Jeep 1996 Grand Cherokee Service Manual - page 1247
SHAFT END PLAY ADJUSTMENT
(1) Place overdrive unit in vertical position. Mount
it on blocks, or in workbench with appropriate size
mounting hole cut into it. Be sure unit is facing
upward for access to direct clutch hub. Also be sure
output shaft is not loaded and internal components
are moved rearward for accurate measurement.
(2) Determine
correct
thickness
intermediate
shaft spacer as follows:
(a) Insert Special Tool 6312 through sun gear,
planetary gear and into pilot bushing in output
shaft. Be sure tool bottoms against planetary
shoulder.
(b) Position Gauge Tool 6311 across face of over-
drive case (Fig. 310). Then position Dial Caliper
C-4962 over gauge tool.
(c) Extend sliding scale of dial caliper downward
through gauge tool slot until scale contacts end of
Gauge Alignment Tool 6312. Lock scale in place.
Remove dial caliper tool and note distance mea-
sured (Fig. 310).
(d) Select proper thickness end play spacer from
spacer chart based on distance measured (Fig.
311).
(e) Remove Gauge Alignment Tool 6312.
(3) Determine correct thickness overdrive piston
thrust plate as follows:
(a) Position Gauge Tool 6311 across face of over-
drive case. Then position Dial Caliper C-4962 over
gauge tool (Fig. 312).
(b) Measure distance to clutch hub thrust bear-
ing seat at four points 90° apart. Then average
measurements by adding them and dividing by 4.
(c) Select and install required thrust plate from
information in thrust plate chart (Fig. 313).
(4) Leave Alignment Tool 6227-2 in place. Tool will
keep planetary and clutch hub splines in alignment
until overdrive unit is ready for installation on trans-
mission.
(5) Transmission speed sensor can be installed at
this time if desired. However, it is recommended that
sensor not be installed until after overdrive unit is
secured to transmission.
Fig. 310 Shaft End Play Measurement
Fig. 311 Intermediate Shaft End Play Spacer
Selection
Fig. 312 Overdrive Piston Thrust Plate Measurement
Fig. 313 Overdrive Piston Thrust Plate Selection
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TRANSMISSION AND TRANSFER CASE
ZJ
DISASSEMBLY AND ASSEMBLY (Continued)