Jeep XJ. Manual — part 441
(5) Install new seal with Seal Installer 7549 (Fig.
202).
(6) Lubricate and install gears in pump body.
(7) Assemble stator shaft and pump body. Tighten
shaft–to–body bolts to 10 N·m (7 ft. lbs.) torque.
(8) Install new O–ring on pump body and new seal
rings on stator shaft.
(9) Install pump in torque converter and check
pump gear rotation (Fig. 203). Gears must rotate
smoothly when turned clockwise and counterclock-
wise.
(10) Lubricate pump O–ring and seal rings with
petroleum jelly.
Fig. 202 Installing Pump Seal
1 – SEAL INSTALLER TOOL
2 – PUMP SEAL
Fig. 203 Checking Pump Gear Rotation
1 – OIL PUMP
2 – TORQUE CONVERTER
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DISASSEMBLY AND ASSEMBLY (Continued)
OVERDRIVE PLANETARY GEAR AND CLUTCH
DISASSEMBLY
(1) Check operation of one–way clutch in clutch
drum (Fig. 204). Hold drum and turn planetary shaft
clockwise and counterclockwise. Shaft should turn
Overdrive Planetary Gear And Clutch Components
1 – CLUTCH DRUM
2 – CLUTCH PISTON
3 – PISTON RETURN SPRING
4 – CLUTCH DISCS
5 – RETAINER PLATE
6 – CLUTCH PACK SNAP RING
7 – CLUTCH PLATES
8 – PISTON SNAP RING
9 – O-RINGS
10 – ONE-WAY CLUTCH
11 – CLUTCH DRUM BEARING AND RACE ASSEMBLY
12 – PLANETARY GEAR
13 – SNAP RING
14 – RING GEAR HUB
15 – THRUST WASHER
16 – BEARING
17 – ONE-WAY CLUTCH OUTER RACE
18 – RETAINING PLATE
19 – SNAP RING
20 – PLANETARY RING GEAR
21 – RACE
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AW–4 AUTOMATIC TRANSMISSION
21 - 301
DISASSEMBLY AND ASSEMBLY (Continued)
clockwise freely but lock when turned counterclock-
wise. Replace one–way clutch if necessary.
(2) Remove overdrive clutch from planetary gear
(Fig. 205).
(3) Measure stroke length of overdrive clutch pis-
ton as follows:
(a) Mount oil pump on torque converter. Then
mount clutch on oil pump (Fig. 206).
(b) Install a suitable threaded bolt/rod into oil
pump for use in mounting Miller Tool C-3339 dial
indicator components securely.
(c) Mount dial indicator on the bolt/rod and posi-
tion the dial indicator squarely on the clutch pis-
ton.
(d) Apply compressed air through clutch feed
hole in oil pump and note piston stroke length.
Stroke length should be 1.85 – 2.15 mm (0.0728 –
0.0846 in.).
(4) Remove thrust bearing and race assembly from
clutch drum (Fig. 207).
(5) Remove clutch pack snap ring and remove the
clutch pack (Fig. 208).
(6) Measure overdrive clutch disc thickness. Mini-
mum allowable thickness is 1.84 mm (0.0724 in.).
(7) If the clutch pack stroke length is out of speci-
fication or any clutch disc fails to meet the minimum
thickness, new discs will need to be installed during
assembly.
(8) Compress piston return spring with Tool 7538
(Fig. 209). Remove snap ring and remove compressor
tool.
(9) Remove the piston return springs.
(10) Mount oil pump on converter. Then mount
clutch on oil pump (Fig. 210).
(11) Hold clutch piston by hand and apply com-
pressed air through oil pump feed hole to ease piston
Fig. 204 Checking One–Way Clutch
1 – CLUTCH DRUM
2 – PLANETARY SHAFT
Fig. 205 Removing Overdrive Clutch From Gear
1 – OVERDRIVE CLUTCH
2 – PLANETARY GEAR
Fig. 206 Assembling Converter, Pump And Clutch
For Test
1 – OVERDRIVE CLUTCH
2 – OIL PUMP
3 – TORQUE CONVERTER
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DISASSEMBLY AND ASSEMBLY (Continued)
out (Fig. 210). Apply only enough air pressure to
remove piston.
(12) Measure free length of piston return springs
with springs in retainer (Fig. 211). Length should be
16.8 mm (0.661 in.). Replace spring and retainer
assembly if necessary.
(13) Check clutch piston check ball (Fig. 212).
Shake piston to see if ball moves freely. Then check
ball sealing by applying low pressure compressed air
to ball inlet as shown. Air should not leak past check
ball.
Fig. 207 Removing Clutch Drum Bearing And Race
1 – CLUTCH DRUM
2 – THRUST BEARING AND RACE
Fig. 208 Removing Clutch Pack Snap Ring
1 – SNAP RING
2 – CLUTCH RETAINER
Fig. 209 Removing Clutch Piston Snap Ring
1 – COMPRESSOR TOOL
2 – CLUTCH PISTON SNAP RING
Fig. 210 Removing Overdrive Clutch Piston
1 – CLUTCH RETAINER
2 – CLUTCH PISTON
3 – OIL PUMP
4 – CONVERTER
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AW–4 AUTOMATIC TRANSMISSION
21 - 303
DISASSEMBLY AND ASSEMBLY (Continued)
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