring Second Brake Piston Return Springs
Fig. 7 Checking Second Brake Piston Operation
Fig. 8 Installing Second Brake Thrust Washer
Fig. 4 Removing/Installing Second Brake Piston Snap Ring
Fig. 5 Removing/Installing Piston And Sleeve
JAW-4 TRANSMISSION OVERHAUL 21 - 233

REAR PLANETARY, NO. 2 ONE-WAY CLUTCH AND
OUTPUT SHAFT OVERHAUL
PLANETARY/BRAKE PACK/OUTPUT SHAFT
DISASSEMBLY
(1) Remove output shaft from gear assembly (Fig.
2).
(2) Remove and discard shaft seal ring (Fig. 4).
(3) Remove brake pack from planetary gear (Fig.
4).
(4) Measure thickness of each brake pack disc.
Minimum thickness is 1.51 mm (0.0594 in.). Replace
all discs if any disc is thinner than specified.
(5) Remove planetary gear from ring gear (Fig. 5).
(6) Check No. 2 one-way clutch. Hold planetary
gear and turn clutch inner race in both directions.Race should turn freely counterclockwise, but lock
when turned clockwise. Replace one-way clutch if
necessary.
Fig. 1 Rear Planetary, Brake Pack, Clutch And Output Shaft Components
Fig. 2 Removing/Installing Output Shaft
21 - 234 AW-4 TRANSMISSION OVERHAULJ

(7) Remove clutch inner race from planetary gear
(Fig. 7).
(8) Remove clutch snap ring and remove No. 2 one-
way clutch from planetary (Fig. 8).
(9) Remove front and rear thrust washers from
planetary gear (Fig. 9).
(10) Remove thrust bearing and washers from ring
gear (Fig. 10).
(11) Remove ring gear snap ring and remove ring
gear hub (Fig. 11).
(12) Inspect and replace any worn or damaged
planetary gear components.
Fig. 7 Removing/Installing Clutch Inner Race
Fig. 5 Removing/Installing Rear Planetary
Fig. 3 Removing/Installing Shaft Seal Ring
Fig. 4 Removing/Installing First-Reverse Brake Pack
Fig. 6 Checking No. 2 One-Way Clutch Operation
JAW-4 TRANSMISSION OVERHAUL 21 - 235

ASSEMBLING REAR PLANETARY, BRAKE
PACK, CLUTCH AND SHAFT
(1) Install hub and snap ring in ring gear (Fig. 11)
(2) Identify ring gear thrust bearing and races by
following dimensions (Fig. 10):
²Outer diameter of bottom race is 44.8 mm (1.764
in.) and inner diameter is 27.6 mm (1.087 in.).
²Outer diameter of bearing is 44.7 mm (1.760 in.)
and inner diameter is 30.1 mm (1.185 in.).
²Outer diameter of upper race is 44.8 mm (1.764
in.) and inner diameter is 28.8 mm (1.134 in.).
(3) Lubricate ring gear thrust bearing and races
with petroleum jelly and install them in ring gear
(Fig. 10).
(4) Coat planetary thrust washers with petroleum
jelly and install them in gear (Fig. 9).
(5) Install No. 2 one-way clutch in planetary gear.
Be sure flanged side of clutch faces upward (Fig. 12).(6) Install clutch retaining snap ring and install
clutch inner race (Fig. 7). Turn race counterclockwise
to ease installation.
(7) Verify one-way clutch operation. Hold gear and
turn inner race in both directions. Race should turn
freely counterclockwise, but lock when turned clock-
wise.
(8) Install planetary gear in ring gear.
(9) Assemble clutch discs and clutch plates (Fig. 4).
Sequence is disc first, then a plate. Use seven discs
and plates in a 6-cyl. transmission.
Fig. 8 Removing.Installing One-Way Clutch
Fig. 9 Removing/Installing Rear Planetary Thrust
Washers
Fig. 10 Removing/Installing Ring Gear Thrust
Bearing And Races
21 - 236 AW-4 TRANSMISSION OVERHAULJ

(10) Install brake pack on planetary gear (Fig. 4).
(11) Install new seal ring on output shaft (Fig. 3).
Be sure ring ends are interlocked as shown.
(12) Set assembled components aside for final as-
sembly.
FIRST-REVERSE BRAKE PISTON AND
TRANSMISSION CASE OVERHAUL
BRAKE DISASSEMBLY AND INSPECTION
(1) Remove bearing and race assembly from trans-
mission case (Fig. 2).
(2) Check first/reverse brake piston operation with
compressed air (Fig. 3). Piston should move smoothly
and not bind or stick. If piston operation is incorrect,
case or piston may require replacement.
(3) Compress piston return springs with Tool 7539
and remove piston snap ring (Fig. 4).
(4) Remove Tool 7539 and remove piston return
springs.
(5) Remove No. 2 first-reverse brake piston with
compressed air. Apply air through same transmission
Fig. 1 First-Reverse Brake Pistons And Transmission Case
Fig. 11 Removing/Installing Ring Gear Hub
Fig. 12 Installing No. 2 One-Way Clutch
JAW-4 TRANSMISSION OVERHAUL 21 - 237

feed hole used for checking piston operation.
(6) Remove reaction sleeve with Sleeve Remover
Tool 7542 (Fig. 5). Insert tool flanges under sleeve
and lift tool and sleeve out of case.
(7) Remove No. 1 first/reverse brake piston with
Piston Puller 7543 (Fig. 6). Slip tool under piston and
lift tool and piston out of case.
(8) Measure free length of piston return springs
with springs mounted in retainer. Length should be
18.382 mm (0.724 in.). Replace springs if length is
less than this.(9) Clean transmission case thoroughly with sol-
vent and dry it with compressed air. Blow com-
pressed air through oil feed passages to remove
solvent residue and ensure that passages are clear.
Inspect the case for wear or damage. Replace case if
necessary.
ASSEMBLING FIRST/REVERSE BRAKE
PISTON
(1) Lubricate and install new O-rings on No. 1
first/reverse brake piston and on reaction sleeve (Fig.
7). Then install piston in sleeve.
(2) Lubricate and install new O-ring on No. 2
brake piston.
(3) Install assembled No. 1 piston and reaction
sleeve on No. 2 piston (Fig. 8).
Fig. 2 Removing/Installing Bearing And Race
Assembly
Fig. 3 Checking First-Reverse Brake Piston
Operation
Fig. 4 Removing/Installing Piston Snap Ring
Fig. 5 Removing/Installing Reaction Sleeve
21 - 238 AW-4 TRANSMISSION OVERHAULJ

(4) Lubricate and install piston assembly in case
(Fig. 9). Align piston and case slots and press piston
assembly into case with hand pressure.
(5) Position piston return springs on No. 2 piston.
(6) Compress piston return springs with Tool 7539
and install piston snap ring (Fig. 4). Be sure snap
ring end gap is not aligned with any tangs on return
spring retainer.
(7) Verify piston operation with compressed air as
outlined in disassembly procedure.
(8) Coat bearing and race assembly with petroleum
jelly and install it in piston assembly (Fig. 2). Bear-
ing and race assembly outer diameter is 57.7 mm
(2.272 in.) and inner diameter is 39.2 mm (1.543 in.).
Fig. 6 Removing/Installing First-Reverse Brake No.1
Piston
Fig. 7 Assembling No. 1 Piston And Sleeve
Fig. 8 Assembling First-Reverse Brake Pistons
Fig. 9 Installing First-Reverse Brake Piston
Assembly
JAW-4 TRANSMISSION OVERHAUL 21 - 239