Jeep XJ. Manual — part 437
(25) Position park lock rod bracket on case and
tighten bracket attaching bolts to 10 N·m (7 ft. lbs.)
torque (Fig. 147).
(26) Verify park lock operation. Move shift sector
to Park position. Park pawl should be firmly engaged
(locked) in planetary ring gear (Fig. 148).
(27) Install No. 1 one–way clutch (Fig. 149). Short
flanged side of clutch faces up and toward case front.
(28) Install second brake pack (Fig. 150). Install
disc then plate. Continue installation sequence until
five discs and five plates are installed.
(29) Install
second
brake
pack
retainer
with
rounded edge of retainer facing disc.
(30) Install second brake pack snap ring.
Fig. 147 Park Rod Bracket Installation
1 – PARK ROD BRACKET
Fig. 148 Checking Park Pawl Engagement
1 – REAR PLANETARY RING GEAR
2 – PARK PAWL
Fig. 149 Installing No. 1 One–Way Clutch
1 – NO. 1 ONE-WAY CLUTCH
Fig. 150 Second Brake Pack Installation
1 – SECOND BRAKE PACK
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DISASSEMBLY AND ASSEMBLY (Continued)
(31) Check brake pack clearance with feeler gauge
(Fig. 151). Clearance should be 0.062 – 1.98 mm
(0.024 – 0.078 in.). If brake pack clearance is not cor-
rect, brake pack components are not seated. Reas-
semble brake pack if necessary.
(32) Install planetary sun gear and input drum
(Fig. 152). Be sure drum thrust washer tabs are
seated in drum. Use petroleum jelly to hold thrust
washer in position if necessary.
(33) Install front planetary gear on sun gear (Fig.
153).
(34) Support output shaft with wood blocks (Fig.
154).
Fig. 151 Checking Second Brake Pack Clearance
1 – BRAKE PACK
2 – FEELER GAUGE
Fig. 152 Installing Sun Gear And Input Drum
1 – SUN GEAR AND INPUT DRUM
Fig. 153 Installing Front Planetary Gear
1 – FRONT PLANETARY GEAR
Fig. 154 Supporting Output Shaft
1 – OUTPUT SHAFT
2 – WOOD BLOCKS
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DISASSEMBLY AND ASSEMBLY (Continued)
(35) Install planetary snap ring on sun gear with
snap ring plier tool 7541 (Fig. 155).
(36) Install tabbed thrust race on front planetary
gear. Washer tabs face down and toward gear. Race
outer diameter is 47.8 mm (1.882 in.). Inside diame-
ter is 34.3 mm (1.350 in.).
(37) Install second coast brake band (Fig. 156).
(38) Install pin in second coast brake band. Then
install retaining ring on pin (Fig. 157).
(39) Install thrust bearing and race in forward–di-
rect clutch (Fig. 158). Coat bearing/race with petro-
leum jelly to hold them in place.
(40) Verify forward–direct clutch thrust bearing
size.
• Race outer diameter is 48.9 mm (1.925 in.) and
inside diameter is 26.0 mm (1.024 in.).
• Bearing outer diameter is 46.7 mm (1.839 in.)
and inside diameter is 26.0 mm (1.024 in.).
(41) Coat front planetary ring gear race with
petroleum jelly and install it in ring gear (Fig. 159).
Fig. 155 Installing Front Planetary Snap Ring
1 – SNAP RING PLIER TOOL
2 – FRONT PLANETARY
3 – SNAP RING
Fig. 156 Installing Second Coast Brake Band
1 – SECOND COAST BRAKE BAND
Fig. 157 Installing Second Coast Brake Band
Retaining Pin
1 – SECOND COAST BRAKE BAND
2 – BAND RETAINING PIN
3 – RETAINING RING (INSTALL ON PIN)
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DISASSEMBLY AND ASSEMBLY (Continued)
(42) Verify ring gear race size. Outer diameter is
47.0 mm (1.850 in.) and inside diameter is 26.5 mm
(1.045 in.).
(43) Align forward–direct clutch disc splines with
screwdriver (Fig. 160).
(44) Align and install front planetary ring gear in
forward–direct clutch (Fig. 161).
(45) Coat bearing and race with petroleum jelly
and install them in ring gear (Fig. 162). Verify bear-
ing/race size.
• Bearing outer diameter is 47.7 mm (1.878 in.)
and inside diameter is 32.6 mm (1.283 in.).
• Race outer diameter is 53.6 mm (2.110 in.) and
inside diameter is 30.6 mm (1.205 in.).
(46) Install assembled planetary gear/forward–di-
rect clutch (Fig. 163).
(47) Check clearance between sun gear input drum
and direct clutch drum (Fig. 164). Clearance should
be 9.8 – 11.8 mm (0.386 – 0.465 in.). If clearance is
incorrect,
planetary
gear/forward–direct
clutch
assembly is not seated or is improperly assembled.
Remove, and correct if necessary.
Fig. 158 Installing Forward–Direct Clutch Thrust
Bearing And Race
1 – THRUST BEARING
2 – RACE
3 – FORWARD-DIRECT CLUTCH ASSEMBLY
Fig. 159 Installing Planetary Ring Gear Race
1 – PLANETARY RING GEAR
2 – THRUST RACE
Fig. 160 Aligning Forward–Direct Clutch Splines
1 – CLUTCH SPLINE ALIGNING TOOL
2 – FORWARD-DIRECT CLUTCH
Fig. 161 Installing Front Planetary Ring Gear
1 – RING GEAR
2 – FORWARD-DIRECT CLUTCH
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DISASSEMBLY AND ASSEMBLY (Continued)
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