1994 JEEP CHEROKEE Service Repair Manual

(12) Remove valve body oil feed tubes (Fig. 7).
(13) Disconnect valve body solenoid wires (Fig. 8).(14) Remove harness bracket bolt and remove har-
ness and bracket Fig. 9).
(15) Remove valve body bolts (Fig. 10).
Fig. 7 Removing Valve Body Oil Tubes
Fig. 8 Solenoid Wire Location
Fig. 9 Removing Bracket And Harness
Fig. 10 Valve Body Bolt Locations
21 - 194 AW-4 TRANSMISSION OVERHAULJ

(16) Disconnect throttle cable from throttle cam
(Fig. 11).
(17) Remove valve body from case. Then remove
accumulator springs, spacers and check ball and
spring (Fig. 12).
(18) Remove second brake and clutch accumulator
pistons with compressed air (Fig. 13). Apply air pres-
sure through feed port and ease the pistons out of
the bore.
(19) Remove overdrive brake accumulator piston
with compressed air (Fig. 13).
(20) Remove overdrive clutch accumulator piston
with compressed air (Fig. 13).
(21) Remove throttle cable.
Fig. 11 Disconnecting Throttle Cable
Fig. 12 Removing Accumulator Springs, Spacers
And Check Ball
Fig. 13 Removing Accumulator Pistons
JAW-4 TRANSMISSION OVERHAUL 21 - 195

(22) Remove oil pump bolts and remove pump with
bridge-type Puller 7536 (Fig. 14).
(23) Remove race from oil pump (Fig. 15).
(24) Remove fourth gear overdrive planetary gear
and overdrive direct clutch assembly (Fig. 16).
(25) Remove race from fourth gear overdrive plan-
etary (Fig. 17).
(26) Remove thrust bearing, race and overdrive
planetary ring gear (Fig. 18).
(27) Measure stroke length of overdrive brake pis-
ton as follows:
(a) Mount dial indicator on case (Fig. 19).
(b) Mount Gauge Tool 7546 so it contacts piston
(Fig. 19).(c) Apply 57-114 psi air pressure through piston
apply port and note piston stroke on dial indicator.
Stroke length should be: 1.40 - 1.70 mm (0.055 -
0.0699 in.).
Fig. 14 Oil Pump Removal
Fig. 15 Oil Pump Race Removal
Fig. 16 Removing Fourth Gear Planetary And Direct
Clutch Assembly
Fig. 17 Fourth Gear Planetary Race Removal
21 - 196 AW-4 TRANSMISSION OVERHAULJ

(d) If stroke is not within limits, replace brake
pack retainer. Select required retainer from Over-
drive Brake Retainer Selection chart in Specifica-
tions section.
(28) Remove overdrive brake snap ring (Fig. 20).(29) Remove overdrive brake discs and plates (Fig.
21). Then measure disc thickness with a micrometer.
Minimum disc thickness is 1.84 mm (0.0724 in.). Re-
place discs if thickness is less than specified.
Fig. 19 Measuring Overdrive Brake Piston Stroke
Fig. 18 Removing Bearing, Race And Planetary Ring
GearFig. 20 Removing Overdrive Brake Snap Ring
Fig. 21 Removing/Measuring Overdrive Brake Disc
Thickness
JAW-4 TRANSMISSION OVERHAUL 21 - 197

(30) Remove overdrive support lower race and up-
per bearing and race assembly (Fig. 22).
(31) Remove overdrive support bolts (Fig. 23).(32) Remove overdrive support snap ring with
Snap Ring Plier Tool 7540 (Fig. 24).
(33) Remove overdrive support (Fig. 25) with
bridge-type Puller 7536.
Fig. 22 Overdrive Support Bearing/Race Removal
Fig. 23 Overdrive Support Bolt Removal
Fig. 24 Removing/Installing Overdrive Support Snap
Ring
Fig. 25 Removing Overdrive Support
21 - 198 AW-4 TRANSMISSION OVERHAULJ

(34) Remove race from hub of overdrive support
(Fig. 26).
(35) Measure stroke length of second coast brake
piston rod as follows:
(a) Make reference mark on piston rod (Fig. 27)
as shown.(b) Apply 57-114 psi air pressure through piston
feed hole and check stroke length with Gauge Tool
7552 (Fig. 27).
(c) Stroke length should be 1.5 - 3.0 mm (0.059 -
0.118 in.).
(d) If stroke length is incorrect, install new pis-
ton rod and recheck stroke. If stroke is still incor-
rect, replace second coast brake band.
(e) Replacement piston rods are available in two
different lengths which are: 71.4 mm (2.811 in.)
and 72.9 mm (2.870 in.).
(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).
Fig. 27 Measuring Second Coast Brake Piston Rod
Stroke
Fig. 26 Remove Overdrive Support Race
Fig. 28 Removing Second Coast Brake Cover And
Piston
JAW-4 TRANSMISSION OVERHAUL 21 - 199

(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).
(40) Remove second coast brake band E-ring from
band pin and remove brake band (Fig. 32).
(41) Remove front planetary ring gear front bear-
ing race and remove front planetary ring gear (Fig.
33).(42) Remove thrust bearing and rear race from
ring gear (Fig. 34).
(43) Remove planetary thrust race (Fig. 35).
(44) Relieve load on planetary snap ring as follows:
Loosen transmission holding fixture. Turn transmis-
Fig. 29 Second Coast Brake Piston Components
Fig. 30 Removing Direct And Forward Clutch
Assembly
Fig. 31 Remove Bearing And Race From Clutch Hub
Fig. 32 Removing Second Coast Brake Band
21 - 200 AW-4 TRANSMISSION OVERHAULJ

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
Fig. 33 Removing Front Planetary Ring Gear
Fig. 34 Removing Ring Gear Bearing And Rear Race
Fig. 35 Relieving Load On Planetary Snap Ring
Fig. 36 Removing Planetary Snap Ring And Gear
JAW-4 TRANSMISSION OVERHAUL 21 - 201