Jeep XJ. Manual — part 446
(20) Measure clutch disc thickness (Fig. 260). Min-
imum allowable thickness is 1.51 mm (0.0595 in.).
Replace clutch pack if any disc falls below specified
minimum thickness.
(21) Measure free length of piston return springs
with springs mounted in retainer (Fig. 261). Length
should be 19.47 mm (0.767 in.). Replace springs and
retainer if length is incorrect.
(22) Inspect clutch piston check ball (Fig. 262).
Ball should move freely within piston. Check ball
seating by applying low pressure compressed air to
ball feed hole. Ball should seat firmly and not leak
air.
(23) Measure inside diameter of bushing in clutch
drum hub. Maximum allowable diameter is 24.08
mm (0.9480 in.). Replace clutch drum if bushing
inside diameter is greater than specified.
ASSEMBLY
(1) Lubricate bearing and race assembly with
petroleum jelly and install it in clutch drum (Fig.
263). Race side of assembly faces downward and
toward drum. Bearing rollers face up (Fig. 263)
(2) Coat new clutch drum shaft seal rings with
petroleum jelly. Before installing drum shaft seal
rings, squeeze each ring so ring ends overlap (Fig.
264). This tightens ring making clutch installation
easier.
(3) Install seal rings on shaft. Keep rings closed as
tightly as possible during installation. Avoid over-
spreading them.
(4) Mount clutch drum on overdrive support.
(5) Lubricate and install new O–ring on clutch
drum hub (Fig. 257).
Fig. 260 Measuring Clutch Disc Thickness
1 – CLUTCH DISC
2 – MICROMETER
Fig. 261 Checking Return Spring Length
1 – PISTON RETURN SPRINGS
2 – SPRING RETAINER
Fig. 262 Testing Piston Check Ball
1 – PISTON CHECK BALL
2 – USE LOW AIR PRESSURE FOR TEST
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DISASSEMBLY AND ASSEMBLY (Continued)
(6) Lubricate new clutch piston O–rings with
Mopar Door Ease, or Ru–Glyde. Install rings on
clutch piston and install piston in drum.
(7) Install piston return springs.
(8) Compress piston return springs with Tool 7538
and shop press and install piston snap ring. Be sure
snap ring end gap is not aligned with any notches in
drum.
(9) Install cushion plate in drum. Concave side of
plate faces downward (Fig. 255).
(10) Install clutch discs, plates and retainer (Fig.
265). Install tabbed plate followed by disc until
required number of plates and discs are installed.
Use six plates and discs.
(11) Install clutch pack snap ring.
(12) Recheck clutch piston stroke length using
same method outlined at beginning of disassembly
procedure. If stroke length is not within specified
limits, replace clutch discs.
(13) Lubricate race and bearing with petroleum
jelly and install them in clutch drum (Fig. 266). Be
sure bearing rollers face up and race lip seats in
drum as shown.
(14) Verify bearing and race size.
• Outer diameter of bearing is 46.7 mm (1.839 in).
• Outer diameter of race is 48.9 mm (1.925 in.).
• Inner diameter of bearing and race is 26.0 mm
(1.024 in.).
(15) Mount forward clutch on direct clutch and
check assembled height (Fig. 267). Height should be
70.3 – 71.5 mm (2.767 – 2.815 in.).
Fig. 263 Installing Thrust Bearing And Race
1 – BEARING ROLLERS FACE UP
2 – THRUST BEARING AND RACE
3 – FORWARD CLUTCH
Fig. 264 Installing Clutch Drum Shaft Seal Rings
1 – SEAL RINGS (COMPRESS BEFORE INSTALLATION)
2 – CLUTCH DRUM SHAFT
Fig. 265 Installing Forward Clutch Discs And Plates
1 – RETAINER
2 – CLUTCH PLATES
3 – CLUTCH DISCS
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DISASSEMBLY AND ASSEMBLY (Continued)
FRONT PLANETARY GEAR
DISASSEMBLY
(1) Remove ring gear from planetary gear (Fig. 268).
(2) Remove front bearing and the two races from
ring gear (Fig. 268).
(3) Remove tabbed thrust race from planetary gear
(Fig. 268).
(4) Remove snap ring attaching planetary gear to
shaft and remove gear.
Fig. 267 Checking Forward Clutch Assembled
Height
1 – DIRECT CLUTCH
2 – APPROXIMATELY 71.2 mm (2.80 in.)
3 – FORWARD CLUTCH
Fig. 268 Front Planetary Gear Components
1 – FORWARD RACE
2 – FRONT PLANETARY RING GEAR
3 – FRONT BEARING
4 – SNAP RING
5 – REAR RACE
6 – REAR BEARING
7 – FRONT PLANETARY GEAR
8 – THRUST RACE
9 – FRONT RACE
Fig. 266 Installing Thrust Bearing And Race
1 – THRUST BEARING AND RACE
2 – CLUTCH DRUM
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DISASSEMBLY AND ASSEMBLY (Continued)
(5) Remove rear bearing and race from planetary gear.
(6) Measure inside diameter of ring gear bushing.
Maximum allowable diameter is 24.08 mm (0.9480
in.). Replace ring gear if bushing inside diameter is
greater than specified.
(7) Check condition of planetary gear. Replace gear
if teeth are worn, pins are loose, or carrier is cracked,
distorted, or worn.
ASSEMBLY
(1) Lubricate planetary and ring gear bearings and
races with petroleum jelly.
(2) Identify planetary bearings and races before
installation. (Fig. 268). Bearings and races can be
identified by following dimensions:
• Outer diameter of rear bearing is 47.7 mm
(1.878 in.). Inner diameter is 35.5 mm (1.398 in.).
• Outer diameter of rear race 47.6 mm (1.874 in.).
Inner diameter is 33.7 mm (1.327 in.).
• Outer diameter of front race is 53.6 mm (2.110
in.). Inner diameter is 30.5 mm (1.201 in.).
• Outer diameter of front bearing is 47.7 mm
(1.878 in.). Inner diameter is 32.6 (1.283 in.).
• Outer diameter of forward race is 47.0 mm
(1.850 in.). Inner diameter is 26.5 mm 1.043 in.).
(3) Install rear race and bearing in gear (Fig. 269).
(4) Turn planetary over and install thrust race
(Fig. 270).
(5) Install front race and bearing and forward race
in ring gear (Fig. 271).
Fig. 269 Front Planetary Rear Bearing and Race
Installation
1 – REAR BEARING AND RACE
2 – PLANETARY GEAR
Fig. 270 Front Planetary Thrust Race Installation
1 – TABBED THRUST RACE
2 – PLANETARY GEAR
Fig. 271 Front Planetary Front Bearing And Races
Installation
1 – FRONT BEARING AND RACE
2 – FORWARD RACE
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DISASSEMBLY AND ASSEMBLY (Continued)
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