Jeep Cherokee (XJ): Front clutch. Rear clutch. Planetary geartrain/output shaft

Front clutch

DISASSEMBLY

(1) Remove waved snap ring and remove pressure plate, clutch plates and clutch discs (Fig. 184).

(2) Compress clutch piston spring with Compressor Tool C-3575-A (Fig. 185). Be sure legs of tool are seated squarely on spring retainer before compressing spring.

(3) Remove retainer snap ring and remove compressor tool.

(4) Remove spring retainer and clutch spring. Note position of retainer on spring for assembly reference.

(5) Remove clutch piston from clutch retainer.

Remove piston by rotating it up and out of retainer.

(6) Remove seals from clutch piston and clutch retainer hub. Discard both seals as they are not reusable.

ASSEMBLY (1) Soak clutch discs in transmission fluid while assembling other clutch parts.

(2) Install new seals on piston and in hub of retainer. Be sure lip of each seal faces interior of clutch retainer.

(3) Lubricate lips of piston and retainer seals with liberal quantity of Mopart Door Ease, or Ru-Glyde.

Then lubricate retainer hub, bore and piston with light coat of transmission fluid.

(4) Install clutch piston in retainer (Fig. 186). Use twisting motion to seat piston in bottom of retainer. A thin strip of plastic (about 0.020" thick), can be used to guide seals into place if necessary.

CAUTION: Never push the clutch piston straight in.

This will fold the seals over causing leakage and clutch slip. In addition, never use any type of metal tool to help ease the piston seals into place. Metal tools will cut, shave, or score the seals.

Fig. 184 Front Clutch Components

1 - RETAINER HUB SEAL
2 - CLUTCH PISTON
3 - PISTON SPRING
4 - SPRING RETAINER SNAP RING
5 - CLUTCH DISCS
6 - PRESSURE PLATE
7 - SNAP RING (WAVED)
8 - CLUTCH PLATES
9 - SPRING RETAINER
10 - PISTON SEAL
11 - FRONT CLUTCH RETAINER

(5) Position spring in clutch piston (Fig. 187).

(6) Position spring retainer on top of piston spring (Fig. 188). Make sure retainer is properly installed. Small raised tabs should be facing upward. Semicircular lugs on underside of retainer are for positioning retainer in spring.

(7) Compress piston spring and retainer with Compressor Tool C-3575-A (Fig. 185). Then install new snap ring to secure spring retainer and spring.

(8) Install clutch plates and discs (Fig. 184).

Install steel plate then disc until all plates and discs are installed. The front clutch uses 4 clutch discs.

(9) Install pressure plate and waved snap ring (Fig. 184).

(10) Using a suitable gauge bar and dial indicator, measure clutch plate clearance (Fig. 189).

(a) Position gauge bar across the clutch drum with the dial indicator pointer on the pressure plate (Fig. 189).

(b) Using two small screw drivers, lift the pressure plate and compress the waved snap-ring. This will assure that the snap-ring is at the top of the groove.

(c) Release the pressure plate and zero the dial indicator.

(d) Lift the pressure plate until it contacts the waved snap-ring and record the dial indicator reading.

Clearance should be 1.70 to 3.40 mm (0.067 to 0.134 in.). If clearance is incorrect, clutch discs, plates pressure plates and snap ring may have to be changed.

Rear clutch

DISASSEMBLY

(1) Remove thrust washer from forward side of clutch retainer.

(2) Remove input shaft front/rear seal rings.

(3) Remove selective clutch pack snap ring (Fig.

190).

Fig. 185 Compressing Front Clutch Piston Spring

1 - FRONT CLUTCH SPRING
2 - COMPRESSOR TOOL C-3575-A
3 - RETAINER SNAP RING
4 - SPRING RETAINER

Fig. 186 Front Clutch Piston Installation

1 - CLUTCH PISTON
2 - FRONT CLUTCH RETAINER

(4) Remove top pressure plate, clutch discs, steel plates, bottom pressure plate and wave snap ring and wave spring (Fig. 190).

(5) Remove clutch piston with rotating motion.

(6) Remove and discard piston seals.

(7) Remove input shaft snap-ring (Fig. 191). It may be necessary to press the input shaft in slightly to relieve tension on the snap-ring (8) Press input shaft out of retainer with shop press and suitable size press tool. Use a suitably sized press tool to support the retainer as close to the input shaft as possible.

Fig. 187 Clutch Piston Spring Installation

1 - RETAINER
2 - CLUTCH SPRING
3 - PISTON

Fig. 188 Correct Spring Retainer Installed Position

1 - SMALL TABS ON RETAINER FACE UPWARD

Fig. 189 Measuring Front Clutch Pack Clearance

1 - DIAL INDICATOR
2 - WAVED SNAP-RING
3 - FRONT CLUTCH
4 - POINTER
5 - GAUGE BAR
6 - PRESSURE PLATE

ASSEMBLY

(1) Soak clutch discs in transmission fluid while assembling other clutch parts.

(2) Install new seal rings on clutch retainer hub and input shaft if necessary (Fig. 192).

(a) Be sure clutch hub seal ring is fully seated in groove and is not twisted.

(3) Lubricate splined end of input shaft and clutch retainer with transmission fluid. Then press input shaft into retainer. Use a suitably sized press tool to support retainer as close to input shaft as possible.

(4) Install input shaft snap-ring (Fig. 191).

(5) Invert retainer and press input shaft in opposite direction until snap-ring is seated.

(6) Install new seals on clutch piston. Be sure lip of each seal faces interior of clutch retainer.

(7) Lubricate lip of piston seals with generous quantity of Mopart Door Ease. Then lubricate retainer hub and bore with light coat of transmission fluid.

(8) Install clutch piston in retainer. Use twisting motion to seat piston in bottom of retainer. A thin strip of plastic (about 0.020" thick), can be used to guide seals into place if necessary.

CAUTION: Never push the clutch piston straight in.

This will fold the seals over causing leakage and clutch slip. In addition, never use any type of metal tool to help ease the piston seals into place. Metal tools will cut, shave, or score the seals.

Fig. 190 Rear Clutch Components

1 - PISTON SPRING
2 - REAR CLUTCH PISTON
3 - CLUTCH PISTON SEALS
4 - OUTPUT SHAFT THRUST WASHER (METAL)
5 - INPUT SHAFT SNAP RING
6 - REAR CLUTCH RETAINER
7 - INPUT SHAFT
8 - REAR CLUTCH THRUST WASHER (FIBER)
9 - CLUTCH PACK SNAP RING (SELECTIVE)
10 - TOP PRESSURE PLATE
11 - CLUTCH DISCS (4)
12 - BOTTOM PRESSURE PLATE
13 - WAVE SPRING
14 - CLUTCH PLATES (3)
15 - RETAINER SEAL RING
16 - SHAFT REAR SEAL RING (PLASTIC)
17 - SHAFT FRONT SEAL RING (TEFLON)

Fig. 191 Removing/Installing Input Shaft Snap-

1 - REAR CLUTCH RETAINER
2 - INPUT SHAFT SNAP RING
3 - SNAP RING PLIERS

(9) Install piston spring in retainer and on top of piston (Fig. 195). Concave side of spring faces downward (toward piston).

(10) Install wave spring in retainer (Fig. 195). Be sure spring is completely seated in retainer groove.

Fig. 192 Rear Clutch Retainer And Input Shaft Seal Ring Installation

1 - REAR CLUTCH RETAINER HUB SEAL RING
2 - INPUT SHAFT SEAL RINGS

(11) Install bottom pressure plate (Fig. 190).

Ridged side of plate faces downward (toward piston) and flat side toward clutch pack.

Fig. 193 Input Shaft Seal Ring Identification

1 - PLASTIC REAR SEAL RING
2 - TEFLON FRONT SEAL RING (SQUEEZE RING TOGETHER SLIGHTLY BEFORE INSTALLATION FOR BETTER FIT)

Fig. 194 Pressing Input Shaft Into Rear Clutch Retainer

1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - PRESS RAM

Fig. 195 Piston Spring/Wave Spring Position

1 - REAR CLUTCH RETAINER
2 - PISTON SPRING
3 - WAVE SPRING
4 - CLUTCH PISTON

(12) Install first clutch disc in retainer on top of bottom pressure plate. Then install a clutch plate followed by a clutch disc until entire clutch pack is installed (4 discs and 3 plates are required) (Fig.

190).

(13) Install top pressure plate.

(14) Install selective snap ring. Be sure snap ring is fully seated in retainer groove.

(15) Using a suitable gauge bar and dial indicator, measure clutch pack clearance (Fig. 196).

(a) Position gauge bar across the clutch drum with the dial indicator pointer on the pressure plate (Fig. 196).

(b) Using two small screw drivers, lift the pressure plate and release it.

(c) Zero the dial indicator.

(d) Lift the pressure plate until it contacts the snap-ring and record the dial indicator reading.

Clearance should be 0.64 - 1.14 mm (0.025 - 0.045 in.). If clearance is incorrect, steel plates, discs, selective snap ring and pressure plates may have to be changed.

The selective snap ring thicknesses are:

•  .107-.109 in.
•  .098-.100 in.
•  .095-.097 in.
•  .083-.085 in.
•  .076-.078 in.
•  .071-.073 in.
•  .060-.062 in.

(16) Coat rear clutch thrust washer with petroleum jelly and install washer over input shaft and into clutch retainer (Fig. 197). Use enough petroleum jelly to hold washer in place.

Fig. 196 Checking Rear Clutch Pack Clearance

1 - DIAL INDICATOR
2 - PRESSURE PLATE
3 - SNAP RING
4 - STAND
5 - REAR CLUTCH
6 - GAUGE BAR

1 - REAR CLUTCH RETAINER
2 - REAR CLUTCH THRUST WASHER

Planetary geartrain/output shaft

DISASSEMBLY

(1) Remove planetary snap ring (Fig. 198).

(2) Remove front annulus and planetary assembly from driving shell (Fig. 198).

(3) Remove snap ring that retains front planetary gear in annulus gear (Fig. 199).

(4) Remove tabbed thrust washer and tabbed thrust plate from hub of front annulus (Fig. 200).

(5) Separate front annulus and planetary gears (Fig. 200).

(6) Remove front planetary gear front thrust washer from annulus gear hub.

(7) Separate and remove driving shell, rear planetary and rear annulus from output shaft (Fig. 201).

(8) Remove front planetary rear thrust washer from driving shell.

(9) Remove tabbed thrust washers from rear planetary gear.

(10) Remove lock ring that retains sun gear in driving shell. Then remove sun gear, spacer and thrust plates.

Fig. 198 Front Annulus And Planetary Assembly Removal

1 - DRIVING SHELL
2 - FRONT ANNULUS AND PLANETARY ASSEMBLY
3 - PLANETARY SNAP RING

Fig. 199 Front Planetary Snap Ring Removal

1 - FRONT ANNULUS GEAR
2 - PLANETARY SNAP RING

ASSEMBLY

(1) Lubricate output shaft and planetary components with transmission fluid. Use petroleum jelly to lubricate and hold thrust washers and plates in position.

(2) Assemble rear annulus gear and support if disassembled.

Be sure support snap ring is seated and that shoulder-side of support faces rearward (Fig.

202).

Fig. 200 Front Planetary And Annulus Gear Disassembly

1 - FRONT ANNULUS
2 - THRUST WASHER
3 - THRUST PLATE
4 - FRONT THRUST WASHER
5 - FRONT PLANETARY

Fig. 201 Removing Driving Shell, Rear Planetary And Rear Annulus

1 - REAR ANNULUS
2 - REAR PLANETARY
3 - DRIVING SHELL
4 - OUTPUT SHAFT

(3) Install rear thrust washer on rear planetary gear. Use enough petroleum jelly to hold washer in place. Also be sure all four washer tabs are properly engaged in gear slots.

(4) Install rear annulus over and onto rear planetary gear (Fig. 202).

(5) Install assembled rear planetary and annulus gear on output shaft (Fig. 203). Verify that assembly is fully seated on shaft.

(6) Install front thrust washer on rear planetary gear (Fig. 204). Use enough petroleum jelly to hold washer on gear. Be sure all four washer tabs are seated in slots.

(7) Install spacer on sun gear (Fig. 205).

(8) Install thrust plate on sun gear (Fig. 206). Note that driving shell thrust plates are interchangeable.

Use either plate on sun gear and at front/rear of shell.

Fig. 202 Assembling Rear Annulus And Planetary Gear

1 - REAR ANNULUS GEAR
2 - TABBED THRUST WASHER
3 - REAR PLANETARY

Fig. 203 Installing Rear Annulus And Planetary On Output Shaft

1 - REAR ANNULUS AND PLANETARY GEAR ASSEMBLY
2 - OUTPUT SHAFT

Fig. 204 Installing Rear Planetary Front Thrust Washer

1 - FRONT TABBED THRUST WASHER
2 - REAR PLANETARY GEAR

Fig. 205 Installing Spacer On Sun Gear

1 - SUN GEAR
2 - SUN GEAR SPACER

Fig. 206 Installing Driving Shell Front Thrust Plate On Sun Gear

1 - SPACER
2 - SUN GEAR
3 - THRUST PLATE

(9) Hold sun gear in place and install thrust plate over sun gear at rear of driving shell (Fig. 207).

(10) Position wood block on bench and support sun gear on block (Fig. 208). This makes it easier to align and install sun gear lock ring. Keep wood block handy as it will also be used for geartrain end play check.

(11) Align rear thrust plate on driving shell and install sun gear lock ring. Be sure ring is fully seated in sun gear ring groove (Fig. 209).

(12) Install assembled driving shell and sun gear on output shaft (Fig. 210).

Fig. 207 Installing Driving Shell Rear Thrust Plate

1 - DRIVING SHELL
2 - SUN GEAR
3 - REAR THRUST PLATE

(13) Install rear thrust washer on front planetary gear (Fig. 211). Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated.

Fig. 208 Supporting Sun Gear On Wood Block

1 - SUN GEAR
2 - DRIVING SHELL
3 - WOOD BLOCK

Fig. 209 Installing Sun Gear Lock Ring

1 - LOCK RING GROOVE
2 - SUN GEAR LOCK RING
3 - DRIVING SHELL
4 - REAR THRUST PLATE

Fig. 210 Installing Assembled Sun Gear And Driving Shell On Output Shaft

1 - SUN GEAR/DRIVING SHELL ASSEMBLY
2 - OUTPUT SHAFT

Fig. 211 Installing Rear Thrust Washer On Front Planetary Gear

1 - FRONT PLANETARY GEAR
2 - REAR TABBED THRUST WASHER

(14) Install front planetary gear on output shaft and in driving shell (Fig. 212).

(15) Install front thrust washer on front planetary gear. Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated.

(16) Assemble front annulus gear and support, if necessary. Be sure support snap ring is seated.

(17) Install front annulus on front planetary (Fig.

212).

(18) Position thrust plate on front annulus gear support (Fig. 213). Note that plate has two tabs on it. These tabs fit in notches of annulus hub.

Fig. 212 Installing Front Planetary And Annulus Gears

1 - FRONT PLANETARY GEAR
2 - FRONT THRUST WASHER
3 - FRONT ANNULUS GEAR

Fig. 213 Positioning Thrust Plate On Front Annulus Support

1 - FRONT ANNULUS
2 - THRUST PLATE

(19) Install thrust washer in front annulus (Fig.

214). Align flat on washer with flat on planetary hub. Also be sure washer tab is facing up.

(20) Install front annulus snap ring (Fig. 215). Use snap ring pliers to avoid distorting ring during installation. Also be sure ring is fully seated.

(21) Install planetary selective snap ring with snap ring pliers (Fig. 216). Be sure ring is fully seated.

(22) Turn planetary geartrain assembly over so driving shell is facing workbench. Then support geartrain on wood block positioned under forward end of output shaft. This allows geartrain components to move forward for accurate end play check.

(23) Check planetary geartrain end play with feeler gauge (Fig. 217). Gauge goes between shoulder on output shaft and end of rear annulus support.

(24) Geartrain end play should be 0.12 to 1.22 mm (0.005 to 0.048 in.). If end play is incorrect, snap ring (or thrust washers) may have to be replaced. Snap ring is available in three different thicknesses for adjustment purposes.

Fig. 214 Installing Front Annulus Thrust Washer

1 - WASHER FLAT ALIGNS WITH FLAT ON PLANETARY HUB
2 - FRONT ANNULUS THRUST WASHER
3 - TAB FACES FRONT

Fig. 215 Installing Front Annulus Snap Ring

1 - SNAP RING PLIERS
2 - FRONT ANNULUS SNAP RING

Fig. 216 Installing Planetary Selective Snap Ring

1 - SELECTIVE SNAP RING
2 - SNAP RING PLIERS

Fig. 217 Checking Planetary Geartrain End

1 - OUTPUT SHAFT
2 - REAR ANNULUS GEAR
3 - FEELER GAUGE