Jeep Cherokee (XJ): Front planetary gear. Sun gear and no. 1 one-way clutch. Second brake

Front planetary gear

DISASSEMBLY

(1) Remove ring gear from planetary gear (Fig. 268).

(2) Remove front bearing and the two races from ring gear (Fig. 268).

Fig. 267 Checking Forward Clutch Assembled Height

1 - DIRECT CLUTCH
2 - APPROXIMATELY 71.2 mm (2.80 in.)
3 - FORWARD CLUTCH

(3) Remove tabbed thrust race from planetary gear (Fig. 268).

(4) Remove snap ring attaching planetary gear to shaft and remove gear.

Fig. 268 Front Planetary Gear Components

1 - FORWARD RACE
2 - FRONT PLANETARY RING GEAR
3 - FRONT BEARING
4 - SNAP RING
5 - REAR RACE
6 - REAR BEARING
7 - FRONT PLANETARY GEAR
8 - THRUST RACE
9 - FRONT RACE

(5) Remove rear bearing and race from planetary gear.

(6) Measure inside diameter of ring gear bushing.

Maximum allowable diameter is 24.08 mm (0.9480 in.). Replace ring gear if bushing inside diameter is greater than specified.

(7) Check condition of planetary gear. Replace gear if teeth are worn, pins are loose, or carrier is cracked, distorted, or worn.

ASSEMBLY

(1) Lubricate planetary and ring gear bearings and races with petroleum jelly.

(2) Identify planetary bearings and races before installation. (Fig. 268). Bearings and races can be identified by following dimensions:

•  Outer diameter of rear bearing is 47.7 mm (1.878 in.). Inner diameter is 35.5 mm (1.398 in.).
•  Outer diameter of rear race 47.6 mm (1.874 in.). Inner diameter is 33.7 mm (1.327 in.).
•  Outer diameter of front race is 53.6 mm (2.110 in.). Inner diameter is 30.5 mm (1.201 in.).
•  Outer diameter of front bearing is 47.7 mm (1.878 in.). Inner diameter is 32.6 (1.283 in.).
•  Outer diameter of forward race is 47.0 mm (1.850 in.). Inner diameter is 26.5 mm 1.043 in.).

(3) Install rear race and bearing in gear (Fig. 269).

(4) Turn planetary over and install thrust race (Fig. 270).

(5) Install front race and bearing and forward race in ring gear (Fig. 271).

Fig. 269 Front Planetary Rear Bearing and Race Installation

1 - REAR BEARING AND RACE
2 - PLANETARY GEAR

Fig. 270 Front Planetary Thrust Race Installation

1 - TABBED THRUST RACE
2 - PLANETARY GEAR

Fig. 271 Front Planetary Front Bearing And Races Installation

1 - FRONT BEARING AND RACE
2 - FORWARD RACE

Sun gear and no. 1 one-way clutch

Sun Gear And One-Way Clutch Components

1 - SNAP RING
2 - SUN GEAR
3 - SUN GEAR INPUT DRUM
4 - THRUST WASHER
5 - ONE-WAY CLUTCH AND SECOND BRAKE HUB ASSEMBLY
6 - SNAP RING
7 - SEAL RINGS

DISASSEMBLY

(1) Hold sun gear and turn second brake hub clockwise and counterclockwise (Fig. 272). Hub should rotate freely clockwise but lock when turned counterclockwise. Replace one-way clutch and hub if they do not operate properly.

(2) Remove one-way clutch/second brake hub assembly from drum (Fig. 273).

Fig. 272 Checking One-Way Clutch Operation

1 - SECOND BRAKE HUB
2 - SUN GEAR

Fig. 273 Removing/Installing Brake Hub And Clutch Assembly

1 - HUB AND CLUTCH ASSEMBLY
2 - DRUM

(3) Remove thrust washer from drum (Fig. 274).

Fig. 274 Removing/Installing Thrust Washer

1 - THRUST WASHER

(4) Remove two seal rings from sun gear (Fig.

275).

Fig. 275 Removing/Installing Sun Gear Seal Rings

1 - SEALS RINGS (2)

(5) Support sun gear on wood block (Fig. 276).

Then remove first sun gear snap ring and separate drum from gear.

Fig. 276 Removing/Installing Sun Gear

1 - SUN GEAR
2 - SNAP RING
3 - WOOD BLOCK
4 - INPUT DRUM

(6) Remove remaining snap ring from sun gear (Fig. 277).

Fig. 277 Removing/Installing Second Snap Ring

1 - SUN GEAR
2 - SECOND SNAP RING

(7) Measure inside diameter of sun gear bushings with bore gauge or inside micrometer (Fig. 278).

Maximum allowable diameter is 27.08 mm (1.0661 in.). Replace sun gear if bushing inside diameter is greater than specified.

Fig. 278 Checking Sun Gear Bushings

1 - BORE GAUGE

ASSEMBLY

(1) Install first snap ring on sun gear.

(2) Install sun gear in drum and install remaining snap ring.

(3) Coat replacement seal rings with petroleum jelly and install them on sun gear. Be sure seal ring ends are interlocked.

(4) Install thrust washer. Be sure washer tabs are seated in drum slots.

Fig. 279 Installing Clutch And Hub Assembly On Sun Gear

1 - CLUTCH AND HUB ASSEMBLY

(5) Install one-way clutch/second brake hub assembly on sun gear. Deep side of hub flange faces upward (Fig. 279).

Second Brake Components

1 - THRUST WASHER
2 - SNAP RING
3 - SPRING RETAINER
4 - PISTON RETURN SPRINGS
5 - REAR PLANETARY/OUTPUT SHAFT/FIRST-REVERSE BRAKE
6 - SECOND BRAKE DRUM
7 - O-RINGS
8 - SECOND BRAKE PISTON
9 - PISTON SLEEVE

(6) Check one-way clutch operation again (Fig.

272). Hold sun gear and turn second brake hub clockwise and counterclockwise. Hub should turn clockwise freely, but lock when turned counterclockwise.

Second brake

DISASSEMBLY

(1) Remove second brake drum from output shaft (Fig. 280).

Fig. 280 Removing/Installing Second Brake Assembly

1 - SECOND BRAKE ASSEMBLY
2 - OUTPUT SHAFT

(2) Remove thrust washer from second brake drum (Fig. 281).

(3) Compress piston return springs with shop press and tool 7538. Then remove piston snap ring (Fig. 282).

(4) Remove compressor tool and remove spring retainer and return springs.

(5) Remove second brake piston and sleeve from drum with compressed air (Fig. 283). Use only enough air pressure to ease piston out of drum.

(6) Remove and discard brake piston O-rings.

(7) Measure free length of piston return springs with springs mounted in retainer (Fig. 284). Length should be approximately 16.05 mm (0.632 in.).

Replace return springs if length is less than specified.

Fig. 281 Removing/Installing Second Brake Drum Thrust Washer

1 - THRUST WASHER
2 - SECOND BRAKE DRUM

Fig. 282 Removing/Installing Second Brake Piston Snap Ring

1 - COMPRESSOR TOOL
2 - PISTON SNAP RING

Fig. 283 Removing/Installing Piston And Sleeve

1 - PISTON AND SLEEVE
2 - DRUM

Fig. 284 Measuring Second Brake Piston Return Springs

1 - PISTON RETURN SPRINGS
2 - SPRING RETAINER

ASSEMBLY

(1) Lubricate and install new O-rings on brake piston. Then install brake piston in drum.

(2) Install return springs and retainer on brake piston.

(3) Compress return springs with shop press and Compressor Tool 7538. Install piston snap ring and remove brake assembly from press.

(4) Check brake piston operation with low pressure compressed air (Fig. 285). Apply air pressure through feed hole in drum. Piston should move smoothly when applying-releasing air pressure.

Fig. 285 Checking Second Brake Piston Operation

1 - PISTON
2 - DRUM

(5) Coat thrust washer with petroleum jelly and install it in drum. Be sure washer notches are aligned with tabs on spring retainer (Fig. 286)

Fig. 286 Installing Second Brake Thrust Washer

1 - THRUST WASHER NOTCHES
2 - SPRING RETAINER TABS