1994 JEEP CHEROKEE length

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

(8) Check clutch piston stroke length a second
time. If length is OK, continue with assembly. If
stroke length is incorrect, replace clutch discs or use
different thickness clutch pack retainer (Fig. 12). See
Specifications section for retainer thicknesses.
(9) Lubricate clutch drum thrust washer with pe-
troleum jelly and install it in drum (Fig. 3).
(10) Mount direct clutch assembly on forward
clutch assembly and check assembled height (Fig.
14). Height should be 70.3 to 71.5 mm (2.767 to 2.815
in.).
(11) If assembled height is incorrect, clutches are
not seated.(12) If clutch height is OK, remove direct clutch
from forward clutch and proceed to forward clutch
overhaul.
Fig. 11 Installing Direct Clutch Discs And Plates
Fig. 12 Install Clutch Pack Retainer
Fig. 13 Adjusting Clutch Pack Snap Ring Position
Fig. 14 Checking Direct Clutch Assembled Height
21 - 222 AW-4 TRANSMISSION OVERHAULJ

FORWARD CLUTCH OVERHAUL
FORWARD CLUTCH DISASSEMBLY (FIG. 1)
(1) Check clutch piston stroke as outlined in fol-
lowing steps.
(2) Position overdrive support on wood blocks and
mount forward clutch drum on support (Fig. 2).
(3) Remove bearing and race from forward clutch
drum (Fig. 2).
(4) Mount dial indicator on clutch drum. Position
dial indicator plunger against clutch piston (Fig. 3).(5) Apply compressed air through right side feed
hole in support and note piston stroke length on dial
indicator.
(6) Stroke length should be 3.55 - 3.73 mm (0.1348
- 0.1469 in.).
(7) Replace clutch discs if stroke length is incor-
rect.
Fig. 1 Forward Clutch Components
JAW-4 TRANSMISSION OVERHAUL 21 - 223

(8) Remove clutch pack snap ring and remove re-
tainer and clutch pack (Fig. 4).
(9) Remove clutch pack cushion plate (Fig. 5).
(10) Compress clutch springs with Tool 7538 and
remove piston snap ring.
(11) Remove spring compressor tool and piston re-
turn springs.
Fig. 2 Positioning Drum And Support On Wood
Blocks
Fig. 3 Checking Forward Clutch Piston Stroke
Length
Fig. 4 Removing Retainer And Clutch Pack
Fig. 5 Removing Cushion Plate
21 - 224 AW-4 TRANSMISSION OVERHAULJ

(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

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