Jeep Cherokee (XJ): Forward clutch

DISASSEMBLY

Fig. 252 Forward Clutch Components

(1) Check clutch piston stroke as outlined in following steps.

(2) Position overdrive support on wood blocks and mount forward clutch drum on support (Fig. 253).

(3) Remove bearing and race from forward clutch drum (Fig. 253).

(4) Install a suitable threaded bolt/rod into the side of the overdrive support.

(5) Mount Miller Tool C-3339 dial indicator components onto the threaded rod as necessary.

(6) Position dial indicator plunger squarely against clutch piston.

Fig. 253 Positioning Drum And Support On Wood Blocks

1 - THRUST BEARING
2 - BEARING RACE
3 - FORWARD CLUTCH DRUM
4 - OVERDRIVE SUPPORT
5 - WOOD BLOCKS

(7) Apply compressed air through right side feed hole in support and note piston stroke length on dial indicator.

(8) Stroke length should be 3.55 - 3.73 mm (0.1348 - 0.1469 in.).

(9) Replace clutch discs if stroke length is incorrect.

(10) Remove clutch pack snap ring and remove retainer and clutch pack (Fig. 254).

(11) Remove clutch pack cushion plate (Fig. 255).

(12) Compress clutch springs with Tool 7538 and remove piston snap ring.

(13) Remove spring compressor tool and piston return springs.

(14) Remount forward clutch drum on overdrive support (Fig. 256).

(15) Apply compressed air through feed hole in support to remove piston (Fig. 256). Use only enough air pressure to ease piston out of drum.

(16) Remove and discard clutch piston O-rings (Fig. 257).

(17) Remove clutch drum O-ring from rear hub of drum.

(18) Remove three seal rings from clutch drum shaft (Fig. 258).

(19) Remove thrust bearing and race assembly from clutch drum (Fig. 259).

Fig. 254 Removing Retainer And Clutch Pack

1 - RETAINER AND CLUTCH PACK
2 - SNAP RING

Fig. 255 Removing Cushion Plate

1 - CUSHION PLATE
2 - RETURN SPRINGS
3 - CUSHION PLATE

Fig. 256 Removing Forward Clutch Piston

1 - CLUTCH PISTON
2 - OVERDRIVE SUPPORT
3 - FEED HOLE
4 - CLUTCH DRUM

Fig. 257 Removing/Installing Clutch Drum O-Ring

1 - CLUTCH DRUM HUB
2 - O-RING

Fig. 258 Removing Clutch Drum Seal Rings

1 - SEAL RINGS
2 - CLUTCH DRUM SHAFT

Fig. 259 Removing Clutch Drum Thrust Bearing Assembly

1 - THRUST BEARING AND RACE ASSEMBLY

(20) Measure clutch disc thickness (Fig. 260). Minimum allowable thickness is 1.51 mm (0.0595 in.).

Replace clutch pack if any disc falls below specified minimum thickness.

Fig. 260 Measuring Clutch Disc Thickness

1 - CLUTCH DISC
2 - MICROMETER

(21) Measure free length of piston return springs with springs mounted in retainer (Fig. 261). Length should be 19.47 mm (0.767 in.). Replace springs and retainer if length is incorrect.

(22) Inspect clutch piston check ball (Fig. 262).

Ball should move freely within piston. Check ball seating by applying low pressure compressed air to ball feed hole. Ball should seat firmly and not leak air.

(23) Measure inside diameter of bushing in clutch drum hub. Maximum allowable diameter is 24.08 mm (0.9480 in.). Replace clutch drum if bushing inside diameter is greater than specified.

ASSEMBLY

(1) Lubricate bearing and race assembly with petroleum jelly and install it in clutch drum (Fig.

263). Race side of assembly faces downward and toward drum. Bearing rollers face up (Fig. 263) (2) Coat new clutch drum shaft seal rings with petroleum jelly. Before installing drum shaft seal rings, squeeze each ring so ring ends overlap (Fig.

264). This tightens ring making clutch installation easier.

Fig. 261 Checking Return Spring Length

1 - PISTON RETURN SPRINGS
2 - SPRING RETAINER

Fig. 262 Testing Piston Check Ball

1 - PISTON CHECK BALL
2 - USE LOW AIR PRESSURE FOR TEST

(3) Install seal rings on shaft. Keep rings closed as tightly as possible during installation. Avoid overspreading them.

(4) Mount clutch drum on overdrive support.

(5) Lubricate and install new O-ring on clutch drum hub (Fig. 257).

Fig. 263 Installing Thrust Bearing And Race

1 - BEARING ROLLERS FACE UP
2 - THRUST BEARING AND RACE
3 - FORWARD CLUTCH

Fig. 264 Installing Clutch Drum Shaft Seal Rings

1 - SEAL RINGS (COMPRESS BEFORE INSTALLATION)
2 - CLUTCH DRUM SHAFT

(6) Lubricate new clutch piston O-rings with Mopar Door Ease, or Ru-Glyde. Install rings on clutch piston and install piston in drum.

(7) Install piston return springs.

(8) Compress piston return springs with Tool 7538 and shop press and install piston snap ring. Be sure snap ring end gap is not aligned with any notches in drum.

(9) Install cushion plate in drum. Concave side of plate faces downward (Fig. 255).

(10) Install clutch discs, plates and retainer (Fig.

265). Install tabbed plate followed by disc until required number of plates and discs are installed.

Use six plates and discs.

Fig. 265 Installing Forward Clutch Discs And Plates

1 - RETAINER
2 - CLUTCH PLATES
3 - CLUTCH DISCS

(11) Install clutch pack snap ring.

(12) Recheck clutch piston stroke length using same method outlined at beginning of disassembly procedure. If stroke length is not within specified limits, replace clutch discs.

(13) Lubricate race and bearing with petroleum jelly and install them in clutch drum (Fig. 266). Be sure bearing rollers face up and race lip seats in drum as shown.

(14) Verify bearing and race size.

•  Outer diameter of bearing is 46.7 mm (1.839 in).
•  Outer diameter of race is 48.9 mm (1.925 in.).
•  Inner diameter of bearing and race is 26.0 mm (1.024 in.).

(15) Mount forward clutch on direct clutch and check assembled height (Fig. 267). Height should be 70.3 - 71.5 mm (2.767 - 2.815 in.).

Fig. 266 Installing Thrust Bearing And Race

1 - THRUST BEARING AND RACE
2 - CLUTCH DRUM