JEEP XJ 1995 Service And Repair Manual

(36) Remove second coast brake piston snap ring
with Snap Ring Plier Tool 7540. Then remove piston
cover and piston assembly with compressed air ap-
plied through piston feed hole (Fig. 28).
(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).
Fig. 28 Removing Second Coast Brake Cover And
Piston
Fig. 29 Second Coast Brake Piston Components
Fig. 30 Removing Direct And Forward Clutch
Assembly
Fig. 31 Bearing And Race Removal From Clutch
Hub
JAW-4 TRANSMISSION OVERHAUL 21 - 209

(40) Remove second coast brake band E-ring from
band pin and remove brake band (Fig. 32).
(41) Remove front planetary ring gear front bearing
race and remove front planetary ring gear (Fig. 33).
(42) Remove thrust bearing and rear race from
ring gear (Fig. 34).
Fig. 32 Second Coast Brake Band Removal
Fig. 33 Front Planetary Ring Gear Removal
Fig. 34 Removing Ring Gear Bearing And Rear Race
21 - 210 AW-4 TRANSMISSION OVERHAULJ

(43) Remove planetary thrust race (Fig. 35).
(44) Relieve load on planetary snap ring as follows:
Loosen transmission holding fixture. Turn transmis-
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
clutch as assembly (Fig. 37).
Fig. 35 Relieving Load On Planetary Snap Ring
Fig. 36 Removing Planetary Snap Ring And Gear
Fig. 37 Removing Sun Gear, Input Drum And
One-Way Clutch
JAW-4 TRANSMISSION OVERHAUL 21 - 211

(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.
(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).
Fig. 40 Removing/Measuring Second Brake Clutch
Disc Thickness
Fig. 41 Removing Park Rod And Bracket
Fig. 38 Checking Second Brake Clutch Pack
Clearance
Fig. 39 Removing Second Brake Clutch Pack Snap
Ring
21 - 212 AW-4 TRANSMISSION OVERHAULJ

(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).
Fig. 42 Removing Park Pawl, Pin And Spring
Fig. 43 Checking First-Reverse Brake Clutch Pack
Clearance
Fig. 44 Removing Second Brake Piston Sleeve
Fig. 45 Removing Rear Planetary, Second Brake
Drum And Output Shaft
JAW-4 TRANSMISSION OVERHAUL 21 - 213

(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