JEEP XJ 1995 Service And Repair Manual

(21) Check brake pack clearance with feeler gauge
(Fig. 16). Clearance should be 0.062 - 1.98 mm (0.024
- 0.078 in.). If brake pack clearance is not correct,
brake pack components are not seated. Reassemble
brake pack if necessary.
(22) Install planetary sun gear and input drum
(Fig. 17). Be sure drum thrust washer tabs are
seated in drum. Use petroleum jelly to hold thrust
washer in position if necessary.(23) Install front planetary gear on sun gear (Fig.
18).
(24) Support output shaft with wood blocks (Fig.
19).
Fig. 16 Checking Second Brake Pack Clearance
Fig. 17 Installing Sun Gear And Input Drum
Fig. 18 Installing Front Planetary Gear
Fig. 19 Supporting Output Shaft
JAW-4 TRANSMISSION OVERHAUL 21 - 269

(25) Install planetary snap ring on sun gear with
snap ring plier tool 7541 (Fig. 20).
(26) Install tabbed thrust race on front planetary
gear (Fig. 21). Washer tabs face down and toward
gear. Race outer diameter is 47.8 mm (1.882 in.). In-
side diameter is 34.3 mm (1.350 in.).
(27) Install second coast brake band (Fig. 22).
(28) Install pin in second coast brake band. Then
install retaining ring on pin (Fig. 23).
(29) Install thrust bearing and race in forward-di-
rect clutch (Fig. 24). Coat bearing/race with petro-
leum jelly to hold them in place.
Fig. 22 Installing Second Coast Brake Band
Fig. 23 Installing Second Coast Brake Band Retaining Pin
Fig. 20 Installing Front Planetary Snap Ring
Fig. 21 Installing Planetary Thrust Race
21 - 270 AW-4 TRANSMISSION OVERHAULJ

(30) Verify forward-direct clutch thrust bearing
size.
²Race outer diameter is 48.9 mm (1.925 in.) and in-
side diameter is 26.0 mm (1.024 in.).
²Bearing outer diameter is 46.7 mm (1.839 in.) and
inside diameter is 26.0 mm (1.024 in.).
(31) Coat front planetary ring gear race with pe-
troleum jelly and install it in ring gear (Fig. 25).
(32) Verify ring gear race size. Outer diameter is
47.0 mm (1.850 in.) and inside diameter is 26.5 mm
(1.045 in.).
(33) Align forward-direct clutch disc splines with
screwdriver (Fig. 26).
(34) Align and install front planetary ring gear in
forward-direct clutch (Fig. 27).
(35) Coat bearing and race with petroleum jelly
and install them in ring gear (Fig. 28). Verify bear-
ing/race size.
²Bearing outer diameter is 47.7 mm (1.878 in.) and
inside diameter is 32.6 mm (1.283 in.).
²Race outer diameter is 53.6 mm (2.110 in.) and in-
side diameter is 30.6 mm (1.205 in.).
(36) Rotate front of transmission case downwardand install assembled planetary gear/forward-direct
clutch (Fig. 29).
(37) Check clearance between sun gear input drum
and direct clutch drum (Fig. 30). Clearance should be
9.8 - 11.8 mm (0.386 - 0.465 in.). If clearance is in-
correct, planetary gear/forward-direct clutch assem-
bly is not seated or is improperly assembled. Remove,
and correct if necessary.
(38) Coat thrust bearing and race assembly with
petroleum jelly and install it on clutch shaft. Bearing
faces up and toward case front as shown (Fig. 31).
Fig. 24 Installing Forward-Direct Clutch Thrust
Bearing And Race
Fig. 25 Installing Planetary Ring Gear Race
Fig. 26 Aligning Forward-Direct Clutch Splines
Fig. 27 Installing Front Planetary Ring Gear
JAW-4 TRANSMISSION OVERHAUL 21 - 271

Verify bearing/race size. Bearing and race outer di-
ameter is 47.8 mm (1.882 in.) and inside diameter is
33.6 mm (1.301 in.).
(39) Assemble second coast brake piston compo-
nents (Fig. 32).
(40) Install assembled second coast brake piston in
case.
(41) Install replacement seals on second coast
brake piston cover and install cover in case.
(42) Install second coast brake piston snap ring
with snap ring plier tool (Fig. 33).(43) Check second coast brake piston stroke as fol-
lows:
(a) Make reference mark on brake piston rod
(Fig. 34).
(b) Apply 57-114 psi air pressure through feed
hole (Fig. 34). Alternately apply and release air
pressure to operate piston.
(c) Check stroke with gauge 7552 (Fig. 35).
(d) If stroke length is incorrect, piston, cover or
snap ring is not seated. Reassemble and check
stroke again if necessary.
(44) Coat thrust race and tabbed washer with pe-
troleum jelly and install them on overdrive support
(Fig. 36). Verify race size. Race outer diameter is 50.9
mm (2.004 in.) and inside diameter is 36.2 mm (1.426
in.).
Fig. 28 Installing Ring Gear Bearing And Race
Fig. 29 Installing Front Planetary And Forward-
Direct Clutch Assembly
Fig. 30 Checking Input Drum-To-Direct Clutch Drum
Clearance
Fig. 31 Installing Clutch Shaft Thrust Bearing And
Race Assembly
21 - 272 AW-4 TRANSMISSION OVERHAULJ

Fig. 32 Assembling Second Coast Brake Piston
Fig. 33 Installing Second Coast Brake Piston Snap
Ring
Fig. 34 Marking Brake Piston Rod
Fig. 35 Checking Second Coast Brake Piston Stroke
Fig. 36 Installing Overdrive Support Thrust Race
And Washer
JAW-4 TRANSMISSION OVERHAUL 21 - 273

(45) Install overdrive support in case. Use two long
bolts to help align and guide support into position
(Fig. 37).
(46) Install overdrive support snap ring with Snap
Ring Plier Tool 7540 (Fig. 38). Chamfered side of
snap ring faces up and toward case front.Snap ring
ends must be aligned with case opening with
ring ends approximately 24 mm (0.94 in.) from
centerline of case opening.(47) Install and tighten overdrive support bolts to
25 Nzm (19 ft-lbs) torque (Fig. 39).
(48) Check output shaft end play with dial indica-
tor (Fig. 40). End play should be 0.27 - 0.86 mm
(0.0106 - 0.0339 in.).
(49) If output shaft end play is incorrect, one or
more of installed components is not seated. Reassem-
ble as necessary and check end play again.
Fig. 37 Installing Overdrive Support
Fig. 38 Installing Overdrive Support Snap Ring
Fig. 39 Installing Overdrive Support Bolts
Fig. 40 Checking Output Shaft End Play
21 - 274 AW-4 TRANSMISSION OVERHAULJ

(50) Install overdrive brake clutch pack (Fig. 41). In-
stall thickest plate first. Rounded edge of plate faces
up. Install first disc followed by another plate until
four discs and three plates are installed.
(51) Install stepped ring retainer plate with flat
side facing disc. Then install brake pack snap ring
(Fig. 42).
(52) Check overdrive brake piston stroke as fol-
lows:
(a) Mount Gauge 7546 in dial indicator and posi-
tion gauge tool against overdrive brake piston (Fig.
43).(b) Apply and release overdrive brake piston
with compressed air and note piston stroke length
on dial indicator. Apply air pressure through feed
hole in case (Fig. 44).
(c) Piston stroke length should be 1.40 - 1.70 mm
(0.55 - 0.66 in.).
(d) If stroke is incorrect, brake pack or piston is
installed incorrectly. Check and correct as neces-
sary and measure piston stroke again.
(53) Remove dial indicator and gauge tool.
(54) Remove overdrive brake piston snap ring and
remove overdrive clutch pack components.
(55) Coat overdrive lower race, thrust bearing and
upper race with petroleum jelly and install them in
overdrive support (Fig. 45). Be sure races and bear-
ing are assembled and installed as shown.
(56) Verify bearing/race sizes before proceeding.
Bearing-race sizes are:
Fig. 41 Installing Overdrive Brake Clutch Pack
Fig. 42 installing Overdrive Brake Snap Ring
Fig. 43 Positioning Gauge Tool And Dial Indicator
Fig. 44 Checking Overdrive Brake Piston Stroke
JAW-4 TRANSMISSION OVERHAUL 21 - 275

²Outer diameter of lower race is 47.8 mm (1.882
in.) and inside diameter is 34.3 mm (1.350 in.).
²Outer diameter of bearing is 47.7 mm (1.878 in.)
and inside diameter is 32.7 mm (1.287 in.).
²Outer diameter of upper race is 47.8 mm (1.882
in.) and inside diameter is 30.7 mm (1.209 in.).
(57) Install overdrive planetary ring gear in sup-
port (Fig. 46).
(58) Coat ring gear thrust race and thrust bearing
assembly with petroleum jelly and install them in
gear (Fig. 47).
(59) Verify bearing/race size before proceeding.²Outer diameter of ring gear race-bearing is 47.8
mm (1.882 in.) and inside diameter is 24.2 mm (0.953
in.).
²Outer diameter of bearing is 46.8 mm (1.844 in.)
and inside diameter is 26.0 mm (1.024 in.).
(60) Coat tabbed thrust race with petroleum jelly
and install it on planetary gear (Fig. 48). Race outer
diameter is 41.8 mm (1.646 in.) and inside diameter
is 27.1 mm (1.067 in.).
(61) Install assembled overdrive planetary gear
and clutch (Fig. 49).
(62) Coat thrust bearing and race assembly with
petroleum jelly and install it on clutch input shaft
(Fig. 50). Bearing and race outer diameter is 50.2
mm (1.976 in.) and inside diameter is 28.9 mm (1.138
in.).
(63) Install overdrive brake pack as follows:
Fig. 45 Installing Overdrive Support Thrust Bearing
And Races
Fig. 46 Installing Overdrive Planetary Ring Gear
Fig. 47 Installing Ring Gear Thrust Bearing And
Race
Fig. 48 Installing Planetary thrust Race
21 - 276 AW-4 TRANSMISSION OVERHAULJ

(a) Install 4.0 mm (0.157 in.) thick plate first.
Rounded edge of plate must face upward.
(b) Install a disc followed by a plate until the re-
quired number of discs and plates are installed. Be
sure to install the stepped plate last with the flat
side of the plate facing the disc (Fig. 51).
(c) Confirm that four discs and three plates have
been installed.
(64) Install clutch pack snap ring (Fig. 52).(65) Coat thrust bearing race with petroleum jelly
and install it in oil pump (Fig. 53). Bearing race
outer diameter is 47.2 mm (1.858 in.) and inside di-
ameter is 28.1 mm (1.106 in.).
(66) Lubricate and install replacement O-ring on
oil pump body.
(67) Install oil pump in case. Align pump and case
bolt holes and carefully ease pump into place (Fig.
54).
CAUTION: Do not use force to seat the pump. The
seal rings on the stator shaft could be damaged if
they bind or stick to the direct clutch drum.
(68) Tighten oil pump bolts to 22 Nzm (16 ft. lbs.)
torque.
Fig. 49 Installing Overdrive Planetary And Clutch
Assembly
Fig. 50 Installing Input Shaft Thrust Bearing And
Race Assembly
Fig. 51 Installing Overdrive Clutch Pack
Fig. 52 Installing Clutch Pack Snap Ring
JAW-4 TRANSMISSION OVERHAUL 21 - 277

(69) Verify input shaft rotation. Shaft should rotate
smoothly and not bind.
(70) Lubricate and install new O-ring on transmis-
sion throttle cable adapter and install cable in case
(Fig. 55).
(71) Check clutch and brake operation. Operate
clutches and brakes with compressed air applied
through feed holes in case (Fig. 56). Listen for clutch
and brake application. If you do not hear a clutch or
brake apply, disassemble transmission and repair
fault before proceeding.It is necessary to block
the overdrive clutch accumulator feed hole No.
8 (Fig. 56) in order to check direct clutch oper-
ation.
(72) Lubricate and install new O-rings on accumu-
lator pistons (Fig. 57).
Fig. 53 Installing Oil Pump Thrust Race
Fig. 54 Installing Oil Pump
Fig. 55 Installing Transmission Throttle Cable
Fig. 56 Clutch And Brake Feed Hole Locations
21 - 278 AW-4 TRANSMISSION OVERHAULJ