1994 JEEP CHEROKEE clutch

(20) Check inside diameter of clutch drum bush-
ings with bore gauge or inside micrometer (Fig. 18).
Maximum inside diameter is 27.11 mm (1.0673 in.).
Replace drum if bushing inside diameter is greater
than specified.
(21) Check inside diameter of planetary gear bush-
ing (Fig. 19). Maximum inside diameter is 11.27 mm
(0.4437 in.). Replace planetary gear if bushing inside
diameter is greater then specified.
Assembling Gear And Clutch
(1) Install thrust washer in planetary gear (Fig.
20).Grooved side of washer faces up and to-
ward front.(2) Install one-way clutch in race (Fig. 21). Flanged
side of clutch must face upward as shown.
(3) Install assembled one-way clutch and outer
race in planetary gear. Be sure flanged side of clutch
is facing upward.
(4) Install clutch pack retaining plate and snap
ring in planetary gear.
(5) Coat planetary race with petroleum jelly and
install it on planetary gear. Outside diameter of race
is 41.8 mm (1.646 in.); inside diameter is 27.1 mm
(1.067 in.).
(6) Install hub in planetary ring gear and install
snap ring.
Fig. 18 Checking Clutch Drum Bushings
Fig. 19 Checking Planetary Bushing
Fig. 20 Install Planetary Thrust Washer
Fig. 21 Assembling One-Way Clutch And Race
21 - 214 AW-4 TRANSMISSION OVERHAULJ

(7) Coat race and bearing with petroleum jelly and
install in planetary ring gear (Fig. 22).
(8) Verify bearing/race size. Outside diameter of race
is 47.8 mm (1.882 in.) and inside diameter is 24.2 mm
(0.953 in.). Outside diameter of bearing is 46.8 mm
(1.843 in.) and inside diameter is 26 mm (1.024 in.).
(9) Lubricate and install new O-rings on clutch pis-
ton. Then install piston in clutch drum.
(10) Install piston return springs in clutch piston
(Fig. 23).
(11) Install piston snap ring. Compress piston re-
turn springs with Tool 7538 and shop press (Fig. 24).(12) Install clutch pack in drum. Install steel plate
first, then a disc (Fig. 25). Continue installation se-
quence until required number of discs and plates
have been installed.
(13) Install clutch pack retainer with flat side fac-
ing downward. Then install retainer snap ring (Fig.
26). Compress springs with suitable tool.
(14) Measure clutch piston stroke length again (re-
fer to procedure outlined in disassembly procedure ).
If stroke length is incorrect, install new clutch discs
or select fit retainer. Retainer thicknesses are out-
lined in the Specifications section.
(15) Install clutch drum bearing and race assembly
(Fig. 27). Be sure bearing rollers face upward as shown.
Outside diameter of assembled bearing and race is 50.2
Fig. 24 Installing Clutch Piston Snap Ring
Fig. 22 Install Ring Gear Bearing And Race
Fig. 23 Installing Piston Return Springs
Fig. 25 Installing Clutch Discs And Plates
JAW-4 TRANSMISSION OVERHAUL 21 - 215

mm (1.976 in.). Inside diameter is 28.9 mm (1.138 in.).
(16) Install clutch on planetary gear.
(17) Verify one-way clutch operation. Hold drum
and turn planetary shaft clockwise and counterclock-wise. Shaft should turn clockwise freely but lock
when turned counterclockwise.
OVERDRIVE SUPPORT OVERHAUL
SUPPORT DISASSEMBLY
(1) Check brake piston operation. Mount support
on clutch (Fig. 2).
(2) Apply compressed air through support feed hole
and observe brake piston movement (Fig. 2). Piston
Fig. 1 Overdrive Support Components
Fig. 26 Installing Retainer And Snap Ring
Fig. 27 Installing Clutch Drum Bearing And Race
Assembly
21 - 216 AW-4 TRANSMISSION OVERHAULJ

should move smoothly and not bind or stick. If oper-
ation is incorrect, replace piston and support.
(3) Remove thrust bearing front race, thrust bear-
ing and rear race (Fig. 3).
(4) Turn overdrive support over and remove bear-
ing race and clutch drum thrust washer (Fig. 4).
(5) Compress piston return spring with Spring
Compressor 7537 and remove piston snap ring (Fig.
5).(6) Mount support in direct clutch and remove
brake piston with compressed air. Apply air to same
feed hole used when checking piston operation.
(7) Remove and discard support O-rings (Fig. 1).
Fig. 2 Checking Brake Piston Movement
Fig. 3 Removing Support Thrust Bearing And Races
Fig. 4 Removing Clutch Drum Thrust Washer And
Race
Fig. 5 Removing/Installing Piston Snap Ring
JAW-4 TRANSMISSION OVERHAUL 21 - 217

(8) Remove support seal rings (Fig. 6).
(9) Measure free length of piston return springs
with springs mounted in retainer (Fig. 7). Length
should be 17.23 mm (0.678 in.).
(10) Clean support components and dry them with
compressed air.
(11) Inspect overdrive support and brake piston. Re-
place support and piston if either part is worn or dam-
aged.
ASSEMBLING OVERDRIVE SUPPORT
(1) Lubricate new support seal rings. Then com-
press rings and install them on support (Fig. 8).
(2) Lubricate and install new O-rings on brake pis-
ton. Then carefully seat piston in support.(3) Install return springs on brake piston.
(4) Compress return springs with Spring Compres-
sor 7537 (Fig. 5) and install piston snap ring.
(5) Install support bearing race and clutch drum
thrust washer (Fig. 4).
(6) Install thrust bearing and front and rear bear-
ing races. Thrust bearing rollers should face upward
as shown (Fig. 9).
(7) Verify thrust bearing/race sizes (Fig. 9).
²Front race outer diameter is 47.8 mm (1.882 in.)
and inside diameter is 30.7 mm (1.209 in.).
Fig. 9 Installing Support Thrust Bearing And Races
Fig. 6 Removing Support Seal Rings
Fig. 7 Checking Piston Return Spring Length
Fig. 8 Installing Support Seal Rings
21 - 218 AW-4 TRANSMISSION OVERHAULJ

²Rear race outer diameter is 47.8 mm (1.882 in.)
and inside diameter is 34.3 mm (1.350 in.).
²Bearing outer diameter is 47.7 mm (1.878 in.) and
inside diameter is 32.7 mm (1.287 in.).
(8) Verify brake piston operation. Use same proce-
dure described at beginning of disassembly. Piston
should operate smoothly and not bind or stick.
DIRECT CLUTCH OVERHAUL
CLUTCH DISASSEMBLY
(1) Remove direct clutch from forward clutch (Fig.
1).
(2) Remove clutch drum thrust washer (Fig. 2).(3) Check clutch piston stroke length as outlined in
following steps.
(4) Mount direct clutch on overdrive support as-
sembly (Fig. 3).
(5) Mount dial indicator on clutch and position in-
dicator plunger on clutch piston (Fig. 4).
(6) Apply 57-114 psi air pressure through feed hole
in overdrive support and note piston stroke length
(Fig. 4). Check stroke at least twice.
Fig. 1 Separate Direct Clutch From Forward Clutch
Fig. 2 Removing Clutch Drum Thrust Washer
Fig. 3 Mount Direct Clutch On Overdrive Support
Fig. 4 Checking Direct Clutch Piston Stroke Length
JAW-4 TRANSMISSION OVERHAUL 21 - 219

(7) Piston stroke length should be 1.37 mm - 1.67
mm (0.054 -0.065 in.). If stroke length is incorrect, ei-
ther the clutch pack retainer or clutch discs will have
to be replaced.
(8) Remove clutch pack snap ring and remove re-
tainer and clutch pack from drum (Fig. 5).
(9) Compress clutch piston return springs with tool
7538 and remove clutch piston snap ring (Fig. 6).
(10) Remove compressor tool and return spring.(11) Remove clutch piston. Remount clutch on
overdrive support (Fig. 7). Apply compressed air
through piston feed hole in support to remove piston.
Use only enough air to ease piston out.
(12) Remove and discard clutch piston O-rings.
(13) Measure clutch disc thickness. Minimum al-
lowable thickness is 1.84 mm (0.0724 in). Replace
discs if below minimum thickness.
(14) Measure free length of piston return springs
with springs in retainer (Fig. 8). Length should be
21.32 mm (0.839 in.). Replace return springs if not
within specification.
Fig. 5 Removing Clutch Pack Snap Ring
Fig. 6 Removing Piston Return Spring
Fig. 7 Removing Direct Clutch Piston
Fig. 8 Checking Piston Return Spring Length
21 - 220 AW-4 TRANSMISSION OVERHAULJ

(15) Check clutch piston check ball (Fig. 9). Shake
piston to see if ball moves freely. Then check ball
seating by applying low pressure compressed air to
ball inlet as shown. Air should not leak past check
ball.
(16) Measure inside diameter of clutch drum bush-
ing. Inside diameter should be no more than 53.97
mm (2.1248 in.). Replace drum if bushing inside di-
ameter is greater than specified.
DIRECT CLUTCH ASSEMBLY
(1) Lubricate and install replacement O-rings on
clutch piston (Fig. 10).
(2) Install clutch piston in drum and install return
springs on piston.
(3) Compress piston return springs with Tool 7538
and install snap ring (Fig. 6). Be sure snap ring end
gap is not aligned with spring retainer tab.
(4) Install clutch discs and plates (Fig. 11). Install
plate then disc until all plates and discs are in-
stalled. Four plates and discs are required.
(5) Install clutch pack retainer in drum (Fig. 12).
(6) Install clutch pack snap ring (Fig. 12).(7) Check snap ring position. If necessary, shift
snap ring until end gap isnotaligned with any
notches in clutch drum (Fig. 12).
Fig. 10 Direct Clutch Components
Fig. 9 Testing Piston Check Ball Seating
JAW-4 TRANSMISSION OVERHAUL 21 - 221