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TJ
CLEANING AND INSPECTION (Continued)
Fig. 174 Retainer Bushing Location/Inspection
REAR CLUTCH
Clean the clutch components with solvent and dry
them with compressed air.
Check condition of the input shaft seal rings. It is
not necessary to remove or replace rings unless they
are broken, cracked, or no longer securely hooked
together.
Inspect the input shaft splines and machined sur-
faces. Very minor nicks or scratches can be smoothed
off with crocus cloth. replace the shaft if the splines
are damaged, or any of the machined surfaces are
severely scored.
Replace the clutch discs if warped, worn, scored,
burned/charred, the lugs are damaged, or if the fac-
ing is flaking off.
Replace the steel plates and the pressure plate if
heavily scored, warped, or broken. Be sure the driv-
ing lugs on the discs and plates are also in good con-
dition. The lugs must not be bent, cracked or
damaged in any way.
Replace the piston spring and wave spring if either
part is distorted, warped or broken.
Check the lug grooves in the clutch retainer. The
steel plates should slide freely in the slots. Replace
the retainer if the grooves are worn or damaged. Also
check action of the retainer check ball. The ball must
move freely and not stick.
Inspect the piston and retainer seal surfaces for
nicks or scratches. Minor scratches can be removed
with crocus cloth. However, replace the piston and/or
retainer if the seal surfaces are seriously damaged.
Check thrust washer condition. Washer thickness
should be 1.55 to 1.60 mm (0.061 to 0.063 in.).
Replace the washer if worn or damaged.
Check condition of the two seal rings on the input
shaft and the single seal ring on the piston retainer
hub. Replace the seal rings only if severely worn,
cracked, or cannot be hooked together.
TRANSMISSION AND TRANSFER CASE
PLANETARY GEARTRAIN/OUTPUT SHAFT
Clean the intermediate shaft and planetary compo-
nents in solvent and dry them with compressed air.
Do not spin the planetary pinion gears with com-
pressed air.
Inspect the planetary gear sets and annulus gears.
The planetary pinions, shafts, washers, and retaining
pins are serviceable. However, if a pinion carrier is
damaged, the entire planetary gear set must be
replaced as an assembly.
Replace the annulus gears if the teeth are chipped,
broken, or worn, or the gear is cracked. Replace the
planetary thrust plates and the tabbed thrust wash-
ers if cracked, scored or worn.
Inspect the machined surfaces of the output shaft.
Be sure the oil passages are open and clear. Replace
the shaft if scored, pitted, or damaged.
Inspect the sun gear and driving shell. If either
component is worn or damaged, remove the sun gear
rear retaining ring and separate the sun gear and
thrust plate from the driving shell. Then replace the
necessary component.
Replace the sun gear as an assembly if the gear
teeth are chipped or worn. Also replace the gear as
an assembly if the bushings are scored or worn. The
sun gear bushings are not serviceable. Replace the
thrust plate if worn, or severely scored. Replace the
driving shell if distorted, cracked, or damaged in any
way.
Replace all snap rings during geartrain assembly.
Reusing snap rings is not recommended.
ADJUSTMENTS
GEARSHIFT CABLE
Check adjustment by starting the engine in Park
and Neutral. Adjustment is OK if the engine starts
only in these positions. Adjustment is incorrect if the
engine starts in one but not both positions. If the
engine starts in any position other than Park or Neu-
tral, or if the engine will not start at all, the park/
neutral position switch may be faulty.
Gearshift Adjustment Procedure
(1) Shift transmission into Park.
(2) Raise vehicle.
(3) Release cable adjuster clamp (at transmission
end of cable) to unlock cable.
21 - 145
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