1994 JEEP CHEROKEE Service Repair Manual

(18) Measure clutch disc thickness (Fig. 10). Mini-
mum allowable thickness is 1.51 mm (0.0595 in.).
(19) Measure free length of piston return springs
with springs mounted in retainer (Fig. 11). Length
should be 19.47 mm (0.767 in.). Replace springs and
retainer if length is incorrect.
(20) Inspect clutch piston check ball (Fig. 12). Ball
should move freely within piston. Check ball seating
by applying low pressure compressed air to ball feed
hole. Ball should seat firmly and not leak air.
(21) Measure inside diameter of bushing in clutch
drum hub. Maximum allowable diameter is 24.08
mm (0.9480 in.). Replace clutch drum if bushing in-
side diameter is greater than specified.
FORWARD CLUTCH ASSEMBLY
(1) Lubricate bearing and race assembly with pe-
troleum jelly and install it in clutch drum (Fig. 13).
Race side of assembly faces downward and toward
drum. Bearing rollers face up (Fig. 13)
(2) Coat new clutch drum shaft seal rings with pe-
troleum jelly. Before installing drum shaft seal rings,
squeeze each ring so ring ends overlap (Fig. 14). This
tightens ring making clutch installation easier.
(3) Install seal rings on shaft. Keep rings closed as
tightly as possible during installation. Avoid over-
spreading them.
(4) Mount clutch drum on overdrive support.
Fig. 10 Measuring Clutch Disc Thickness
Fig. 11 Checking Return Spring Length
Fig. 12 Testing Piston Check Ball
Fig. 13 Installing Thrust Bearing And Race
21 - 226 AW-4 TRANSMISSION OVERHAULJ

(5) Lubricate and install new O-ring on clutch
drum hub (Fig. 7).
(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). In-
stall tabbed plate followed by disc until required 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
JAW-4 TRANSMISSION OVERHAUL 21 - 227

FRONT PLANETARY GEAR OVERHAUL
FRONT PLANETARY DISASSEMBLY
(1) Remove ring gear from planetary gear (Fig. 1).
(2) Remove front bearing and the two races from
ring gear (Fig. 1).
(3) Remove tabbed thrust race from planetary gear
(Fig. 1).
(4) Remove snap ring attaching planetary gear to
shaft and remove gear.
(5) Remove rear bearing and race from planetary
gear.
(6) Measure inside diameter of ring gear bushing.
Maximum allowable diameter is 24.08 mm (0.9480
in.). Replace ring gear if bushing inside diameter is
greater than specified.
FRONT PLANETARY ASSEMBLY
(1) Lubricate planetary and ring gear bearings and
races with petroleum jelly.
(2) Identify planetary bearings and races before in-
stallation. (Fig. 1). Bearings and races can be identi-
fied by following dimensions:
²Outer diameter of rear bearing is 47.7 mm (1.878
in.). Inner diameter is 35.5 mm (1.398 in.).
²Outer diameter of rear race 47.6 mm (1.874 in.).
Inner diameter is 33.7 mm (1.327 in.).
²Outer diameter of front race is 53.6 mm (2.110
in.). Inner diameter is 30.5 mm (1.201 in.).
²Outer diameter of front bearing is 47.7 mm (1.878
in.). Inner diameter is 32.6 (1.283 in.).
²Outer diameter of forward race is 47.0 mm (1.850
in.). Inner diameter is 26.5 mm 1.043 in.).
(3) Install rear race and bearing in gear (Fig. 2).
Fig. 1 Front Planetary Gear Components
Fig. 2 Installing Front Planetary Rear Bearing and
Race
21 - 228 AW-4 TRANSMISSION OVERHAULJ

(4) Turn planetary over and install race thrust
race (Fig. 3).
(5) Install front race and bearing and forward race
in ring gear (Fig. 4).
(6) Set planetary gear assembly aside for final as-
sembly.
SUN GEAR AND NO. 1 ONE-WAY CLUTCH
OVERHAUL
SUN GEAR AND CLUTCH DISASSEMBLY
(1) Hold sun gear and turn second brake hub
clockwise and counterclockwise (Fig. 2). Hub should
rotate freely clockwise but lock when turned counter-clockwise. Replace one-way clutch and hub if they do
not operate properly.
(2) Remove one-way clutch/second brake hub as-
sembly from drum (Fig. 3).
(3) Remove thrust washer from drum (Fig. 4).
(4) Remove two seal rings from sun gear (Fig. 5).
Fig. 1 Sun Gear And One-Way Clutch Components
Fig. 3 Installing Front Planetary Thrust Race
Fig. 4 Installing Front Planetary Front Bearing And
Races
JAW-4 TRANSMISSION OVERHAUL 21 - 229

(5) Support sun gear on wood block (Fig. 6). Then
remove first sun gear snap ring and separate drum
from gear.
(6) Remove remaining snap ring from sun gear
(Fig. 7).
(7) Measure inside diameter of sun gear bushings
with bore gauge or inside micrometer (Fig. 8). Maxi-
mum allowable diameter is 27.08 mm (1.0661 in.).
Replace sun gear if bushing inside diameter is
greater than specified.
SUN GEAR AND CLUTCH ASSEMBLY
(1) Install first snap ring on sun gear.
(2) Install sun gear in drum and install remaining
snap ring.(3) Coat replacement seal rings with petroleum
jelly and install them on sun gear.Be sure seal
ring ends are interlocked.
(4) Install thrust washer. Be sure washer tabs are
seated in drum slots.
(5) Install one-way clutch/second brake hub assem-
bly on sun gear. Deep side of hub flange faces up-
ward (Fig. 9).
(6) Check one-way clutch operation again (Fig. 2).
Hold sun gear and turn second brake hub clockwise
and counterclockwise. Hub should turn clockwise
freely, but lock when turned counterclockwise.
Fig. 2 Checking One-Way Clutch Operation
Fig. 3 Removing/Installing Brake Hub And Clutch
Assembly
Fig. 4 Removing/Installing Thrust Washer
Fig. 5 Removing/Installing Sun Gear Seal Rings
21 - 230 AW-4 TRANSMISSION OVERHAULJ

(7) Set sun gear/clutch assembly aside for final as-
sembly.
Fig. 6 Removing/Installing Sun Gear
Fig. 7 Removing/Installing Second Snap Ring
Fig. 8 Checking Sun Gear Bushings
Fig. 9 Installing Clutch And Hub Assembly On Sun
Gear
JAW-4 TRANSMISSION OVERHAUL 21 - 231

SECOND BRAKE OVERHAUL
BRAKE DISASSEMBLY
(1) Remove second brake drum from output shaft
(Fig. 2).
(2) Set output shaft assembly aside for overhaul.
Refer to Rear Planetary Gear and Output Shaft
Overhaul procedures.
(3) Remove thrust washer from second brake drum
(Fig. 3).
(4) Compress piston return springs with shop press
and tool 7538. Then remove piston snap ring (Fig. 4).
(5) Remove compressor tool and remove spring re-
tainer and return springs.
(6) Remove second brake piston and sleeve from
drum with compressed air (Fig. 5). Use only enough
air pressure to ease piston out of drum.
(7) Remove and discard brake piston O-rings.(8) Measure free length of piston return springs
with springs mounted in retainer (Fig. 6). Length
should be approximately 16.05 mm (0.632 in.). Re-
place return springs if length is less than specified.
SECOND BRAKE ASSEMBLY
(1) Lubricate and install new O-rings on brake pis-
ton. Then install brake piston in drum.
(2) Install return springs and retainer on brake
piston.
Fig. 1 Second Brake Components
Fig. 2 Removing/Installing Second Brake Assembly
Fig. 3 Removing/Installing Second Brake Drum
Thrust Washer
21 - 232 AW-4 TRANSMISSION OVERHAULJ

(3) Compress return springs with shop press and
Compressor Tool 7538. Install piston snap ring and
remove brake assembly from press.
(4) Check brake piston operation with low pressure
compressed air (Fig. 7). Apply air pressure through
feed hole in drum. Piston should move smoothly
when applying-releasing air pressure.
(5) Coat thrust washer with petroleum jelly and
install it in drum. Be sure washer notches are
aligned with tabs on spring retainer (Fig. 8).
(6) Set brake components aside for final assembly.
Fig. 6 Measuring Second Brake Piston Return Springs
Fig. 7 Checking Second Brake Piston Operation
Fig. 8 Installing Second Brake Thrust Washer
Fig. 4 Removing/Installing Second Brake Piston Snap Ring
Fig. 5 Removing/Installing Piston And Sleeve
JAW-4 TRANSMISSION OVERHAUL 21 - 233