1994 JEEP CHEROKEE clutch

(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

clutch as assembly (Fig. 37).
(47) Measure second brake clutch pack clearance
(Fig. 38). Clearance should be 0.62 - 1.98 mm (0.0244
- 0.0780 in.). Replace discs if clearance is not within
specifications.(48) Remove second brake clutch pack snap ring
(Fig. 39).
(49) Remove second brake clutch pack (Fig. 40).
Measure disc thickness with micrometer. Minimum
thickness should be 1.84 mm (0.0724 in.). Replace
discs if not within specifications.
Fig. 37 Removing Sun Gear, Input Drum And
One-Way Clutch
Fig. 38 Checking Second Brake Clutch Pack
Clearance
Fig. 39 Removing Second Brake Clutch Pack Snap
Ring
Fig. 40 Remove/Measure Second Brake Clutch Disc
Thickness
21 - 202 AW-4 TRANSMISSION OVERHAULJ

(50) Remove bolts attaching park rod bracket to
case. Then disconnect park rod from manual shaft le-
ver and remove rod and bracket (Fig. 41).
(51) Remove park pawl spring, pin and pawl (Fig. 42).
(52) Measure clearance of first-reverse brake
clutch pack (Fig. 43). Clearance should be: 0.70 - 1.2
mm (0.028 - 0.047 in.). Replace discs if clearance is
not as specified.
(53) Remove second brake piston sleeve (Fig. 44).
Cover remover tool with tape to avoid damaging case.
(54) Remove rear planetary gear, second brake
drum and output shaft as an assembly (Fig. 45).
(55) Remove planetary and brake drum thrust
bearing and race assembly (Fig. 46).
Fig. 41 Removing Park Rod And Bracket
Fig. 42 Removing Park Pawl, Pin And Spring
Fig. 43 Checking First-Reverse Brake Clutch Pack
Clearance
Fig. 44 Removing Second Brake Piston Sleeve
JAW-4 TRANSMISSION OVERHAUL 21 - 203

During overhaul assembly operations, lubricate the
transmission components with Jeep or Mopar Mer-
conŸ automatic transmission fluid or petroleum jelly
as indicated. Petroleum jelly should be used to prelu-
bricate thrust bearings, washers and races. It can
also be used to hold parts in position during assem-
bly.
Soak replacement clutch and brake pack com-
ponents in transmission fluid for at least 30
minutes before installation.
MANUAL VALVE SHAFT OVERHAUL
(1) Cut shaft spacer sleeve in half with chisel and
remove it from lever and shaft (Fig. 2).
(2) Remove shift sector retaining pin with pin
punch (Fig. 3).
(3) Pull shaft out of case and remove manual lever.
(4) Carefully pry shaft seals from case.
(5) Lubricate new seals with petroleum jelly and
install them in case (Fig. 4).
(6) Install new spacer sleeve on shift sector (Fig.
5).
(7) Install sector and sleeve on shaft and install
shaft in case.
(8) Align sector and sleeve and install new retain-
ing pin.
(9) Align notch in sleeve with depression in sector
and stake sleeve in two places. Be sure lever and
shaft rotate smoothly.
Fig. 1 Manual Valve Shaft Components
Fig. 2 Cutting Shaft Spacer Sleeve
Fig. 3 Removing/Installing Sector Retaining Pin
JAW-4 TRANSMISSION OVERHAUL 21 - 205

OVERDRIVE PLANETARY GEAR AND CLUTCH
OVERHAUL
GEAR AND CLUTCH DISASSEMBLY
(1) Check operation of one-way clutch in clutch
drum. Hold drum and turn planetary shaft clockwise
and counterclockwise. Shaft should turn clockwise
freely but lock when turned counterclockwise. Re-
place one-way clutch if necessary.
(2) Remove overdrive clutch from planetary gear
(Fig. 3).
(3) Remove thrust bearing and race assembly from
clutch drum (Fig. 4).
Fig. 1 Overdrive Planetary Gear And Clutch Components
JAW-4 TRANSMISSION OVERHAUL 21 - 209

(4) Measure stroke length of clutch piston as fol-
lows:
(a) Mount oil pump on torque converter. Then
mount clutch on oil pump (Fig. 5).
(b) Mount dial indicator on clutch and position
indicator stylus on clutch piston (Fig. 6).
(c) Apply compressed air through clutch feed hole
in oil pump and note piston stroke length. Stroke
length should be 1.85 - 2.15 mm (0.0728 - 0.0846
in.).
(5) Replace clutch pack retainer if stroke length is
incorrect. Refer to chart in Specifications section for
replacement retainer thicknesses.
Fig. 2 Checking One-Way Clutch
Fig. 3 Removing Overdrive Clutch From Gear
Fig. 4 Removing Clutch Drum Bearing And Race
Fig. 5 Assembling Converter, Pump And Clutch For
Test
21 - 210 AW-4 TRANSMISSION OVERHAULJ

(6) Remove clutch pack snap ring and remove the
clutch pack.
(7) Compress piston return spring with Tool 7538
(Fig. 8). Remove snap ring and remove compressor
tool.
(8) Remove compressor tool and piston return
springs.
(9) Mount oil pump on converter. Then mount
clutch on oil pump (Fig. 9).
(10) Hold clutch piston by hand and apply com-
pressed air through oil pump feed hole to ease piston
out (Fig. 9). Apply only enough air pressure to re-
move piston.
Fig. 6 Checking Overdrive Clutch Piston Stroke
Fig. 7 Removing Clutch Pack Snap Ring
Fig. 8 Removing Clutch Piston Snap Ring
Fig. 9 Removing Overdrive Clutch Piston
JAW-4 TRANSMISSION OVERHAUL 21 - 211

(15) Remove one-way clutch and outer race as as-
sembly. Then separate race from clutch (Fig. 14).
(16) Remove thrust washer (Fig. 15).
(17) Measure clutch disc thickness. Minimum al-
lowable thickness is 1.84 mm (0.0724 in.).(18) Measure free length of piston return springs
with springs in retainer (Fig. 16). Length should be
16.8 mm (0.661 in.).
(19) Check clutch piston check ball (Fig. 17). Shake
piston to see if ball moves freely. Then check ball
sealing by applying low pressure compressed air to
ball inlet as shown. Air should not leak past check
ball.
Fig. 14 Removing One-Way Clutch
Fig. 15 Removing Planetary Thrust Washer
Fig. 16 Checking Piston Return Spring Length
Fig. 17 Testing Clutch Piston Check Ball
JAW-4 TRANSMISSION OVERHAUL 21 - 213