1995 JEEP YJ brake

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.
(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.
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
21 - 228 AW-4 TRANSMISSION OVERHAULJ

(4) Turn planetary over and install thrust race
(Fig. 3).
(5) Install front race and bearing and forward race
in ring gear (Fig. 4).
(6) Set planetary gear assembly aside for final as-
sembly.
SUN GEAR AND NO. 1 ONE-WAY CLUTCH
OVERHAUL
SUN GEAR AND CLUTCH DISASSEMBLY
(1) Hold sun gear and turn second brake hub
clockwise and counterclockwise (Fig. 2). Hub shouldrotate freely clockwise but lock when turned counter-
clockwise. Replace one-way clutch and hub if they do
not operate properly.
Fig. 3 Installing Front Planetary Thrust Race
Fig. 1 Sun Gear And One-Way Clutch Components
Fig. 4 Installing Front Planetary Front Bearing And
Races
21 - 238 AW-4 TRANSMISSION OVERHAULJ

(2) Remove one-way clutch/second brake hub assem-
bly from drum (Fig. 3).(3) Remove thrust washer from drum (Fig. 4).
(4) Remove two seal rings from sun gear (Fig. 5).
Fig. 2 Checking One-Way Clutch Operation
Fig. 3 Removing/Installing Brake Hub And Clutch
Assembly
Fig. 4 Removing/Installing Thrust Washer
Fig. 5 Removing/Installing Sun Gear Seal Rings
JAW-4 TRANSMISSION OVERHAUL 21 - 239

(5) Support sun gear on wood block (Fig. 6). Then
remove first sun gear snap ring and separate drum
from gear.
(6) Remove remaining snap ring from sun gear
(Fig. 7).
(7) Measure inside diameter of sun gear bushings
with bore gauge or inside micrometer (Fig. 8). Maxi-
mum allowable diameter is 27.08 mm (1.0661 in.).
Replace sun gear if bushing inside diameter is
greater than specified.
SUN GEAR AND CLUTCH ASSEMBLY
(1) Install first snap ring on sun gear.
(2) Install sun gear in drum and install remaining
snap ring.(3) Coat replacement seal rings with petroleum
jelly and install them on sun gear.Be sure seal
ring ends are interlocked.
(4) Install thrust washer. Be sure washer tabs are
seated in drum slots.
(5) Install one-way clutch/second brake hub assem-
bly on sun gear. Deep side of hub flange faces up-
ward (Fig. 9).
(6) Check one-way clutch operation again (Fig. 2).
Hold sun gear and turn second brake hub clockwise
and counterclockwise. Hub should turn clockwise
freely, but lock when turned counterclockwise.
(7) Set sun gear/clutch assembly aside for final as-
sembly.
Fig. 6 Removing/Installing Sun Gear
Fig. 7 Removing/Installing Second Snap Ring
Fig. 8 Checking Sun Gear Bushings
Fig. 9 Installing Clutch And Hub Assembly On Sun
Gear
21 - 240 AW-4 TRANSMISSION OVERHAULJ

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).
Fig. 1 Second Brake Components
Fig. 2 Removing/Installing Second Brake Assembly
Fig. 3 Removing/Installing Second Brake Drum
Thrust Washer
JAW-4 TRANSMISSION OVERHAUL 21 - 241

(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.
Fig. 4 Removing/Installing Second Brake Piston
Snap Ring
Fig. 5 Removing/Installing Piston And Sleeve
Fig. 6 Measuring Second Brake Piston Return
Springs
21 - 242 AW-4 TRANSMISSION OVERHAULJ

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.
(3) Compress return springs with shop press and
Compressor Tool 7538. Install piston snap ring and
remove brake assembly from press.
(4) Check brake piston operation with low pressure
compressed air (Fig. 7). Apply air pressure through
feed hole in drum. Piston should move smoothly
when applying-releasing air pressure.(5) Coat thrust washer with petroleum jelly and
install it in drum. Be sure washer notches are
aligned with tabs on spring retainer (Fig. 8).
(6) Set brake components aside for final assembly.
Fig. 7 Checking Second Brake Piston Operation
Fig. 8 Installing Second Brake Thrust Washer
JAW-4 TRANSMISSION OVERHAUL 21 - 243

REAR PLANETARY, NO. 2 ONE-WAY CLUTCH AND OUTPUT SHAFT OVERHAUL
PLANETARY/BRAKE PACK/OUTPUT SHAFT
DISASSEMBLY
(1) Remove output shaft from gear assembly (Fig.
2).
(2) Remove and discard shaft seal ring (Fig. 4).
(3) Remove brake pack from planetary gear (Fig.
4).
(4) Measure thickness of each brake pack disc.
Minimum thickness is 1.51 mm (0.0594 in.). Replace
all discs if any disc is thinner than specified.
(5) Remove planetary gear from ring gear (Fig. 5).
(6) Check No. 2 one-way clutch. Hold planetary
gear and turn clutch inner race in both directions.
Fig. 1 Rear Planetary, Brake Pack, Clutch And Output Shaft Components
Fig. 2 Removing/Installing Output Shaft
21 - 244 AW-4 TRANSMISSION OVERHAULJ