Jeep XJ. Manual — part 443
installation sequence until required number of discs
and plates have been installed.
(13) Install clutch pack retainer with flat side fac-
ing downward. Then install retainer snap ring (Fig.
227). Compress springs with suitable tool.
Fig. 225 Installing Clutch Piston Snap Ring
1 – PRESS RAM
2 – COMPRESSOR TOOL
3 – SNAP RING
Fig. 224 Installing Piston Return Springs
1 – RETURN SPRINGS
2 – CLUTCH PISTON
Fig. 226 Installing Overdrive Clutch Discs And Plates
1 – CLUTCH DISC
2 – STEEL PLATE
3 – CLUTCH DRUM
Fig. 227 Installing Retainer And Snap Ring
1 – CLUTCH PACK RETAINER
2 – RETAINER SNAP RING
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DISASSEMBLY AND ASSEMBLY (Continued)
(14) Install clutch drum bearing and race assembly
(Fig. 228). Be sure bearing rollers face upward as
shown. Outside diameter of assembled bearing and
race is 50.2 mm (1.976 in.). Inside diameter is 28.9
mm (1.138 in.).
(15) Install clutch on planetary gear.
(16) Verify one–way clutch operation. Hold drum
and turn planetary shaft clockwise and counterclock-
wise. Shaft should turn clockwise freely but lock
when turned counterclockwise.
OVERDRIVE SUPPORT
DISASSEMBLY
(1) Check brake piston operation. Mount support
on clutch (Fig. 229).
(2) Apply compressed air through support feed
hole and observe brake piston movement (Fig. 229).
Piston should move smoothly and not bind or stick. If
operation is incorrect, replace piston and support.
(3) Remove thrust bearing front race, thrust bear-
ing and rear race (Fig. 230).
(4) Turn overdrive support over and remove bear-
ing race and clutch drum thrust washer (Fig. 231).
(5) Compress piston return spring with Spring
Compressor 7537 and remove piston snap ring (Fig.
232).
Fig. 228 Installing Clutch Drum Bearing And Race
Assembly
1 – BEARING AND RACE ASSEMBLY
2 – CLUTCH DRUM
3 – RACE
4 – ROLLERS
Fig. 229 Checking Brake Piston Movement
1 – BRAKE PISTON
2 – OVERDRIVE SUPPORT
3 – SUPPORT FEED HOLE
4 – CLUTCH
Fig. 230 Removing Support Thrust Bearing And
Races
1 – THRUST BEARING
2 – FRONT RACE
3 – REAR RACE
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21 - 309
DISASSEMBLY AND ASSEMBLY (Continued)
(6) Mount support in direct clutch and remove
brake piston with compressed air. Apply air to same
feed hole used when checking piston operation.
(7) Remove and discard support O–rings (Fig. 233).
(8) Remove support seal rings (Fig. 234).
(9) Measure free length of piston return springs
with springs mounted in retainer (Fig. 235). Length
should be 17.23 mm (0.678 in.).
(10) Clean support components and dry them with
compressed air.
(11) Inspect overdrive support and brake piston.
Replace support and piston if either part is worn or
damaged.
ASSEMBLY
(1) Lubricate new support seal rings. Then com-
press rings and install them on support (Fig. 236).
(2) Lubricate and install new O–rings on brake
piston. Then carefully seat piston in support.
(3) Install return springs on brake piston.
(4) Compress return springs with Spring Compres-
sor 7537 (Fig. 232) and install piston snap ring.
(5) Install support bearing race and clutch drum
thrust washer (Fig. 231).
(6) Install thrust bearing and front and rear bear-
ing races. Thrust bearing rollers should face upward
as shown (Fig. 236).
(7) Verify thrust bearing/race sizes (Fig. 237).
• Front race outer diameter is 47.8 mm (1.882 in.)
and inside diameter is 30.7 mm (1.209 in.).
• Rear race outer diameter is 47.8 mm (1.882 in.)
and inside diameter is 34.3 mm (1.350 in.).
• Bearing 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.
Fig. 231 Removing Clutch Drum Thrust Washer And
Race
1 – BEARING RACE
2 – OVERDRIVE SUPPORT
3 – THRUST WASHER
Fig. 232 Removing/Installing Piston Snap Ring
1 – COMPRESSOR TOOL
2 – SNAP RING
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 233 Overdrive Support Components
1 – PISTON SNAP RING
2 – BRAKE PISTON
3 – FRONT RACE
4 – REAR RACE
5 – OVERDRIVE SUPPORT
6 – THRUST BEARING
7 – BEARING RACE
8 – CLUTCH DRUM THRUST WASHER
9 – SUPPORT SEAL RINGS
10 – BRAKE PISTON O-RINGS
11 – PISTON RETURN SPRING
Fig. 234 Removing Support Seal Rings
1 – SEAL RINGS (2)
2 – SUPPORT
Fig. 235 Checking Piston Return Spring Length
1 – PISTON RETURN SPRINGS
2 – SPRING RETAINER
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DISASSEMBLY AND ASSEMBLY (Continued)
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