Jeep XJ. Manual — part 436
(61) Remove No. 2 first–reverse brake piston with
compressed air. Apply air through same transmission
feed hole used for checking piston operation.
(62) Remove reaction sleeve with Sleeve Remover
Tool 7542 (Fig. 136). Insert tool flanges under sleeve
and lift tool and sleeve out of case.
(63) Remove No. 1 first/reverse brake piston with
Piston Puller 7543 (Fig. 137). Slip tool under piston
and lift tool and piston out of case.
ASSEMBLY
(1) During assembly, lubricate components with
transmission fluid or petroleum jelly as indicated.
(2) Verify thrust bearing and race installation dur-
ing assembly. Refer to the Thrust Bearing Chart (Fig.
Fig. 135 Removing/Installing Piston Snap Ring
1 – RETURN SPRINGS
2 – COMPRESSOR TOOL
3 – PISTON SNAP RING
Fig. 134 Checking First–Reverse Brake Piston
Operation
1 – LOW-PRESSURE AIR
2 – FIRST-REVERSE BRAKE (IN CASE)
Fig. 136 Removing/Installing Reaction Sleeve
1 – REACTION SLEEVE
2 – TOOL
Fig. 137 Removing/Installing First–Reverse Brake
No.1 Piston
1 – NO. 1 PISTON
2 – TOOL
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DISASSEMBLY AND ASSEMBLY (Continued)
138) for bearing and race location and correct posi-
tioning.
(3) Install new seals onto the No.1 first-reverse
brake piston. Lubricate seals with transmission fluid.
(4) Install the No.1 first-reverse brake piston into
the transmission case.
(5) Install new seal onto the first-reverse brake
piston reaction sleeve. Lubricate seals with transmis-
sion fluid.
(6) Install the first-reverse brake piston reaction
sleeve into the transmission case.
(7) Install new seal onto the No.2 first-reverse
brake piston. Lubricate seals with transmission fluid.
(8) Install the No.2 first-reverse brake piston into
the transmission case.
(9) Install the spring plate into the No.2 first-re-
verse brake piston.
(10) Install Spring Compressor 7539 onto the first-
reverse brake piston.
(11) Compress the first-reverse brake piston spring
and install the first-reverse brake piston snap-ring.
(12) Remove Spring Compressor 7539.
(13) Install rear planetary gear, second brake
drum and output shaft as outlined in following steps:
(14) Verify No. 10 thrust bearing and race (Fig.
138). Bearing and race outer diameter is 57.7 mm
(2.272 in.) and inside diameter is 39.2 mm (1.543 in.).
(15) Coat thrust bearing and race assembly with
petroleum jelly and install in case (Fig. 139). Race
faces down. Bearing rollers face up.
(16) Align teeth of second brake drum and clutch
pack (Fig. 140).
Fig. 138 Thrust Bearing Chart
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21 - 281
DISASSEMBLY AND ASSEMBLY (Continued)
(17) Align rear planetary-output shaft assembly
teeth with case slots and install assembly in case
(Fig. 141).
(18) Install rear planetary snap ring with snap
ring pliers. Chamfered side of snap ring faces up and
toward case front (Fig. 142).
(19) Check first–reverse brake pack clearance with
feeler gauge (Fig. 143). Clearance should be 0.70 –
1.20 mm (0.028 – 0.047 in.). If clearance is incorrect,
planetary assembly, thrust bearing or snap ring is
not properly seated in case. Remove and reinstall
components if necessary.
(20) Install second brake piston sleeve (Fig. 144).
Sleeve lip faces up and toward case front as shown.
(21) Install second brake drum gasket.
Fig. 139 Installing Thrust Bearing And No. 10 Race
1 – THRUST BEARING AND RACE
Fig. 140 Aligning Second Brake Drum And Clutch
Pack Teeth
1 – SECOND BRAKE DRUM
2 – CLUTCH PACK
3 – ALIGN DRUM AND CLUTCH PACK TEETH
Fig. 141 Output Shaft/Rear Planetary Assembly
Installation
1 – ALIGN CLUTCH/DRUM TEETH WITH CASE SLOTS
2 – CASE SLOTS
Fig. 142 Planetary Snap Ring Installation
1 – REAR PLANETARY SNAP RING
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DISASSEMBLY AND ASSEMBLY (Continued)
(22) Install park lock pawl, spring and pin (Fig.
145).
(23) Install the manual valve shift assembly.
(24) Connect park lock rod to manual valve shift
sector (Fig. 146).
Fig. 143 Checking First–Reverse Brake Pack
Clearance
1 – FEELER GAUGE
Fig. 144 Second Brake Piston Sleeve Installation
1 – PISTON SLEEVE
Fig. 145 Park Lock Pin, Spring And Pawl Installation
1 – SPRING
2 – PIN
3 – PAWL
Fig. 146 Park Lock Rod Installation
1 – SHIFT SECTOR
2 – PARK LOCK ROD
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AW–4 AUTOMATIC TRANSMISSION
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DISASSEMBLY AND ASSEMBLY (Continued)
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