1995 JEEP XJ brake

Race should turn freely counterclockwise, but lock
when turned clockwise. Replace one-way clutch if
necessary.
(7) Remove clutch inner race from planetary gear
(Fig. 7).
(8) Remove clutch snap ring and remove No. 2 one-
way clutch from planetary (Fig. 8).
(9) Remove front and rear thrust washers from
planetary gear (Fig. 9).
(10) Remove thrust bearing and washers from ring
gear (Fig. 10).
(11) Remove ring gear snap ring and remove ring
gear hub (Fig. 11).
Fig. 3 Removing/Installing Shaft Seal Ring
Fig. 4 Removing/Installing First-Reverse Brake Pack
Fig. 5 Removing/Installing Rear Planetary
Fig. 6 Checking No. 2 One-Way Clutch Operation
Fig. 7 Removing/Installing Clutch Inner Race
JAW-4 TRANSMISSION OVERHAUL 21 - 245

(12) Inspect and replace any worn or damaged
planetary gear components.
ASSEMBLING REAR PLANETARY, BRAKE
PACK, CLUTCH AND SHAFT
(1) Install hub and snap ring in ring gear (Fig. 11)
(2) Identify ring gear thrust bearing and races by
following dimensions (Fig. 10):
²Outer diameter of bottom race is 44.8 mm (1.764
in.) and inner diameter is 27.6 mm (1.087 in.).
²Outer diameter of bearing is 44.7 mm (1.760 in.)
and inner diameter is 30.1 mm (1.185 in.).
²Outer diameter of upper race is 44.8 mm (1.764
in.) and inner diameter is 28.8 mm (1.134 in.).
(3) Lubricate ring gear thrust bearing and races
with petroleum jelly and install them in ring gear
(Fig. 10).
(4) Coat planetary thrust washers with petroleum
jelly and install them in gear (Fig. 9).(5) Install No. 2 one-way clutch in planetary gear.
Be sure flanged side of clutch faces upward (Fig. 12).
(6) Install clutch retaining snap ring and install
clutch inner race (Fig. 7). Turn race counterclockwise
to ease installation.
(7) Verify one-way clutch operation. Hold gear and
turn inner race in both directions. Race should turn
freely counterclockwise, but lock when turned clock-
wise.
(8) Install planetary gear in ring gear.
Fig. 8 Removing.Installing One-Way Clutch
Fig. 9 Removing/Installing Rear Planetary Thrust
Washers
Fig. 10 Removing/Installing Ring Gear Thrust
Bearing And Races
21 - 246 AW-4 TRANSMISSION OVERHAULJ

(9) Assemble clutch discs and clutch plates (Fig. 4).
Sequence is disc first, then a plate. Use seven discs
and plates in a 6-cyl. transmission.
(10) Install brake pack on planetary gear (Fig. 4).
(11) Install new seal ring on output shaft (Fig. 3).
Be sure ring ends are interlocked as shown.(12) Set assembled components aside for final as-
sembly.
FIRST-REVERSE BRAKE PISTON AND
TRANSMISSION CASE OVERHAUL
BRAKE DISASSEMBLY AND INSPECTION
(1) Remove bearing and race assembly from trans-
mission case (Fig. 2).
(2) Check first/reverse brake piston operation with
compressed air (Fig. 3). Piston should move smoothly
and not bind or stick. If piston operation is incorrect,
case or piston may require replacement.
(3) Compress piston return springs with Tool 7539
and remove piston snap ring (Fig. 4).
Fig. 12 Installing No. 2 One-Way Clutch
Fig. 1 First-Reverse Brake Pistons And Transmission Case
Fig. 11 Removing/Installing Ring Gear Hub
JAW-4 TRANSMISSION OVERHAUL 21 - 247

(4) Remove Tool 7539 and remove piston return
springs.
(5) Remove No. 2 first-reverse brake piston with
compressed air. Apply air through same transmission
feed hole used for checking piston operation.
(6) Remove reaction sleeve with Sleeve Remover
Tool 7542 (Fig. 5). Insert tool flanges under sleeve
and lift tool and sleeve out of case.
(7) Remove No. 1 first/reverse brake piston with
Piston Puller 7543 (Fig. 6). Slip tool under piston and
lift tool and piston out of case.(8) Measure free length of piston return springs
with springs mounted in retainer. Length should be
18.382 mm (0.724 in.). Replace springs if length is
less than this.
(9) Clean transmission case thoroughly with sol-
vent and dry it with compressed air. Blow com-
pressed air through oil feed passages to remove
solvent residue and ensure that passages are clear.
Inspect the case for wear or damage. Replace case if
necessary.
ASSEMBLING FIRST/REVERSE BRAKE
PISTON
(1) Lubricate and install new O-rings on No. 1
first/reverse brake piston and on reaction sleeve (Fig.
7). Then install piston in sleeve.
Fig. 2 Removing/Installing Bearing And Race
Assembly
Fig. 3 Checking First-Reverse Brake Piston
Operation
Fig. 4 Removing/Installing Piston Snap Ring
Fig. 5 Removing/Installing Reaction Sleeve
21 - 248 AW-4 TRANSMISSION OVERHAULJ

(2) Lubricate and install new O-ring on No. 2
brake piston.
(3) Install assembled No. 1 piston and reaction
sleeve on No. 2 piston (Fig. 8).
(4) Lubricate and install piston assembly in case
(Fig. 9). Align piston and case slots and press piston
assembly into case with hand pressure.
(5) Position piston return springs on No. 2 piston.
(6) Compress piston return springs with Tool 7539
and install piston snap ring (Fig. 4). Be sure snap
ring end gap is not aligned with any tangs on return
spring retainer.
(7) Verify piston operation with compressed air as
outlined in disassembly procedure.(8) Coat bearing and race assembly with petroleum
jelly and install it in piston assembly (Fig. 2). Bear-
ing and race assembly outer diameter is 57.7 mm
(2.272 in.) and inner diameter is 39.2 mm (1.543 in.).
Fig. 6 Removing/Installing First-Reverse Brake No.1
Piston
Fig. 7 Assembling No. 1 Piston And Sleeve
Fig. 8 Assembling First-Reverse Brake Pistons
Fig. 9 Installing First-Reverse Brake Piston
Assembly
JAW-4 TRANSMISSION OVERHAUL 21 - 249

TRANSMISSION ASSEMBLY AND ADJUSTMENT
(1) During assembly, lubricate components with
transmission fluid or petroleum jelly as indicated.
(2) If any of the transmission components are still
assembled after overhaul checking procedures, disas-
semble as necessary in preparation for transmission
assembly.
(3) Verify thrust bearing and race installation dur-
ing assembly. Refer to the Thrust Bearing Chart (Fig.
2) for bearing and race location and correct position-
ing.
(4) Install rear planetary gear, second brake drum
and output shaft as outlined in following steps:
(5) Verify No. 10 thrust bearing and race (Fig. 2).
Bearing and race outer diameter is 57.7 mm (2.272
in.) and inside diameter is 39.2 mm (1.543 in.).
(6) Coat thrust bearing and race assembly with pe-
troleum jelly and install in case (Fig. 3). Race faces
down. Bearing rollers face up.
Fig. 2 Thrust Bearing Chart
Fig. 3 Installing Thrust Bearing And Race (No. 10)
JAW-4 TRANSMISSION OVERHAUL 21 - 265

(7) Align teeth of second brake drum and clutch
pack (Fig. 4).
(8) Align rear planetary-output shaft assembly
teeth with case slots and install assembly in case
(Fig. 5).(9) Install rear planetary snap ring with snap ring
pliers. Chamfered side of snap ring faces up and to-
ward case front (Fig. 6).
(10) Check first-reverse brake pack clearance with
feeler gauge. Clearance should be 0.70 - 1.20 mm
(0.028 - 0.047 in.). If clearance is incorrect, planetary
assembly, thrust bearing or snap ring is not properly
seated in case. Remove and reinstall components if
necessary.
Fig. 4 Aligning Second Brake Drum And Clutch
Pack Teeth
Fig. 5 Installing Output Shaft And Rear Planetary
Assembly
Fig. 6 Installing Planetary Snap Ring
Fig. 7 Checking First-Reverse Brake Pack Clearance
21 - 266 AW-4 TRANSMISSION OVERHAULJ

(11) Install second brake piston sleeve (Fig. 8).
Sleeve lip faces up and toward case front as shown.
(12) Install second brake drum gasket with In-
staller Tool 7544 (Fig. 9). Gasket depth is 43.7 mm
(1.720 in.).(13) Install park lock pawl, spring and pin (Fig.
10).
(14) Connect park lock rod to manual valve shift
sector (Fig. 11).
Fig. 8 Installing Second Brake piston Sleeve
Fig. 9 Installing Second Brake Drum Gasket
Fig. 10 Installing Park Lock Pin, Spring And Pawl
Fig. 11 Installing Park Lock Rod
JAW-4 TRANSMISSION OVERHAUL 21 - 267