Jeep XJ. Manual — part 434
(19) Remove oil pump bolts and remove pump with
bridge–type Puller 7536 (Fig. 105).
(20) Remove race from oil pump (Fig. 106).
(21) Remove overdrive planetary gear and clutch
assembly (Fig. 107).
(22) Remove race from overdrive planetary (Fig.
108).
(23) Remove thrust bearing, race and overdrive
planetary ring gear (Fig. 109).
(24) Measure stroke length of overdrive brake pis-
ton as follows:
Fig. 105 Oil Pump Removal
1 – PULLER TOOL
2 – OIL PUMP
Fig. 106 Oil Pump Race Removal
1 – OIL PUMP RACE
2 – OIL PUMP
Fig. 107 Removing Overdrive Planetary And Clutch
Assembly
1 – PLANETARY AND CLUTCH ASSEMBLY
Fig. 108 Fourth Gear Planetary Race Removal
1 – PLANETARY (OVERDRIVE)
2 – RACE
21 - 272
AW–4 AUTOMATIC TRANSMISSION
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(a) Mount dial indicator on case using Miller
Tool C-3339 and a suitable bolt threaded into the
transmission case.
(b) Verify that the dial indicator is mounted sol-
idly and square to the direction of the piston
travel.
(c) Apply 57–114 psi air pressure through piston
apply port and note piston stroke on dial indicator.
Stroke length should be: 1.40 – 1.70 mm (0.055 –
0.0699 in.).
(d) Record the reading for use during re-assem-
bly.
(e) Remove the dial indicator set-up from the
transmission.
(25) Measure stroke length of second coast brake
piston rod as follows:
(a) Install a small wire tie strap around the sec-
ond coast brake piston rod tight against the trans-
mission case.
(b) Apply 57–114 psi air pressure through piston
feed hole and check stroke length with Gauge Tool
7552.
(c) Stroke length should be 1.5 – 3.0 mm (0.059
– 0.118 in.).
(d) Record the reading for use during re-assem-
bly.
(26) Remove the bolt holding the input speed sen-
sor to the transmission case.
(27) Remove the input speed sensor from the
transmission case.
(28) Remove overdrive brake pack snap ring (Fig.
110).
(29) Remove
overdrive
brake
pack
discs
and
plates. Inspect and replace as necessary.
(30) Remove overdrive support lower race and
upper bearing and race assembly (Fig. 111).
Fig. 109 Removing Bearing, Race And Planetary
Ring Gear
1 – THRUST BEARING
2 – RACE
3 – OVERDRIVE PLANETARY RING GEAR
Fig. 110 Removing Overdrive Brake Pack Snap Ring
1 – OVERDRIVE BRAKE SNAP RING
Fig. 111 Overdrive Support Bearing/Race Removal
1 – UPPER BEARING AND RACE
2 – LOWER RACE
XJ
AW–4 AUTOMATIC TRANSMISSION
21 - 273
DISASSEMBLY AND ASSEMBLY (Continued)
(31) Remove overdrive support snap ring with
Snap Ring Plier Tool 7540 (Fig. 112).
(32) Remove overdrive support bolts (Fig. 113).
(33) Remove overdrive support (Fig. 114) with
bridge–type Puller 7536.
(34) Remove race from hub of overdrive support
(Fig. 115).
(35) Remove second coast brake piston snap ring
with Snap Ring Plier Tool 7540. Then remove piston
cover and piston assembly.
(36) Disassemble second coast brake piston (Fig.
116), if necessary.
(37) Remove direct and forward clutch assembly
(Fig. 117).
Fig. 112 Overdrive Support Snap Ring Removal/
Installation
1 – SNAP RING PLIERS
2 – SUPPORT SNAP RING
Fig. 113 Overdrive Support Bolt Removal
1 – SUPPORT BOLTS
Fig. 114 Removing Overdrive Support
1 – BRIDGE-TYPE PULLER TOOL
2 – OVERDRIVE SUPPORT
Fig. 115 Remove Overdrive Support Race
1 – RACE
2 – OVERDRIVE SUPPORT
21 - 274
AW–4 AUTOMATIC TRANSMISSION
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(38) Remove thrust bearing and race from clutch
hub (Fig. 118).
(39) Remove second coast brake band E–ring from
band pin and remove pin and brake band (Fig. 119).
Fig. 116 Second Coast Brake Piston Components
1 – SERVO PISTON
2 – SEAL RING
3 – SPRING AND RETAINER
4 – PISTON ROD
5 – PISTON SPRING
6 – SERVO COVER O-RINGS
7 – SERVO COVER
8 – SNAP RING
9 – E-RING
Fig. 117 Removing Direct And
Forward Clutch Assembly
1 – DIRECT AND FORWARD CLUTCH ASSEMBLY
Fig. 118 Bearing And Race Removal From Clutch Hub
1 – BEARING
2 – RACE
3 – DIRECT CLUTCH
Fig. 119 Second Coast Brake Band Removal
1 – BRAKE BAND E-RING
2 – SECOND COAST BRAKE BAND
XJ
AW–4 AUTOMATIC TRANSMISSION
21 - 275
DISASSEMBLY AND ASSEMBLY (Continued)
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