seats JEEP YJ 1995 Service And User Guide

VALVE COMPONENT REPLACEÐCYLINDER HEAD
NOT REMOVED
ROCKER ARMS AND PUSH RODS
This procedure can be done with the engine in or
out of the vehicle.
REMOVAL
(1) Remove the engine cylinder head cover.
(2) Remove the capscrews at each bridge and pivot
assembly (Fig. 2). Alternately loosen the capscrews
one turn at a time to avoid damaging the bridges.
(3) Check for rocker arm bridges which are causing
misalignment of the rocker arm to valve tip area.
(4) Remove the bridges, pivots and corresponding
pairs of rocker arms (Fig. 2). Place them on a bench
in the same order as removed.
(5) Remove the push rods and place them on a
bench in the same order as removed.
CLEANING
Clean all the components with cleaning solvent.
Use compressed air to blow out the oil passages in
the rocker arms and push rods.
INSPECTION
Inspect the pivot surface area of each rocker arm.
Replace any that are scuffed, pitted, cracked or ex-
cessively worn.
Inspect the valve stem tip contact surface of each
rocker arm and replace any rocker arm that is deeply
pitted.
Inspect each push rod end for excessive wear and
replace as required. If any push rod is excessivelyworn because of lack of oil, replace it and inspect the
corresponding hydraulic tappet for excessive wear.
Inspect the push rods for straightness by rolling
them on a flat surface or by shining a light between
the push rod and the flat surface.
A wear pattern along the length of the push rod is
not normal. Inspect the engine cylinder head for ob-
struction if this condition exists.
INSTALLATION
(1) Lubricate the ball ends of the push rods with
Mopar Engine Oil Supplement, or equivalent and in-
stall push rods in their original locations. Ensure
that the bottom end of each push rod is centered in
the tappet plunger cap seat.
(2) Using Mopar Engine Oil Supplement, or equiv-
alent, lubricate the area of the rocker arm that the
pivot contacts. Install rocker arms, pivots and bridge
above each cylinder in their originally position.
(3) Loosely install the capscrews through each
bridge.
(4) At each bridge, tighten the capscrews alter-
nately, one turn at a time, to avoid damaging the
bridge. Tighten the capscrews to 28 Nzm (21 ft. lbs.)
torque.
(5) Install the engine cylinder head cover.
VALVE STEM SEAL AND SPRING REPLACEMENT
This procedure can be done with the engine cylin-
der head installed on the block.
REMOVAL
Each valve spring is held in place by a retainer and
a set of conical valve locks. The locks can be removed
only by compressing the valve spring.
(1) Remove the engine cylinder head cover.
(2) Remove capscrews, bridge and pivot assemblies
and rocker arms for access to each valve spring to be
removed.
(3) Remove push rods. Retain the push rods,
bridges, pivots and rocker arms in the same order
and position as removed.
(4) Inspect the springs and retainer for cracks and
possible signs of weakening.
(5) Remove the spark plug(s) adjacent to the cylin-
der(s) below the valve springs to be removed.
(6) Connect an air hose to the adapter and apply
air pressure slowly. Maintain at least 621 kPa (90
psi) of air pressure in the cylinder to hold the valves
against their seats. For vehicles equipped with an air
conditioner, use a flexible air adaptor when servicing
the No.1 cylinder.
(7) Tap the retainer or tip with a rawhide hammer
to loosen the lock from the retainer. Use Valve Spring
Compressor Tool MD-998772A to compress the spring
and remove the locks (Fig. 3).
(8) Remove valve spring and retainer (Fig. 3).
Fig. 2 Rocker Arm Assembly
J4.0L ENGINE 9 - 65

(2) After refacing, a margin of at least 0.787 mm
(0.031 inch) must remain (Fig. 8). If the margin is
less than 0.787 mm (0.031 inch), the valve must be
replaced.
VALVE SEAT REFACING
(1) Install a pilot of the correct size in the valve
guide bore. Reface the valve seat to the specified an-
gle with a good dressing stone. Remove only enough
metal to provide a smooth finish.
(2) Use tapered stones to obtain the specified seat
width when required.
(3) Control valve seat runout to a maximum of
0.0635 mm (0.0025 in.) (Fig. 9).
VALVE STEM OIL SEAL REPLACEMENT
Valve stem oil seals are installed on each valve
stem to prevent rocker arm lubricating oil from en-
tering the combustion chamber through the valve
guide bores. One seal is marked INT (intake valve)
and the other is marked EXH (exhaust valve).
Replace the oil seals whenever valve service is per-
formed or if the seals have deteriorated.
VALVE GUIDES
The valve guides are an integral part of the engine
cylinder head and are not replaceable.
When the valve stem guide clearance is excessive,
the valve guide bores must be reamed oversize. Ser-
vice valves with oversize stems are available in 0.076
mm (0.003 inch) and 0.381 mm (0.015 inch) incre-
ments.
Corresponding oversize valve stem seals are also
available and must be used with valves having 0.381
mm (0.015 inch) oversize stems.
If the valve guides are reamed oversize, the
valve seats must be ground to ensure that the
valve seat is concentric to the valve guide.
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
Valve stem-to-guide clearance may be measured by
either of the following two methods.
PREFERRED METHOD:
(1) Remove the valve from the head.
(2) Clean the valve stem guide bore with solvent
and a bristle brush.
(3) Insert a telescoping gauge into the valve stem
guide bore approximately 9.525 mm (.375 inch) from
the valve spring side of the head (Fig. 10).
(4) Remove and measure telescoping gauge with a
micrometer.
(5) Repeat the measurement with contacts length-
wise to engine cylinder head.
(6) Compare the crosswise to lengthwise measure-
ments to determine out-of-roundness. If the measure-
Fig. 10 Measurement of Valve Guide Bore Diameter
Fig. 8 Valve Facing Margin
Fig. 9 Measurement of Valve Seat Runout
9 - 70 4.0L ENGINEJ

ments differ by more than 0.0635 mm (0.0025 in.),
ream the guide bore to accommodate an oversize
valve stem.
(7) Compare the measured valve guide bore diam-
eter with specifications (7.95-7.97 mm or 0.313-0.314
inch). If the measurement differs from specification
by more than 0.076 mm (0.003 inch), ream the guide
bore to accommodate an oversize valve stem.
ALTERNATIVE METHOD:
(1) Use a dial indicator to measure the lateral
movement of the valve stem (stem-to-guide clear-
ance). This must be done with the valve installed in
its guide and just off the valve seat (Fig. 11).
(2) Correct clearance is 0.025-0.0762 mm (0.001-
0.003 inch). If indicated movement exceeds the spec-
ification ream the valve guide to accommodate an
oversize valve stem.
Valve seats must be ground after reaming the
valve guides to ensure that the valve seat is
concentric to the valve guide.
VALVE SPRING TENSION TEST
Use a universal Valve Spring Tester and a torque
wrench to test each valve spring for the specified ten-
sion value (Fig. 12).
Replace valve springs that are not within specifica-
tions.
INSTALLATION
(1) Thoroughly clean the valve stems and the valve
guide bores.
(2) Lightly lubricate the stem.
(3) Install the valve in the original valve guide
bore.
(4) Install the replacement valve stem oil seals on
the valve stems. If the 0.381 mm (0.015 inch) over-
size valve stems are used, oversize oil seals are re-
quired.(5) Position the valve spring and retainer on the
engine cylinder head and compress the valve spring
with Valve Spring Compressor Tool MD-998772A.
(6) Install the valve locks and release the tool.
(7) Tap the valve spring from side to side with a
hammer to ensure that the spring is properly seated
at the engine cylinder head. Also tap the top of the
retainer to seat the valve locks.
(8) Install the engine cylinder head.
VALVE TIMING
Disconnect the spark plug wires and remove the
spark plugs.
Remove the engine cylinder head cover.
Remove the capscrews, bridge and pivot assembly,
and rocker arms from above the No.1 cylinder.
Alternately loosen each capscrew, one turn at a
time, to avoid damaging the bridge.
Rotate the crankshaft until the No.6 piston is at
top dead center (TDC) on the compression stroke.
Rotate the crankshaft counterclockwise (viewed
from the front of the engine) 90É.
Install a dial indicator on the end of the No.1 cyl-
inder intake valve push rod. Use rubber tubing to se-
cure the indicator stem on the push rod.
Set the dial indicator pointer at zero.
Rotate the crankshaft clockwise (viewed from the
front of the engine) until the dial indicator pointer
indicates 0.305 mm (0.012 inch) travel distance (lift).
The timing notch index on the vibration damper
should be aligned with the TDC mark on the timing
degree scale.
If the timing notch is more than 13 mm (1/2 inch)
away from the TDC mark in either direction, the
valve timing is incorrect.
If the valve timing is incorrect, the cause may be a
broken camshaft pin. It is not necessary to replace
the camshaft because of pin failure. A spring pin is
available for service replacement.
Fig. 11 Measurement of Lateral Movement of Valve
Stem
Fig. 12 Valve Spring Tester
J4.0L ENGINE 9 - 71

(8) Remove fuel pump module and O-ring seal.
Discard old O-ring and fuel pump module inlet filter.
DISASSEMBLYÐXJ MODELS
(1) Remove and discard fuel pump inlet filter.
The wire terminals to the fuel pump motor are dif-
ferent in size and cannot be connected to the wrong
terminal.
(2) Disconnect fuel pump terminal wires.
(3) Remove fuel pump outlet hose and clamp. Re-
place the hose if it shows any signs of fatigue or fail-
ure.
(4) Remove fuel pump top mounting bracket nut.
Remove fuel pump (Fig. 2).
ASSEMBLYÐXJ MODELS
Whenever the fuel pump is replaced, the fuel pump
inlet filter (sock) must also be replaced.
(1) Place fuel pump top mounting bracket over top
of pump.
(2) Position fuel pump into lower bracket. Slide
stud of top bracket through hole in fuel pump side
bracket. Tighten fuel pump top mounting nut.
(3) Install new fuel pump outlet hose. Secure with
new clamps.
(4) Connect wire terminals to motor.
(5) Install new fuel pump inlet filter.
INSTALLATIONÐXJ MODELS
Whenever the fuel pump is replaced, the fuel
pump inlet filter must also be replaced.
(1) Install new fuel pump inlet filter onto fuel
pump.(2) Install fuel pump module assembly and new O-
ring seal. The rubber stopper on the end of the fuel
return tube of the assembly must be inserted into the
cup in the fuel tank reservoir (Fig. 3).
(3) Using a brass punch and a hammer, install lock
ring. Carefully tap lock ring clockwise until it seats
against stop on fuel tank.
(4) Connect fuel supply and return hoses to fittings
on fuel pump module. Tighten hose clamps.
(5) Connect fuel pump module electrical harness
connector to main harness connector.
(6) Lower vehicle.
(7) Fill fuel tank. Install fuel tank cap.
(8) Connect negative battery cable.
(9) Start vehicle and inspect for leaks.
REMOVALÐYJ MODELS
The fuel tank must be removed to remove the fuel
pump module.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING THE FUEL PUMP MODULE,
THE FUEL SYSTEM PRESSURE MUST BE RE-
LEASED. REFER TO THE FUEL PRESSURE RE-
LEASE PROCEDURE IN THIS GROUP.
WARNING: EXTINGUISH ALL TOBACCO SMOKING
PRODUCTS BEFORE SERVICING THE FUEL SYS-
TEM. KEEP OPEN FLAME AWAY FROM FUEL SYS-
TEM COMPONENTS.
(1) Remove negative battery cable.
Fig. 2 Fuel Pump ModuleÐXJ ModelsÐ
Disassemble/Assemble
Fig. 3 Fuel Pump ModuleÐXJ ModelsÐInstallation
14 - 4 FUEL DELIVERY SYSTEMJ

(2) Raise skid plate/fuel tank until gauge sender
wire connector can be connected to harness connec-
tor.
(3) Finish raising skid plate/fuel tank assembly
into position. Tighten mounting nuts to 16 Nzm (12
ft. lbs.) torque. Remove transmission jack.
(4) Connect fuel fill hose and fill vent hose to filler
neck. Tighten hose clamps.
(5) Connect vent hose to vent tube.
(6) Connect fuel supply hose to the supply tube
and fuel return hose to return tube. Tighten hose
clamps.
(7) Install fuel filler neck shroud with push clips.
(8) Lower vehicle.
(9) Fill fuel tank. Install filler cap.
(10) Connect negative battery cable to battery.
(11) Start vehicle and inspect for leaks.
FUEL GAUGE SENDING UNIT
The fuel gauge sending unit is attached to the fuel
pump module. Refer to Fuel Pump Module in the
Fuel Delivery System section of this group.
FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE
The fuel tank is equipped with a pressure relief/
rollover valve (Fig. 8). The dual function valve will
relieve fuel tank pressure and prevent fuel flow
through the fuel tank vent tubes in the event of ac-
cidental vehicle rollover.
The valve consists of a plunger, spring and orifice/
guide plate (Fig. 9). The valve is normally open al-
lowing fuel vapor to vent to the EVAP canister. Here
it is stored until it can be consumed by the engine
(under controlled conditions). The plunger seats inthe guide plate at the orifice preventing liquid fuel
from reaching the EVAP canister. This is done if bot-
tom of plunger is contacted by fuel sloshing in tank
when vehicle is cornering.
In the event of accidental vehicle rollover, the valve
is inverted. In this position the plunger is forced
against the guide plate and raw fuel is prevented
from flowing through the valve orifice into the fuel
tank vent tube.
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING THE PRESSURE RELIEF/
ROLLOVER VALVE, THE FUEL SYSTEM PRESSURE
MUST BE RELEASED. REFER TO THE FUEL PRES-
SURE RELEASE PROCEDURE IN THIS GROUP.
(1) Disconnect negative battery cable.
(2) Remove the fuel filler cap and drain fuel tank.
Refer to Fuel Tank Removal.
(3) Remove fuel tank. Refer to Fuel Tank Removal.
(4) The rollover valve is seated in a grommet. Re-
move by prying one side upward and then roll the
grommet out of tank (Fig. 8).
INSTALLATION
(1) Start one side of grommet into opening in fuel
tank. Using finger pressure only, press valve/grom-
met into place.
(2) Install fuel tank. Refer to Fuel Tank Installa-
tion.
(3) Fill fuel tank. Install fuel tank filler cap.
(4) Connect negative battery cable.
(5) Start vehicle and check for leaks.
Fig. 8 Valve LocationÐTypical
Fig. 9 Pressure Relief/Rollover Valve Operation
14 - 16 FUEL TANKSJ

PITMAN SHAFT AND SIDE COVER REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
(2) Remove pitman arm from steering gear. Refer
to Pitman Arm Removal in the Steering Linkage sec-
tion.
(3) Rotate stub shaft back and forth to drain power
steering fluid.
DISASSEMBLE
²Clean exposed end of pitman shaft and housing.
²Clean pitman shaft spline with a wire brush.
(1) Remove preload adjuster nut.
(2) Rotate stub shaft with socket to center gear.
Remove side cover bolts.
(3) Remove side cover, gasket and pitman shaft as
an assembly.
(4) Remove pitman shaft from the side cover (Fig.
15).
ASSEMBLE
(1) Install pitman shaft to side cover by screwing
shaft in until it fully seats to side cover.
(2) Install preload adjuster nut.Do not tighten
nut until after pitman shaft adjustment has
been made.(3) Install gasket to side cover and bend tabs
around edges of side cover.
(4) Install pitman shaft assembly and side cover to
housing.
(5) Install side cover bolts and tighten to 60 Nzm
(44 ft. lbs.).
(6) Adjust pitman shaft, refer to Over-Center Ad-
justment.
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
(2) Install pitman arm onto steering gear. Refer to
Steering Linkage in this Group.
HOUSING END PLUG
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
(2) Remove pitman arm from steering gear. Refer
to Steering Linkage in this Group.
(3) Rotate stub shaft back and forth to drain power
steering fluid.
DISASSEMBLE
²Rotate stub shaft back and forth to drain fluid
(1) Rotate retaining ring until one end is under the
hole in the housing. Unseat and force ring from
groove (Fig. 16).
(2) Rotate stub shaft slowly COUNTER-CLOCK-
WISE to remove end plug out from housing (Fig. 17).
Fig. 15 Side Cover and Pitman Shaft
Fig. 16 End Plug Retaining Ring
19 - 28 STEERINGJ

CONNECTING COOLER LINES AND FITTINGS
(ALL TYPES)
(1) Wipe cooler line and fitting clean with shop
towel.
(2) Insert cooler line into fitting. Then push line
inward until retainer or insert secures line. A snap or
click sound will be heard when the insert tabs or re-
tainer clip seats behind the cooler line flange.
(3)Pull outward on cooler lines/fittings to
verify they are properly secured.
CAUTION: The wire retainer clips or insert release
tabs secure the cooler lines. If the clips or tabs are
deformed, distorted, or not fully seated, normal
fluid pressure could unseat the lines resulting in
fluid loss and transmission damage. Be very sure
the cooler lines are firmly secured as described in
step (3).
CONVERTER DRAINBACK CHECK VALVE SERVICE
The converter drainback check valve is located in
the cooler outlet (pressure) line near the radiator
lower tank. The valve prevents fluid drainback when
the vehicle is parked for lengthy periods. The valve
check ball is spring loaded and has an opening pres-
sure of approximately 2 psi. Refer to the cooler flow
test procedure for valve testing.
The valve is serviced as an assembly; it is not re-
pairable. Do not clean the valve if restricted, or con-
taminated by sludge, or debris. If the valve fails, or if
a transmission malfunction occurs that generates
sludge and/or clutch particles and metal shavings,
the valve must be replaced.
The valve must be removed whenever the cooler
and lines are reverse flushed. The valve can be flow
tested when necessary. The procedure is exactly the
same as for flow testing a cooler.
If the valve is restricted, installed backwards, or in
the wrong line, it will cause an overheat condition
and possible transmission failure.
CAUTION: The drainback valve is a one-way valve.
As such, it must be properly oriented in terms of
flow direction. In addition, the valve must only beinstalled in the pressure line. Otherwise flow will be
blocked causing overheat and eventual transmis-
sion failure.
TRANSMISSION COOLER FLOW TESTING
The transmission main and auxiliary coolers, plus
the drainback valve, should be flow tested whenever
fluid overheating is noted.
Restricted flow caused by contamination, or a
cooler malfunction, reduces lubrication fluid flow
throughout the transmission. This can result in fluid
overheating, fluid breakdown, bushing wear, shift
problems and component failure.
Normal color of transmission fluid varies from
bright red, to light pink. Fluid overheating is indi-
cated when fluid color ranges from orange-brown to
black, and the fluid smells burned, or contains
sludge.
CAUTION: If a transmission malfunction contami-
nates the fluid with clutch disc and metal particles,
the cooler and lines must be reverse flushed thor-
oughly. Flushing will prevent sludge and particles
from flowing back into the transmission and con-
verter after repair.
Cooler flow is tested by measuring the amount of
fluid pumped through the cooler in a specified time
by the transmission oil pump.The same flow test
procedure is used for the drainback valve, main
cooler, and auxiliary cooler.
Cooler And Drainback Valve Flow Test Procedure
(1) Test flow throughdrainback valveas follows:
(a) Add extra quart of ATF Plus to transmission.
(b) Disconnect pressure line at radiator fitting, or
at drainback valve and position hose or valve end
in one quart test container.
(c) Shift transmission into neutral, run engine at
idle speed for 20 seconds, and note flow from valve.
Use stopwatch to check test time.
(d) Replace drainback valve if flow is less than
one quart in 20 seconds, is intermittent, or does
not flow at all.
(e) Connect pressure hose to radiator fitting and
proceed to cooler flow test.
(2) Test flow throughmain cooleras follows:
(a) Disconnect cooler return (rear) line at trans-
mission and place it in one quart test container.
(b) Add extra quart of fluid to transmission.
(c) Shift transmission into neutral, run engine at
idle speed for 20 seconds, and note flow from valve.
Use stopwatch to check test time.
(d) Replace cooler if fluid flow is less than one
quart in 20 seconds, is intermittent, or does not
flow at all.
Fig. 33 New Style Fitting Insert (On Cooler Line)
J30RH/32RH IN-VEHICLE SERVICE 21 - 113

VALVE BODY ASSEMBLY AND ADJUSTMENT
CAUTION: Do not force valves or plugs into place
during reassembly. If the valve body bores, valves
and plugs are free of distortion or burrs, the valve
body components should all slide into place easily.
In addition, do not overtighten the transfer plate
and valve body screws during reassembly. Over-
tightening can distort the valve body resulting in
valve sticking, cross leakage and unsatisfactory op-
eration. Tighten valve body screws to recom-
mended torque only.
(1) Lubricate valve body bores, valves and plugs
with Mopar ATF Plus transmission fluid.
(2) Insert rear clutch and rear servo check balls in
transfer plate (Fig. 120).
(3) Install filter screen in separator plate (Fig.
120).
(4) Align and install separator plate on transfer
plate. Verify check ball position before installing sep-
arator plate on transfer plate.
(5) Install new O-ring on converter clutch solenoid
and insert solenoid in separator plate (Fig. 120).
Then secure solenoid in position with attaching
screw. Tighten screw to 4 Nzm 35 in. lbs.) torque.
(6) Position valve body so internal passages and
check ball seats are facing upward. Then install
check balls in valve body (Fig. 121). There are a total
of seven check balls; The one large check ball is ap-
proximately 11/32 inch in diameter. The remaining
check balls are approximately 1/4 inch in diameter.
Note that check balls will be steel on some very early
production models and plastic on later production
models.
(7) Align and install assembled transfer and sepa-
rator plates on valve body. Install and tighten valve
body screws alternately in a diagonal pattern to 4
Nzm (35 in. lbs.) torque.
(8) Assemble and install lockup module and compo-
nents on valve body (Fig. 122).
(9) Assemble regulator valve line pressure plug,
sleeve, throttle plug and spring (Fig. 113). Insert as-sembly in valve body and install end plate. Tighten
end plate screws to 4 Nzm (35 in. lbs.) torque.
(10) Install 1-2 and 2-3 shift valves and springs
(Fig. 118).
(11) Install 1-2 shift control valve and spring (Fig.
118)
(12) Install shuttle valve as follows:
(a) Insert shuttle valve in bore.
(b) Insert plastic guides in shuttle valve second-
ary spring.
(c) Install spring on end of valve.
(d) Hold shuttle valve in place. Then compress
secondary spring and install E-clip in groove at end
of valve.
(e) Verify that spring and E-clip are properly
seated before proceeding.
(13) Install shuttle valve cover plate (Fig. 118).
Tighten end plate screws to 4 Nzm (35 in. lbs.)
torque.
(14) Install 1-2 and 2-3 valve governor plugs in
valve body (Fig. 113). Then install shuttle valve pri-
mary spring and throttle plug.
(15) Align and install governor plug end plate on
valve body and install end plate screws. Tighten
screws to 4 Nzm (35 in. lbs.) torque.
(16) Install manual valve (Fig. 117).
(17) Install throttle valve and spring. Then install
kickdown valve and detent (Fig. 117).
(18) Install pressure regulator valve and switch
valve in valve body.
(19) Install manual lever detent spring in housing.
Place detent ball on end of spring and push ball and
spring into housing. Secure ball and spring with De-
tent Retainer 6583 (Fig. 108).
Fig. 120 Installing Converter Clutch Solenoid
Fig. 121 Correct Position Of Valve Body Check Balls
J30RH/32RH TRANSMISSION OVERHAUL 21 - 153

(6) Lubricate and install new O-rings on clutch pis-
ton and install piston in drum.
(7) Install piston return springs.
(8) Compress piston return springs with Tool 7538
and shop press and install piston snap ring. Be sure
snap ring end gap is not aligned with any notches in
drum.
(9) Install cushion plate in drum. Concave side of
plate faces downward (Fig. 5).
(10) Install clutch discs, plates and retainer (Fig.
15). Install tabbed plate followed by disc until re-
quired number of plates and discs are installed. Use
six plates and discs.(11) Install clutch pack snap ring.
(12) Recheck clutch piston stroke length using
same method outlined at beginning of disassembly
procedure. If stroke length is not within specified
limits, replace clutch discs.
(13) Lubricate race and bearing with petroleum jelly
and install them in clutch drum (FIg. 16). Be sure bear-
ing rollers face up and race lip seats in drum as shown.
(14) Verify bearing and race size.
²Outer diameter of bearing is 46.7 mm (1.839 in).
²Outer diameter of race is 48.9 mm (1.925 in.).
²Inner diameter of bearing and race is 26.0 mm
(1.024 in.).
(15) Mount forward clutch on direct clutch and
check assembled height (Fig. 17). Height should be
70.3 - 71.5 mm (2.767 - 2.815 in.).
Fig. 15 Installing Forward Clutch Discs And Plates
Fig. 16 Installing Thrust Bearing And Race
Fig. 17 Checking Forward Clutch Assembled Height
Fig. 14 Installing Clutch Drum Shaft Seal Rings
21 - 236 AW-4 TRANSMISSION OVERHAULJ

(8) Remove input gear bearing from front case
with Tool Handle C-4171 and Tool C-4210, 7828, or
5062. Use tool that is best fit in bearing (Fig. 34).
(9) Turn front case over.
(10) Start bearing in case by hand. Then seat bear-
ing with Tools C-4171 and C-4210, or 7828 until snap
ring seats against case surface (Fig. 35).
INPUT AND LOW RANGE GEAR ASSEMBLY
AND INSTALLATION
(1) Remove mainshaft pilot bearing from input
gear with Tool MD-998346, or similar tool as follows:
(a) Turn puller tool bolt until jaws retract
enough to fit into bearing (Fig. 36).
(b) Insert puller bolt and jaws into bearing. Then
turn puller bolt clockwise so ramp on bolt spreads
jaws forcing them under bearing (Fig. 37).
Fig. 34 Input Gear Bearing Removal
Fig. 35 Input Gear Bearing Installation
Fig. 36 Puller Jaws In Retracted Position
Fig. 37 Puller Bolt And Jaws Seated Under Needle
Bearing
21 - 296 NP231 TRANSFER CASEJ