Jeep XJ. Manual — part 444
DIRECT CLUTCH
DISASSEMBLY
(1) Remove direct clutch from forward clutch (Fig.
238).
(2) Remove clutch drum thrust washer (Fig. 239).
Fig. 236 Installing Support Seal Rings
1 – COMPRESS SEAL RINGS BEFORE INSTALLATION
2 – OVERDRIVE SUPPORT
Fig. 237 Installing Support Thrust Bearing And
Races
1 – REAR RACE
2 – THRUST BEARING
3 – FRONT RACE
Fig. 238 Separate Direct Clutch From Forward
Clutch
1 – DIRECT CLUTCH
2 – FORWARD CLUTCH
Fig. 239 Removing Clutch Drum Thrust Washer
1 – THRUST WASHER
2 – CLUTCH DRUM
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DISASSEMBLY AND ASSEMBLY (Continued)
(3) Check clutch piston stroke length as outlined
in following steps.
(4) Mount
direct
clutch
on
overdrive
support
assembly (Fig. 240).
(5) Mount dial indicator on clutch and position
indicator plunger on clutch piston (Fig. 241).
(6) Apply 57–114 psi air pressure through feed
hole in overdrive support and note piston stroke
length (Fig. 241). Check stroke at least twice.
(7) Piston stroke length should be 1.37 mm – 1.67
mm (0.054 – 0.065 in.). If stroke length is incorrect,
either the clutch pack retainer or clutch discs will
have to be replaced.
(8) Remove clutch pack snap ring and remove
retainer and clutch pack from drum (Fig. 242).
(9) Compress clutch piston return springs with tool
7538 and remove clutch piston snap ring (Fig. 243).
(10) Remove compressor tool and return spring.
(11) Remove clutch piston. Remount clutch on
overdrive support (Fig. 244). Apply compressed air
through piston feed hole in support to remove piston.
Use only enough air to ease piston out.
(12) Remove and discard clutch piston O–rings.
(13) Measure
clutch
disc
thickness.
Minimum
allowable thickness is 1.84 mm (0.0724 in). Replace
clutch pack if any disc is below minimum thickness.
(14) Measure free length of piston return springs
with springs in retainer (Fig. 245). Length should be
21.32 mm (0.839 in.). Replace return springs if not
within specification.
(15) Check clutch piston check ball (Fig. 246).
Shake piston to see if ball moves freely. Then check
ball seating by applying low pressure compressed air
Fig. 240 Mount Direct Clutch On Overdrive Support
1 – DIRECT CLUTCH
2 – OVERDRIVE SUPPORT
Fig. 241 Checking Direct Clutch Piston Stroke
Length
1 – INDICATOR PLUNGER
2 – DIAL INDICATOR
3 – CLUTCH PISTON
4 – OVERDRIVE SUPPORT
5 – CLUTCH PISTON
Fig. 242 Removing Clutch Pack Snap Ring
1 – CLUTCH PACK SNAP RING
2 – DIRECT CLUTCH DRUM
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DISASSEMBLY AND ASSEMBLY (Continued)
to ball inlet as shown. Air should not leak past check
ball.
(16) Measure inside diameter of clutch drum bush-
ing. Inside diameter should be no more than 53.97
mm (2.1248 in.). Replace drum if bushing inside
diameter is greater than specified.
Fig. 243 Removing Piston Return Spring
1 – PRESS RAM
2 – COMPRESSOR TOOL
3 – SNAP RING PLIERS
4 – RETURN SPRING
Fig. 244 Removing Direct Clutch Piston
1 – DIRECT CLUTCH DRUM
2 – CLUTCH PISTON
3 – OVERDRIVE SUPPORT
4 – SUPPORT FEED HOLE
Fig. 245 Checking Piston Return Spring Length
1 – PISTON RETURN SPRINGS
2 – SPRING RETAINER
Fig. 246 Testing Piston Check Ball Seating
1 – PISTON CHECK BALL
2 – USE LOW-PRESSURE AIR TO CHECK SEATING
3 – DIRECT CLUTCH PISTON
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DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
(1) Lubricate and install replacement O–rings on
clutch piston (Fig. 247).
(2) Install clutch piston in drum and install return
springs on piston.
(3) Compress piston return springs with Tool 7538
and install snap ring (Fig. 243). Be sure snap ring
end gap is not aligned with spring retainer tab.
(4) Install clutch discs and plates (Fig. 248).
Install plate then disc until all plates and discs are
installed. Four plates and discs are required.
(5) Install clutch pack retainer in drum (Fig. 249).
(6) Install clutch pack snap ring (Fig. 249).
(7) Check snap ring position. If necessary, shift
snap ring until end gap is not aligned with any
notches in clutch drum (Fig. 250).
(8) Lubricate clutch drum thrust washer with
petroleum jelly and install it in drum (Fig. 240).
(9) Mount direct clutch assembly on forward clutch
assembly and check assembled height (Fig. 251).
Height should be 70.3 to 71.5 mm (2.767 to 2.815
in.).
(10) If assembled height is incorrect, clutches are
not seated.
Fig. 247 Direct Clutch Components
1 – DIRECT CLUTCH DRUM
2 – DIRECT CLUTCH PISTON
3 – O-RINGS
4 – PISTON RETURN SPRINGS
5 – CLUTCH DRUM THRUST WASHER
6 – CLUTCH PISTON SNAP RING
7 – CLUTCH PACK SNAP RING
8 – RETAINER
9 – CLUTCH PACK
10 – CLUTCH DISC*
11 – CLUTCH PLATE*
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DISASSEMBLY AND ASSEMBLY (Continued)
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