1994 JEEP CHEROKEE transmission

(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

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

(56) Remove second brake drum gasket from case
with gasket scraper or screwdriver (Fig. 47). Retain
tube shaped gasket if condition is OK.
(57) Measure inside diameter of transmission case
rear bushing with bore gauge or inside micrometer
(Fig. 48). Maximum allowable diameter is 38.18 mm
(1.5031 in.).Replace transmission case if bush-
ing I.D. is greater than specified. Bushing is not
serviceable.
CLEANING AND INSPECTION
Clean the transmission components with solvent
and dry them with compressed air only. Do not use
shop towels or rags.
Blow compressed air through all oil feed passages
and channels to be sure they are clear. Inspect the
transmission components for wear and damage. Re-
place components that are damaged or worn beyond
the limits specified in the individual overhaul proce-
dures.
Replace all O-rings, gaskets and seals. These com-
ponents are not reusable. Also replace any snap ring
that is distorted or damaged.
Fig. 45 Removing Rear Planetary, Second Brake
Drum And Output Shaft
Fig. 46 Removing Planetary And Brake Drum Thrust
Bearing And Race Assembly
Fig. 47 Removing Brake Drum Gasket
Fig. 48 Checking Rear Bushing Inside Diameter
21 - 204 AW-4 TRANSMISSION OVERHAULJ

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