Page 1769 of 2158
(29) Remove overdrive brake clutch pack (Fig. 21).
Then measure disc thickness with a micrometer.
Minimum disc thickness is 1.84 mm (0.0724 in.). Re-
place clutch pack if necessary.
(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).
Fig. 21 Removing/Measuring Overdrive Brake Disc
Thickness
Fig. 22 Overdrive Support Bearing/Race Removal
Fig. 23 Overdrive Support Bolt Removal
Fig. 24 Removing/Installing Overdrive Support Snap
Ring
JAW-4 TRANSMISSION OVERHAUL 21 - 207
Page 1770 of 2158
(33) Remove overdrive support (Fig. 25) with
bridge-type Puller 7536.
(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.).
Fig. 25 Removing Overdrive Support
Fig. 26 Remove Overdrive Support Race
Fig. 27 Measuring Second Coast Brake Piston Rod
Stroke
21 - 208 AW-4 TRANSMISSION OVERHAULJ
Page 1771 of 2158
(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).
(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).
Fig. 28 Removing Second Coast Brake Cover And
Piston
Fig. 29 Second Coast Brake Piston Components
Fig. 30 Removing Direct And Forward Clutch
Assembly
Fig. 31 Bearing And Race Removal From Clutch
Hub
JAW-4 TRANSMISSION OVERHAUL 21 - 209
Page 1772 of 2158
(40) Remove second coast brake band E-ring from
band pin and remove brake band (Fig. 32).
(41) Remove front planetary ring gear front bearing
race and remove front planetary ring gear (Fig. 33).
(42) Remove thrust bearing and rear race from
ring gear (Fig. 34).
Fig. 32 Second Coast Brake Band Removal
Fig. 33 Front Planetary Ring Gear Removal
Fig. 34 Removing Ring Gear Bearing And Rear Race
21 - 210 AW-4 TRANSMISSION OVERHAULJ
Page 1773 of 2158
(43) Remove planetary thrust race (Fig. 35).
(44) Relieve load on planetary snap ring as follows:
Loosen transmission holding fixture. Turn transmis-
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
clutch as assembly (Fig. 37).
Fig. 35 Relieving Load On Planetary Snap Ring
Fig. 36 Removing Planetary Snap Ring And Gear
Fig. 37 Removing Sun Gear, Input Drum And
One-Way Clutch
JAW-4 TRANSMISSION OVERHAUL 21 - 211
Page 1774 of 2158
(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.
(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).
Fig. 40 Removing/Measuring Second Brake Clutch
Disc Thickness
Fig. 41 Removing Park Rod And Bracket
Fig. 38 Checking Second Brake Clutch Pack
Clearance
Fig. 39 Removing Second Brake Clutch Pack Snap
Ring
21 - 212 AW-4 TRANSMISSION OVERHAULJ
Page 1775 of 2158
(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).
Fig. 42 Removing Park Pawl, Pin And Spring
Fig. 43 Checking First-Reverse Brake Clutch Pack
Clearance
Fig. 44 Removing Second Brake Piston Sleeve
Fig. 45 Removing Rear Planetary, Second Brake
Drum And Output Shaft
JAW-4 TRANSMISSION OVERHAUL 21 - 213
Page 1776 of 2158

(55) Remove planetary and brake drum thrust
bearing and race assembly (Fig. 46).
(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.
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.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 - 214 AW-4 TRANSMISSION OVERHAULJ