1994 JEEP CHEROKEE Service Repair Manual

(17) Install No. 1 one-way clutch (Fig. 14). Short
flanged side of clutch faces up and toward case front.
(18) Install second brake pack (Fig. 15). Install
disc then plate. Continue installation sequence until
correct number of discs-plates are installed. Use five
discs and five plates.
(19) Install second brake pack retainer with
rounded edge of retainer facing disc.
(20) Install second brake pack snap ring.
(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.
Fig. 14 Installing No. 1 One-Way Clutch
Fig. 12 Installing Park Rod Bracket
Fig. 13 Checking Park Pawl Engagement
Fig. 15 Installing Second Brake Pack
Fig. 16 Checking Second Brake Pack Clearance
21 - 258 AW-4 TRANSMISSION OVERHAULJ

(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).
(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.
(30) Verify forward-direct clutch thrust bearing
size.
Fig. 17 Installing Sun Gear And Input Drum
Fig. 18 Installing Front Planetary Gear
Fig. 19 Supporting Output Shaft
Fig. 20 Installing Front Planetary Snap Ring
JAW-4 TRANSMISSION OVERHAUL 21 - 259

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).
Fig. 24 Installing Forward-Direct Clutch Thrust Bearing
And Race
Fig. 21 Installing Planetary Thrust Race
Fig. 22 Installing Second Coast Brake Band
Fig. 23 Installing Second Coast Brake Band Retaining Pin
21 - 260 AW-4 TRANSMISSION OVERHAULJ

(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 downward
and install assembled planetary gear/forward-direct
clutch (Fig. 29).
Fig. 25 Installing Planetary Ring Gear Race
Fig. 26 Aligning Forward-Direct Clutch Splines
Fig. 27 Installing Front Planetary Ring Gear
Fig. 28 Installing Ring Gear Bearing And Race
ART: j8921-696; SIZE (3) = 3-1/2h x 3-1/2w
Fig. 29 Installing Front Planetary And Forward-
Direct Clutch Assembly
JAW-4 TRANSMISSION OVERHAUL 21 - 261

(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).
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. 30 Checking Input Drum-To-Direct Clutch Drum
Clearance
Fig. 31 Installing Clutch Shaft Thrust Bearing And
Race Assembly
Fig. 32 Assembling Second Coast Brake Piston
Fig. 33 Installing Second Coast Brake Piston Snap
Ring
21 - 262 AW-4 TRANSMISSION OVERHAULJ

(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.
(50) Install overdrive clutch pack (Fig. 41). Install
thickest clutch plate first. Rounded edge of plate
faces up. Install first disc followed by another plate
until correct number of discs-plates are installed. In-
stall four discs and three plates.
(51) Install stepped ring retainer plate with flat
side facing disc. Then install brake pack snap ring
(Fig. 42).
Fig. 36 Installing Overdrive Support Thrust Race
And Washer
Fig. 37 Installing Overdrive Support
Fig. 34 Marking Brake Piston Rod
Fig. 35 Checking Second Coast Brake Piston Stroke
JAW-4 TRANSMISSION OVERHAUL 21 - 263

(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.
Fig. 38 Installing Overdrive Support Snap Ring
Fig. 39 Installing Overdrive Support Bolts
Fig. 40 Checking Output Shaft End Play
Fig. 41 Install Overdrive Clutch Pack
Fig. 42 installing Overdrive Brake Snap Ring
21 - 264 AW-4 TRANSMISSION OVERHAULJ

(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:
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.).
Fig. 43 Positioning Gauge Tool And Dial Indicator
Fig. 44 Checking Overdrive Brake Piston Stroke
Fig. 45 Installing Overdrive Support Thrust Bearing
And Races
Fig. 46 Installing Overdrive Planetary Ring Gear
JAW-4 TRANSMISSION OVERHAUL 21 - 265