JEEP XJ 1995 Service And Repair Manual

(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

(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