JEEP CHEROKEE 1995 Service Repair Manual

(55) Remove planetary and brake drum thrust
bearing and race assembly (Fig. 46).
(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.
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.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 - 214 AW-4 TRANSMISSION OVERHAULJ

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
Fig. 4 Installing Manual Shaft Seals
JAW-4 TRANSMISSION OVERHAUL 21 - 215

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). Diameter
should be maximum of 38.19 mm (1.5035 in.). Replace
pump body if bushing I.D. is greater than specified.
(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
Fig. 1 Oil Pump Components
Fig. 5 Installing Manual Shaft And Sector
Fig. 2 Checking Pump/Stator Shaft Bushings
21 - 216 AW-4 TRANSMISSION OVERHAULJ

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).
²
Clearance 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.
(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.
Fig. 3 Checking Pump Gear ClearancesFig. 5 Checking Pump Gear Rotation
Fig. 4 Installing Pump Seal
JAW-4 TRANSMISSION OVERHAUL 21 - 217

(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.
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) Replace overdrive brake clutch pack if discs are
worn below thickness of 1.84 mm (0.0724 in.). This is
clutch pack that fits on clutch drum and in case.
Fig. 1 Overdrive Planetary Gear And Clutch Components
21 - 218 AW-4 TRANSMISSION OVERHAULJ

(3) Remove overdrive clutch from planetary gear
(Fig. 3).(4) Remove thrust bearing and race assembly from
clutch drum (Fig. 4).
(5) Measure stroke length of clutch piston as fol-
lows:
(a) Mount oil pump on torque converter. Then
mount clutch on oil pump (Fig. 5).
Fig. 2 Checking One-Way Clutch
Fig. 3 Removing Overdrive Clutch From Gear
Fig. 4 Removing Clutch Drum Bearing And Race
Fig. 5 Assembling Converter, Pump And Clutch For
Test
JAW-4 TRANSMISSION OVERHAUL 21 - 219

(b) Mount dial indicator on clutch and position
indicator stylus on clutch piston (Fig. 6).
(c) Apply compressed air through clutch feed hole
in oil pump and note piston stroke length. Stroke
length should be 1.85 - 2.15 mm (0.0728 - 0.0846
in.).
(6) Replace clutch pack if stroke length is incor-
rect.
(7) Remove clutch pack snap ring and remove the
clutch pack.(8) Compress piston return spring with Tool 7538
(Fig. 8). Remove snap ring and remove compressor
tool.
(9) Remove compressor tool and piston return
springs.
(10) Mount oil pump on converter. Then mount
clutch on oil pump (Fig. 9).
(11) Hold clutch piston by hand and apply com-
pressed air through oil pump feed hole to ease piston
out (Fig. 9). Apply only enough air pressure to re-
move piston.
Fig. 6 Checking Overdrive Clutch Piston Stroke
Fig. 7 Removing Clutch Pack Snap Ring
Fig. 8 Removing Clutch Piston Snap Ring
Fig. 9 Removing Overdrive Clutch Piston
21 - 220 AW-4 TRANSMISSION OVERHAULJ

(12) Remove bearing and race from ring gear (Fig.
10).
(13) Remove snap ring from ring gear and remove
ring gear hub (Fig. 11).(14) Remove race from planetary gear (Fig. 12).
(15) Remove snap ring and remove retaining plate
(Fig. 13).
Fig. 10 Removing Ring Gear Bearing And Race
Fig. 11 Removing Ring Gear Hub
Fig. 12 Remove Planetary Gear Race
Fig. 13 Removing Snap Ring And Retaining Plate
JAW-4 TRANSMISSION OVERHAUL 21 - 221

(16) Remove one-way clutch and outer race as as-
sembly. Then separate race from clutch (Fig. 14).
(17) Remove planetary thrust washer (Fig. 15).
(18) Check overdrive clutch disc thickness. Mini-
mum allowable thickness is 1.84 mm (0.0724 in.).(19) Measure free length of piston return springs
with springs in retainer (Fig. 16). Length should be
16.8 mm (0.661 in.).
(20) Check clutch piston check ball (Fig. 17). Shake
piston to see if ball moves freely. Then check ball
sealing by applying low pressure compressed air to
ball inlet as shown. Air should not leak past check
ball.
Fig. 14 Removing One-Way Clutch
Fig. 15 Removing Planetary Thrust Washer
Fig. 16 Checking Piston Return Spring Length
Fig. 17 Testing Clutch Piston Check Ball
21 - 222 AW-4 TRANSMISSION OVERHAULJ

(21) Check inside diameter of clutch drum bush-
ings with bore gauge or inside micrometer (Fig. 18).
Maximum inside diameter is 27.11 mm (1.0673 in.).
Replace drum if bushing inside diameter is greater
than specified.
(22) Check inside diameter of planetary gear bush-
ing (Fig. 19). Maximum inside diameter is 11.27 mm
(0.4437 in.). Replace planetary gear if bushing inside
diameter is greater then specified.
Assembling Gear And Clutch
(1) Install thrust washer in planetary gear (Fig.
20).Grooved side of washer faces up and to-
ward front.(2) Install one-way clutch in race (Fig. 21). Flanged
side of clutch must face upward as shown.
(3) Install assembled one-way clutch and outer
race in planetary gear. Be sure flanged side of clutch
is facing upward.
(4) Install clutch pack retaining plate and snap
ring in planetary gear.
(5) Coat planetary race with petroleum jelly and
install it on planetary gear. Outside diameter of race
is 41.8 mm (1.646 in.); inside diameter is 27.1 mm
(1.067 in.).
Fig. 18 Checking Clutch Drum Bushings
Fig. 19 Checking Planetary Bushing
Fig. 20 Install Planetary Thrust Washer
Fig. 21 Assembling One-Way Clutch And Race
JAW-4 TRANSMISSION OVERHAUL 21 - 223