Toyota
Jeep Cherokee
 Service Manual
Transmission and transfer case » AW-4 automatic transmission » Disassembly and assembly
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 clockwise freely but lock when turned counterclockwise.

Replace one-way clutch if necessary.

Overdrive Planetary Gear And Clutch Components
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

Fig. 204 Checking One-Way Clutch
Fig. 204 Checking One-Way Clutch

1 - CLUTCH DRUM
2 - PLANETARY SHAFT

(2) Remove overdrive clutch from planetary gear (Fig. 205).

Fig. 205 Removing Overdrive Clutch From Gear
Fig. 205 Removing Overdrive Clutch From Gear

1 - OVERDRIVE CLUTCH
2 - PLANETARY GEAR

(3) Measure stroke length of overdrive clutch piston as follows:

(a) Mount oil pump on torque converter. Then mount clutch on oil pump (Fig. 206).

Fig. 206 Assembling Converter, Pump And Clutch
Fig. 206 Assembling Converter, Pump And Clutch For Test

1 - OVERDRIVE CLUTCH
2 - OIL PUMP
3 - TORQUE CONVERTER

(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 position the dial indicator squarely on the clutch piston.

(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. Minimum allowable thickness is 1.84 mm (0.0724 in.).

(7) If the clutch pack stroke length is out of specification 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 compressed air through oil pump feed hole to ease pis out (Fig. 210). Apply only enough air pressure to remove piston

Fig. 207 Removing Clutch Drum Bearing And Race
Fig. 207 Removing Clutch Drum Bearing And Race

1 - CLUTCH DRUM
2 - THRUST BEARING AND RACE

Fig. 208 Removing Clutch Pack Snap Ring
Fig. 208 Removing Clutch Pack Snap Ring

1 - SNAP RING
2 - CLUTCH RETAINER

(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. 209 Removing Clutch Piston Snap Ring
Fig. 209 Removing Clutch Piston Snap Ring

1 - COMPRESSOR TOOL
2 - CLUTCH PISTON SNAP RING

Fig. 210 Removing Overdrive Clutch Piston
Fig. 210 Removing Overdrive Clutch Piston

1 - CLUTCH RETAINER
2 - CLUTCH PISTON
3 - OIL PUMP
4 - CONVERTER

Fig. 211 Checking Piston Return Spring Length
Fig. 211 Checking Piston Return Spring Length

1 - PISTON RETURN SPRINGS
2 - SPRING RETAINER

Fig. 212 Testing Clutch Piston Check Ball
Fig. 212 Testing Clutch Piston Check Ball

1 - CLUTCH PISTON CHECK BALL
2 - USE LOW-PRESSURE COMPRESSED AIR TO TEST BALL SEATING

(14) Check inside diameter of clutch drum bushings with bore gauge or inside micrometer (Fig. 213).

Maximum inside diameter is 27.11 mm (1.0673 in.).

Replace drum if bushing inside diameter is greater than specified.

(15) Remove bearing and race from ring gear (Fig.

214).

Fig. 213 Checking Clutch Drum Bushings
Fig. 213 Checking Clutch Drum Bushings

1 - CLUTCH DRUM

Fig. 214 Removing Ring Gear Bearing And Race
Fig. 214 Removing Ring Gear Bearing And Race

1 - BEARING
2 - RACE
3 - RING GEAR

(16) Remove snap ring from ring gear and remove ring gear hub (Fig. 215).

Fig. 215 Removing Ring Gear Hub
Fig. 215 Removing Ring Gear Hub

1 - SNAP RING
2 - RING GEAR
3 - RING GEAR HUB

(17) Remove race from planetary gear (Fig. 216).

Fig. 216 Remove Planetary Gear Race
Fig. 216 Remove Planetary Gear Race

1 - PLANETARY GEAR
2 - RACE

(18) Remove snap ring and remove retaining plate (Fig. 217).

Fig. 217 Removing Snap Ring And Retaining Plate
Fig. 217 Removing Snap Ring And Retaining Plate

1 - SNAP RING
2 - PLANETARY GEAR
3 - RETAINING PLATE

(19) Remove one-way clutch and outer race as assembly. Then separate race from clutch (Fig. 218).

Fig. 218 Removing One-Way Clutch
Fig. 218 Removing One-Way Clutch

1 - ONE-WAY CLUTCH AND OUTER RACE ASSEMBL
2 - PLANETARY GEAR
3 - RACE
4 - CLUTCH

(20) Remove thrust washer (Fig. 219).

(21) Check inside diameter of planetary gear bushing (Fig. 220). Maximum inside diameter is 11.27 mm (0.4437 in.). Replace planetary gear if bushing inside diameter is greater then specified.

Fig. 219 Removing Planetary Thrust Washer
Fig. 219 Removing Planetary Thrust Washer

1 - THRUST WASHER
2 - PLANETARY GEAR

Fig. 220 Checking Planetary Bushing
Fig. 220 Checking Planetary Bushing

1 - PLANETARY BUSHING
2 - PLANETARY GEAR

ASSEMBLY

(1) Install thrust washer in planetary gear (Fig.

221). Grooved side of washer faces up and toward front.

Fig. 221 Install Planetary Thrust Washer
Fig. 221 Install Planetary Thrust Washer

1 - THRUST WASHER
2 - PLANETARY GEAR

(2) Install clutch race into planetary gear.

(3) Install one-way clutch into the outer race (Fig.

222). Be sure flanged side of clutch is facing upward.

(4) Install clutch retaining plate and snap ring in planetary gear.

(5) Coat planetary race with petroleum jelly and install it on planetary gear. Outside diameter of race should be 41.8 mm (1.646 in.); inside diameter is 27.1 mm (1.067 in.).

(6) Install hub in planetary ring gear and install snap ring.

(7) Coat race and bearing with petroleum jelly and install in planetary ring gear (Fig. 223).

(8) Verify bearing/race size. Outside diameter of race is 47.8 mm (1.882 in.) and inside diameter is 24.2 mm (0.953 in.). Outside diameter of bearing is 46.8 mm (1.843 in.) and inside diameter is 26 mm (1.024 in.).

(9) Lubricate new clutch piston O-rings with Mopart Door Ease, or Ru-Glyde. Then install rings on clutch piston and install piston in clutch drum.

(10) Install piston return springs in clutch piston (Fig. 224).

(11) Install piston snap ring. Compress piston return springs with Tool 7538 and shop press (Fig. 225).

Fig. 222 Assembling One-Way Clutch And Race
Fig. 222 Assembling One-Way Clutch And Race

1 - FLANGED SIDE OF CLUTCH FACES UP
2 - ONE-WAY CLUTCH
3 - CLUTCH RACE

Fig. 223 Install Ring Gear Bearing And Race
Fig. 223 Install Ring Gear Bearing And Race

1 - BEARING
2 - RACE
3 - RING GEAR

(12) Install overdrive clutch pack in drum. Install steel plate first, then a disc (Fig. 226). Continue installation sequence until required number of discs and plates have been installed.

Fig. 224 Installing Piston Return Springs
Fig. 224 Installing Piston Return Springs

1 - RETURN SPRINGS
2 - CLUTCH PISTON

(13) Install clutch pack retainer with flat side facing downward. Then install retainer snap ring (Fig.

227). Compress springs with suitable tool.

Fig. 225 Installing Clutch Piston Snap Ring
Fig. 225 Installing Clutch Piston Snap Ring

1 - PRESS RAM
2 - COMPRESSOR TOOL
3 - SNAP RING

Fig. 226 Installing Overdrive Clutch Discs And Plates
Fig. 226 Installing Overdrive Clutch Discs And Plates

1 - CLUTCH DISC
2 - STEEL PLATE
3 - CLUTCH DRUM

Fig. 227 Installing Retainer And Snap Ring
Fig. 227 Installing Retainer And Snap Ring

1 - CLUTCH PACK RETAINER
2 - RETAINER SNAP RING

(14) Install clutch drum bearing and race assembly (Fig. 228). Be sure bearing rollers face upward as shown. Outside diameter of assembled bearing and race is 50.2 mm (1.976 in.). Inside diameter is 28.9 mm (1.138 in.).

Fig. 228 Installing Clutch Drum Bearing And Race Assembly
Fig. 228 Installing Clutch Drum Bearing And Race Assembly

1 - BEARING AND RACE ASSEMBLY
2 - CLUTCH DRUM
3 - RACE
4 - ROLLERS

(15) Install clutch on planetary gear.

(16) Verify one-way clutch operation. Hold drum and turn planetary shaft clockwise and counterclockwise.

Shaft should turn clockwise freely but lock when turned counterclockwise.

    More about «Disassembly and assembly»:

    Transmission

    Oil pump

    Overdrive planetary gear and clutch

    Overdrive support

    Direct clutch

    Forward clutch

    Front planetary gear

    Sun gear and no. 1 one-way clutch

    Second brake

    Planetary/brake pack/output shaft

    Transmission valve body

    Jeep Cherokee Service Manual / Transmission and transfer case / AW-4 automatic transmission / Disassembly and assembly / Overdrive planetary gear and clutch

    Jeep Cherokee Service Manual

    Categories


    © 2017-2022 Copyright www.jcherokee.com