Jeep 1996 Grand Cherokee Service Manual - page 1212
(22) Coat intermediate shaft thrust washer with
petroleum jelly. Then install washer in rear clutch
hub (Fig. 171). Use enough petroleum jelly to hold
washer in place. Be sure grooved side of washer
faces rearward (toward output shaft) as shown.
Also note that washer only fits one way in
clutch hub. Note thickness of this washer. It is a
select fit part and is used to control transmission end
play.
(23) Align drive teeth on rear clutch discs with
small screwdriver (Fig. 172). This makes installation
on front planetary easier.
(24) Raise front end of transmission upward as far
as possible and support case with wood blocks. Front/
rear clutch and oil pump assemblies are easier to
install if transmission is as close to upright position
as possible.
(25) Install front and rear clutch units as assembly
(Fig. 173). Align rear clutch with front annulus gear
and install assembly in driving shell. Be sure out-
put shaft thrust washer and thrust plate are
not displaced during installation.
(26) Carefully work assembled clutches back and
forth to engage and seat rear clutch discs on front
annulus gear. Also be sure front clutch drive lugs are
fully engaged in slots of driving shell after installa-
tion.
(27) Slide front band over front clutch retainer
(Fig. 174).
(28) Insert front band lever pivot shaft part way
into case (Fig. 174).
(29) Install front band lever, strut and adjusting
screw (Fig. 175).
(30) Push front band lever shaft completely into
place. Then tighten band adjusting screw until band
just grips clutch retainer. Verify that front/rear
clutches are still seated before continuing.
(31) Coat band reaction pin access plug with sealer
and install plug in converter housing.
(32) Check seal rings on reaction shaft support
hub. Verify that seal rings are hooked together and
that front clutch thrust washer is properly positioned
(Fig. 176). Use extra petroleum jelly to hold thrust
washer in place if necessary.
CAUTION:
The thrust washer bore ID is chamfered
on one side. Make sure this side of the washer is
facing toward the front of the transmission.
Fig. 172 Aligning Rear Clutch Disc Lugs
Fig. 171 Installing Intermediate Shaft Thrust Washer
Fig. 173 Installing Front/Rear Clutch Assemblies
ZJ
TRANSMISSION AND TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)