Jeep Cherokee (XJ): Oil pump. Overdrive planetary gear and clutch. Overdrive support

Oil pump

DISASSEMBLY

(1) Remove pump body O-ring (Fig. 199).

(2) Remove pump seal.

(3) Remove pump seal rings (Fig. 199).

(4) Remove bolts attaching stator shaft to pump body and separate components.

(5) Remove drive gear and driven gear from pump body (Fig. 199).

Fig. 199 Oil Pump Components

1 - PUMP SEAL
2 - PUMP BODY
3 - STATOR SHAFT
4 - SEAL RINGS
5 - GEAR
6 - O-RING

ASSEMBLY

(1) Measure inside diameter of pump body bushing with bore gauge or inside micrometer (Fig. 200).

Diameter should be maximum of 38.19 mm (1.5035 in.). Replace pump body if bushing I. D. is greater than specified.

(2) Measure inside diameter of stator shaft bushing (Fig. 200). Take measurements at front and rear of bushing. Diameter should be maximum of 21.58 mm (0.08496 in.) at front and 27.08 mm (1.0661 in.) at rear. Replace stator shaft if bushing diameter is greater than specified.

Fig. 200 Checking Pump/Stator Shaft Bushings

1 - BORE GAUGE
2 - PUMP BODY BUSHING
3 - BORE GAUGE
4 - STATOR SHAFT BUSHING

(3) Measure oil pump clearances (Fig. 201).

•  Clearance between pump driven gear and pump body should be maximum of 0.3 mm (0.012 in).
•  Clearance between tips of pump gear teeth should be maximum of 0.3 mm (0.012 in).
•  Clearance between rear surface of pump housing and pump gears should be maximum of 0.1 mm (0.004 in.).

(4) Replace pump body and gears if any clearance is greater than specified.

Fig. 201 Checking Pump Gear Clearances

(5) Install new seal with Seal Installer 7549 (Fig.

202).

Fig. 202 Installing Pump Seal

1 - SEAL INSTALLER TOOL
2 - PUMP SEAL

(6) Lubricate and install gears in pump body.

(7) Assemble stator shaft and pump body. Tighten shaft-to-body bolts to 10 N·m (7 ft. lbs.) torque.

(8) Install new O-ring on pump body and new seal rings on stator shaft.

(9) Install pump in torque converter and check pump gear rotation (Fig. 203). Gears must rotate smoothly when turned clockwise and counterclockwise.

(10) Lubricate pump O-ring and seal rings with petroleum jelly.

Fig. 203 Checking Pump Gear Rotation

1 - OIL PUMP
2 - TORQUE CONVERTER

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

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

1 - CLUTCH DRUM
2 - PLANETARY SHAFT

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

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 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

1 - CLUTCH DRUM
2 - THRUST BEARING AND RACE

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

1 - COMPRESSOR TOOL
2 - CLUTCH PISTON SNAP RING

Fig. 210 Removing Overdrive Clutch Piston

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

Fig. 211 Checking Piston Return Spring Length

1 - PISTON RETURN SPRINGS
2 - SPRING RETAINER

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

1 - CLUTCH DRUM

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

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

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

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

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

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

1 - THRUST WASHER
2 - PLANETARY GEAR

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

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

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

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

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

Fig. 226 Installing Overdrive Clutch Discs And Plates

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

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

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.

Overdrive support

DISASSEMBLY

(1) Check brake piston operation. Mount support on clutch (Fig. 229).

(2) Apply compressed air through support feed hole and observe brake piston movement (Fig. 229).

Piston should move smoothly and not bind or stick. If operation is incorrect, replace piston and support.

(3) Remove thrust bearing front race, thrust bearing and rear race (Fig. 230).

(4) Turn overdrive support over and remove bearing race and clutch drum thrust washer (Fig. 231).

(5) Compress piston return spring with Spring Compressor 7537 and remove piston snap ring (Fig.

232).

Fig. 229 Checking Brake Piston Movement

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

Fig. 230 Removing Support Thrust Bearing And Races

1 - THRUST BEARING
2 - FRONT RACE
3 - REAR RACE

Fig. 231 Removing Clutch Drum Thrust Washer And Race

1 - BEARING RACE
2 - OVERDRIVE SUPPORT
3 - THRUST WASHER

Fig. 232 Removing/Installing Piston Snap Ring

1 - COMPRESSOR TOOL
2 - SNAP RING

(6) Mount support in direct clutch and remove brake piston with compressed air. Apply air to same feed hole used when checking piston operation.

(7) Remove and discard support O-rings (Fig. 233).

(8) Remove support seal rings (Fig. 234).

(9) Measure free length of piston return springs with springs mounted in retainer (Fig. 235). Length should be 17.23 mm (0.678 in.).

(10) Clean support components and dry them with compressed air.

(11) Inspect overdrive support and brake piston.

Replace support and piston if either part is worn or damaged.

ASSEMBLY

(1) Lubricate new support seal rings. Then compress rings and install them on support (Fig. 236).

(2) Lubricate and install new O-rings on brake piston. Then carefully seat piston in support.

(3) Install return springs on brake piston.

(4) Compress return springs with Spring Compressor 7537 (Fig. 232) and install piston snap ring.

(5) Install support bearing race and clutch drum thrust washer (Fig. 231).

(6) Install thrust bearing and front and rear bearing races. Thrust bearing rollers should face upward as shown (Fig. 236).

(7) Verify thrust bearing/race sizes (Fig. 237).

•  Front race outer diameter is 47.8 mm (1.882 in.) and inside diameter is 30.7 mm (1.209 in.).
•  Rear race outer diameter is 47.8 mm (1.882 in.) and inside diameter is 34.3 mm (1.350 in.).
•  Bearing outer diameter is 47.7 mm (1.878 in.) and inside diameter is 32.7 mm (1.287 in.).

(8) Verify brake piston operation. Use same procedure described at beginning of disassembly. Piston should operate smoothly and not bind or stick.

Fig. 233 Overdrive Support Components

1- PISTON SNAP RING
2 - BRAKE PISTON
3 - FRONT RACE
4 - REAR RACE
5 - OVERDRIVE SUPPORT
6 - THRUST BEARING
7 - BEARING RACE
8 - CLUTCH DRUM THRUST WASHER
9 - SUPPORT SEAL RINGS
10 - BRAKE PISTON O-RINGS
11 - PISTON RETURN SPRING

Fig. 234 Removing Support Seal Rings

1 - SEAL RINGS (2)
2 - SUPPORT

Fig. 235 Checking Piston Return Spring Length

1 - PISTON RETURN SPRINGS
2 - SPRING RETAINER

Fig. 236 Installing Support Seal Rings

1 - COMPRESS SEAL RINGS BEFORE INSTALLATION
2 - OVERDRIVE SUPPORT

Fig. 237 Installing Support Thrust Bearing And Races

1 - REAR RACE
2 - THRUST BEARING
3 - FRONT RACE