1995 JEEP YJ transmission

(22) Remove oil pump bolts and remove pump with
bridge-type Puller 7536 (Fig. 14).
(23) Remove race from oil pump (Fig. 15).(24) Remove overdrive planetary gear and clutch
assembly (Fig. 16).
(25) Remove race from overdrive planetary (Fig.
17).
Fig. 14 Oil Pump Removal
Fig. 15 Oil Pump Race Removal
Fig. 16 Removing Overdrive Planetary
And Clutch Assembly
Fig. 17 Overdrive Planetary Race Removal
JAW-4 TRANSMISSION OVERHAUL 21 - 205

(26) Remove thrust bearing, race and overdrive
planetary ring gear (Fig. 18).
(27) Measure stroke length of overdrive brake pis-
ton as follows:
(a) Mount dial indicator on case (Fig. 19).
(b) Mount Gauge Tool 7546 so it contacts piston
(Fig. 19).(c) Apply 57-114 psi air pressure through piston ap-
ply port and note piston stroke on dial indicator. Stroke
length should be: 1.40 - 1.70 mm (0.055 - 0.0699 in.).
(d) If stroke is not within limits, replace piston
and retainer.
(28) Remove overdrive brake snap ring (Fig. 20).
Fig. 18 Removing Bearing, Race And
Planetary Ring Gear
Fig. 19 Measuring Overdrive Brake Piston Stroke
Fig. 20 Removing Overdrive Brake Snap Ring
21 - 206 AW-4 TRANSMISSION OVERHAULJ

(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

(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

(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

(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

(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

(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