manual transmission JEEP CJ 1953 User Guide

'Jeep*
UNIVERSAL
SERIES
SERVICE
MANUAL
H
FIG.
H-59—HEAD LAMP

1—
Door

2—
Retaining
Screw

3—
Retaining
Ring

4—
Sealed
Beam
Unit
5—
Mounting
Ring

6—
Adjusting
Screw 7—
Housing

8—
Wires

9—
Door
Screw 310669
to cross the vertical
tapes
at the measured height
of each lamp center respectively.

g.
Remove the head lamp doors.
h.
Clean
the head lamps.

H-132.
Aiming Head Lamps

a.
Turn
the headlights on low beam. Cover the lamp not being aimed. Be sure to use the horizontal reference line on the screen that is the same dimen­
sion as the vehicle lamp height.
b.
Turn
the vertical aiming screw counterclock­
wise until the lamp beam is considerably lower

than
the horizontal reference line on the screen.
Then,
turn
the screw clockwise until the top
edge

of the high intensity
area
is even with the horizontal

line.
See Fig. H-60.
I
(T)

JT)

1'.'' | '':'
11460

FIG.
H-60—HEADLIGHT AIMING
CHART
1—
Vertical
Tape,
Left
Lamp
Center

2—
Vehicle
Centerline

3—
—Vertical
Tape,
Right
Lamp
Center
4—
Zone
of Greatest Intensity
5—
2
*
(Two Inches)
6— 25'0
'
7—
2
*
(Two Inches)
8—
Height
of
Lamp
Centers
9—
Horizontal
Tape

Note:
Always bring the beam into final position
by turning both aiming screws clockwise so that
the unit is held under proper tension when the operation is complete.

c. Turn
the horizontal aiming screw counterclock­
wise until the beam is off.
Then,
turn
the same
screw
clockwise until the
left
edge
of the high
intensity area is 2" [5,08 cm.] to the right of the
lamp center line. See Fig. H-60.

d.
Cover the lamp that has been aimed and aim
the other lamp using the same procedure.
e.
Carefully
reinstall the head lamp doors.

H-133.
Parking
and
Turn Signal Light
The
parking lights are mounted in the radiator

guard
panel just below the headlights. These lights

are
on only when the main switch control knob is
pulled
out to the first notch.

To
replace a parking lamp, remove two screws allowing the lens and colored reflector to be re­
moved. Replace the lamp, which is recessed back

in
the housing.

If
the
complete
parking light assembly is to be
removed for service or replacement, disconnect the

wire
plug at the back of the housing.
Then
remove
the nuts and lock washers securing the parking light assembly and remove out the front of the

panel.

H-134. Tail, Stop
and
Turn Signal Light

Refer
to Fig. H-57 and H-58.

The
tail
lights are mounted in the
rear
corner
posts

of the body. They are on whenever the main switch
control
knob is pulled out to any position.

a.
To replace a lamp, remove the snap ring on

early
models
and remove the lens; on late
models
remove lens screws, lens and gasket.
Clean
lens
and
reflector before replacing.
b. To remove the parking and
tail
light housing,
disconnect wiring, remove the two nuts and lock
washers securing
tail
light assembly to body and remove from
rear
of body.

H-135-
Backup Lights •
Refer to Fig. H-61.

The
backup lights on late production vehicles are located on the
rear
of the vehicle directly below
the
tail
light. The backup lights are actuated
through a switch when the ignition is on and the

transmission
is in reverse. 215

'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL

The
correct distance should be 10%"
[26,04
cm.].

If
the length of the clutch release pedal rod is
other than
10
W
[26,04
cm.], the vheicle is equipped with the early
type
Clutch
Control
Lever

and
Tube Assembly, which should be removed, and^trie latest
designed
parts should be installed.

The
free pedal clearance is adjusted by lengthening
or shortening the" clutch fork cable. To make this adjustment,
loosen
the jam nut on the cable clevis

and
lengthen or shorten the cable to obtain %"
[19,05
mm.] free travel at the pedal pad, then
tighten the jam unit.
•
Clutch
Control Cable Type

Refer
to Fig. 1-2.

a.
With the clutch pedal pad against the floor
panel, (pedal up, clutch
engaged)
adjust ball ad­
justing nut until slack is removed from the cable
and
the clutch throwout bearing contacts the clutch
pressure plate, release levers or diaphragm plate.
b. Back-off ball adjusting nut 2
V2
turns to obtain
approximately %"
[19,05
mm.] free travel.
Lock

hex nut.
FIG.

1-3—AUBURN
CLUTCH
ASSEMBLY —
HURRICANE F4 ENGINE 1—
Driven
Plate and Hub
2—
Pressure
Plate

3—
Pivot Pin
4—
Bracket
5—
Spring
Cup 6—
Pressure
Spring 7— Release
Lever

8—
Return
Spring
9—
Adjusting
Screw
10—
Jam
Nut 11—
Washer
Note:
Some older 'Jeep' vehicles may
develop
side

movement
of the clutch and brake pedals resulting
from wear of the pedals, shafts, and bushings. One way to
compensate
for this wear is to install a pedal

slack
adjuster kit 1-4.
CLUTCH
—
HURRICANE
F4
ENGINE
•
Auburn
Vehicles equipped with the Hurricane F4
engine

have a 9.25" [23,4 cm.] driven plate. The auburn clutch driving (pressure) plate assembly (Fig. 1-3)
has three pressure springs and three levers or
fingers.
1-5.
Clutch
Removal

When
necessary to remove the clutch,
follow
the procedures outlined in Section J for the removal
of the transmission and transfer case from the vehicle. Then remove the flywheel housing and use
the following procedures for removing the clutch assembly.

Note:
The F4
engine
may be removed from the
vehicle when inspecting or replacing the clutch.
Refer
to Section D for Hurricane F4
engine
re­moval and then
follow
the instructions given
below

to remove the clutch assembly.

a.
Mark
the clutch pressure plate and
engine
fly­
wheel with a center punch so the clutch assembly
may be installed in the same position after adjust­

ments
or replacement are completed.
b. Remove the clutch pressure plate bracket
bolts

equally, a little at a time, to prevent distortion and
to relieve the clutch springs evenly.
c. Remove the pressure plate assembly and driven
plate from the flywheel.
1-6.
Clutch
Pressure Plate and Disc Inspection
Inspect the pressure plate face for
cracks,
chips,

and
warpage.
Check
the pressure plate levers for
excessive
wear and the springs for breaks. If any of the
above
conditions exist, the
complete
pressure
plate must be replaced.
Check
the clutch disc for

excessive
wear,
loose
or damaged facings, broken
vibration damper springs and evidence of grease
or oil. If any of the
above
conditions exist, replace
the clutch disc.
1-7.
Clutch
Pressure Plate Adjustment —
Auburn
The
clutch pressure plate must be checked
before
installing a new or reconditioned clutch. The proper 11339

FIG.
1-4—CHECKING
AUBURN
CLUTCH
LEVER
ADJUSTMENT
1— Adjustment Gauge
2—
Fixture
Mounting Bolt

3—
Clutch
Fixture
227

'Jeep'
UNIVERSAL
SERIES SERVICE
MANUAL

I
Note:
The clutch release bearing is lubricated at
time of assembly and no attempt should be made
to lubricate it Refer to Fig. 1-23 when lubricating
the clutch throwout bearing collar. c. Reassembly

To
assemble the clutch to the flywheel, first put
a
small amount of light cup grease in the flywheel
pilot bushing, install the driven plate, with short
end of hub toward the flywheel, then place the pressure plate assembly in position.
With
a clutch
plate aligning arbor or a spare transmission main
shaft, align the driven plate splines leaving the
arbor
in position while tightening the pressure plate
screws evenly.
Next, assemble the flywheel housing to the
engine
and
reinstall the transmission and transfer case or
install
the
engine
in the vehicle, depending on the
procedure of removal. Make sure that the clutch
release bearing
carrier
return spring is hooked in place. For the remainder of the assembly reverse
the operations that were used in removing the
transmission and transfer case or the
engine
referring
to the instructions given in Section J for the transmission and Section D and Dl for the
engine.

d.
Adjust the clutch control cable so there is 3A" [19,05 mm.] free pedal travel. (Refer to Par. 1-3)

1-10.
CLUTCH
—
DAUNTLESS
V-6
ENGINE
•
Diaphragm Spring Type
(Early
Models)

*
Jeep' vehicles equipped with a Dauntless V-6 en­
gine
use a 10.4" [26,4 cm.] single-plate, dry-disc

clutch,
incorporating a diaphragm-type spring as­
sembly.

When
the clutch pedal is depressed, it
moves
the
clutch
fork in the direction shown in Fig. 1-8. The

clutch
fork, pivoting on a
ball
stud, acts upon the
throwout bearing. The bearing then forces the
prongs of the diaphragm spring in the direction shown in
Fig.
1-8. The diaphragm spring is mounted
so that it pivots on its retaining rings.
This
reverses
the direction of force.
Force
is applied directly to
the three retracting springs which then
move
the
pressure plate
rearward,
away from the driven plate.

The
clutch driven plate assembly slides freely on
the transmission main drive gear splined shaft. It is keyed to the gear shaft by ten splines. The
front end of the main drive gear shaft is piloted by a bushing pressed into a recess in the
rear
end
of the
engine
crankshaft. See Fig. 1-8.

The
outer area of the driven plate is divided into

segments
formed in low waves to provide springs

between
the plate facings and cushion
engagement

of the clutch. A molded facing is riveted to each
side of every
segment.
When the clutch is fully
released, the waved
segments
cause the facings to

spread
approximately .045" [1,14 mm.]. Pressure
plate movement provides an additional clearance
of approximately .030" [0.76 mm.] to assure
full
release of the driven plate. See Fig. 1-8.

The
driven plate assembly is designed to prevent
torsional fluctuation of the
engine
from being
transmitted to the transmission gears. Its hub is
FIG.
1-8—CLUTCH
RELEASE
ACTION

1—
Pressure
Plate 5—Engine
Crankshaft

2—
Throwout
Bearing
6—Pilot
Bearing

3—
Pivot
Point
7—Flywheel

4—
Clutch
Fork
8—Driven
Plate
driven
through torsional coil springs; additional

frictional
dampening is supplied by molded
fric-

tional washers.

1-11.
Clutch
Removal

a.
Remove transmission as described in Section J. b. Remove clutch throwout bearing and pedal re­

turn
spring from clutch fork.
c. Remove flvwheel housing from engine.
d.
Disconnect clutch fork from
ball
stud by forc­
ing it toward the center of the vehicle.
e.
Mark
clutch cover and flywheel with a center

punch
so that cover can later be installed in the same position on the flywheel.
This
is necessary to

maintain
engine
balance.
f. Loosen the clutch attaching
bolts
alternately,
one
turn
at a time, to avoid distorting the clutch
cover flange, until diaphragm spring is released.
g. Support the pressure plate and cover assembly
while removing last bolts; remove pressure plate
and
driven plate from flywheel.

Caution:
Use extreme care to keep clutch driven plate clean.

h.
If it is necessary to disassemble pressure plate,
remove three drive strap-to-pressure plate
bolts
and
retracting springs. Remove pressure plate from

clutch
cover.

Note:
When disassembling,
note
position of
grooves

on
edge
of pressure plate and cover. These marks must be aligned in assembly to maintain balance.

i.
The clutch diaphragm spring and two pivot rings

are
riveted to the clutch cover. Inspect spring, rings

and
cover for excessive wear or damage. If there
is a
defect,
replace the complete cover assembly.

1-12.
Clutch
inspection

Wash
all metal parts of clutch, except release bear­
ing and driven plate, in suitable cleaning solution to remove
dirt
and grease. If solvent
seeps
into

bearing,
lubricant may be dissolved. Cleaning sol­
vent
will
also damage the facings of driven plate,
a.
Inspect friction surfaces of flywheel and pres­

sure
plate for scoring or roughness. Slight roughness
may be smoothed with fine emery cloth. If surface 229

'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL

I thickness: .285"
[0,724
cm.], .305"
[0,775
cm.].

Each
spacer should be hardened and ground to size, and then have the dimensional thickness
stamped thereon.

c.
From
flat bar stock at least Vfe" [3 mm.] thick,
make a
gauge
as shown in Fig. 1-22. Harden, grind
to size, and stamp sizes on the
gauge.

1-27.
Clutch Installation

a.
Very
sparingly, apply wheel bearing lubricant
to inner surface of pilot bushing in crankshaft.

Caution:
If
excessive
lubricant is applied to pilot bushing, it
will
run out on face of flywheel when
hot and
ruin
the driven plate facings.
b. Make sure that splines in the driven plate hub
are
clean; apply a light coat of lubricant to splines
of hub and transmission drive gear shaft. Slide plate over gear shaft several times; remove plate
from shaft and wipe off
excess
lubricant.

Caution:
Driven plate facings must be kept clean

and
dry.

c.
Fill
groove
in throwout bearing collar with wheel bearing lubricant. See Fig. 1-23. Make sure
that front bearing retainer of transmission is clean;
apply a light coat of wheel bearing lubricant. Slide
throwout bearing over bearing retainer several times. Remove bearing from retainer and wipe off

excess
lubricant.

12736
FIG.
1-23—LUBRICATION
POINTS
—

CLUTCH
THROWOUT
BEARING
COLLAR

1—Coat
This
Groove 2—Pack
This
Recess
d.
Clean
and apply wheel bearing lubricant to ball
stud in flywheel housing and to the
seat
in clutch

fork.

e.
If disassembled, install pressure plate in the cover assembly, lining up the
groove
on its
edge

with the
groove
on the
edge
of the cover.
Install

pressure plate retracting springs, and the three
drive
strap-to-pressure plate
bolts
and lock washers.

Torque
bolts
11 lb-ft. [1,51 kg-m.].

Note:
The diaphragm
type
clutch assembly is fac­
tory calibrated and requires no adjustment
before
installation. Refer to Par. 1-14 to adjust Borg and

Beck
coil spring
type
clutch assembly.
f.
Install
the pressure plate and driven plate on
flywheel. Support both assemblies with a spare
main
drive gear.

Note:
Be certain that
mark
on clutch cover is
aligned with the
mark
made on the flywheel during
clutch removal.
g.
Install
clutch attaching
bolts
and tighten alter­ nately so that clutch is drawn squarely
into
position
on flywheel.
Each
bolt
must be
tightened
one turn at a time to avoid bending the clutch cover flange.

Torque
bolts
30 to 40 lb-ft. [4,1 a 5,5 kg-m.].

h.
Lubricate
the ball stud and clutch fork with
wheel bearing lubricant and install clutch fork.

Note:
Be certain that fork retaining spring is
tight

on pivot ball stud.

i.
Install
flywheel housing on
engine
cylinder
block.

Caution:
Be certain that dowel pins are installed

in
cylinder block.

j.
Lubricate
the recess on the inside of the throw-
out bearing collar. Be careful not to use too much
lubricant.
See Fig. 1-23.

Caution:
Make certain that the lips of the spring
retainer (attached to the clutch fork) are in
groove
of the bearing. See Fig. 1-24.
k.
Install
throwout bearing assembly and connect
clutch linkage.
I.
Install
transmission as described in Section J. m. Adjust clutch for %"
[19,05
mm.] free travel,
see
Par.
1-3. 235

'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL

I
1-28.
SERVICE
DIAGNOSIS

SYMPTOMS
PROBABLE
REMEDY

Slipping:
Improper Pedal Adjustment Adjust Pedal Free
Travel

Weak Pressure Springs Replace
Lining
Oil Soaked Install New Driven Plate
Worn
Linings or
Torn
Loose from Plate Install New Driven Plate
Burned Clutch Replace

Grabbing
or
Chattering:
Gummy or Worn Linings Install New Driven Plate
Loose Engine
Mountings
Tighten Scored or Broken Pressure Plate Install New Pressure Plate
Improper Clutch Finger Adjustment............ Readjust

Clutch
Plate Crimp or Cushion Flattened Out.... Replace Driven Plate
Dragging: Too Much Pedal Play. Adjust Improper Finger Adjustment. Readjust
Pressure Plate Binds in Bracket Adjust
Warped Pressure or Driven Plate Replace
Torn
or Loose Clutch Facing. Replace

Rattling:
Broken or Weak Return Springs in Driven Plate.. Replace

Worn
Throwout Bearing Replace
Fingers Improperly Adjusted Readjust

Worn
Driven Plate Hub of Transmission Main Gear Shaft.............. Replace
Pilot Bushings in Flywheel Worn.
.............
Replace
Pilot Bushing in Crankshaft Worn Replace
1-29.
CLUTCH
SPECIFICATIONS

ENGINE
HURRICANE
F4
DAUNTLESS
V-6

DAUNTLESS
V-6

EARLY
MODELS
LATE
MODELS

Pressure Plate;
Auburn
G.M.

Borg and Beck
Type
Single
Dry Plate
Single
Plate, Dry Disc.

Single
Plate, Dry Disc.
No. of Springs 3 Diaphragm Type

Coil
Spring Type (9)

Total
Plate Pressure 1150 lb.
[521,6
kg.]
1600 lb. [725 kg.] 1765 lb. [800 kg.]
Driven Plate Make
Auburn
or Borg & Beck
G.M.

Borg and Beck
Facings Woven
Asbestos
Woven
Asbestos

Woven
Asbestos

Diameter 9.25" [23,4 cm.] 10.4" [26,4 cm.]
10.4" [26,4 cm.]
Thickness .125" [3,17 mm.] .135" [3,38 mm.]
.135" [3,38 mm.]
Torque Capacity 216 lb-ft.
[29,87
kg-m.]
246 lb-ft.
[34.01
kg-m.]

250 lb-ft.
[34,57
kg-m]

Clutch
Release Bearing: Sealed
Ball
Bearing

.
Type Sealed
Ball
Bearing Sealed
Ball
Bearing Sealed
Ball
Bearing

.
Type
Prelubricated Prelubricated
Prelubricated

Clutch
Pilot Bushing:
In
Crankshaft

In
Flywheel
In
Crankshaft
In
Crankshaft

Material
Bronze Bronze
Bronze
Size.
I.D.
.628" [15,9 mm.]
I.D.
.592"
[18,05
mm.]

I.D.
.592"
[18,05
mm.]

Clutch
Pedal Adjustment. .. W
[19,05
mm.]
%n
[19,05
mm.]

%n
[19,05
mm.]
1-30.
CLUTCH
ADJUSTING
FIXTURE
DATA

Manufacturer Disc Diameter Spacer Thickness Gauge Length

Auburn
9j£"
[23,4 cm.]
10.4" [26,4 cm.] .285"
.305"

0,723
cm.]

0,774
cm.]
mtf
[4,9 cm.]
2.0" [5,08 cm.]

9j£"
[23,4 cm.]
10.4" [26,4 cm.] .285"
.305"

0,723
cm.]

0,774
cm.]
mtf
[4,9 cm.]
2.0" [5,08 cm.]

'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL

J
THREE-SPEED
TRANSMISSION

Contents

SUBJECT
PAR.

GENERAL
J-l
TRANSMISSION
SHIFTING
CONTROL.
. J-2
TRANSMISSION
REMOTE
CONTROL
ADJUSTMENT
J-3

REMOTE
CONTROL
DISASSEMBLY
J-4

REMOTE
CONTROL
REASSEMBLY.
. . . . J-5
TRANSMISSION
REMOVAL
J-6

SEPARATING
TRANSMISSION
AND
TRANSFER
CASE
J-7
SUBJECT
PAR.

DISASSEMBLY
OF
CANE
SHIFT
TRANSMISSION
J-8, J-12, J-16
Transmission
Cleaning and
Inspection J-10, J-18

Transmission
Interlocking Sleeve Inspection J-9

REASSEMBLY
OF
CANE
SHIFT
TRANSMISSION
J-ll,
J-14, J-19

SERVICE
DIAGNOSIS
J-20

TRANSMISSION
SPECIFICATIONS
J-21
J-1.
GENERAL
A
three speed synchromesh transmission is standard
equipment on all 'Jeep' Universal vehicles.
The
models T90 and T96 transmissions are used

with
the
Hurricane
F4 engine, and models
T86AA
and
T14A transmissions are used with the Daunt­
less
V-6 engine. All model transmissions are similar

in
design with exception of the T14A which is a

fully
synchronized (all forward gears) transmission

with
helical drive gears throughout.
The
transmission assembly is attached to the
rear

face of the flywheel bell housing and is supported on a rubber insulator at the frame center cross member which forms the
rear
engine
support.

All
4-wheel-drive vehicles are equipped with a
transfer
case attached to the
rear
of the trans­mission.
Transfer
case service and repair procedures

are
described in Section
K.

Models
CJ-5A,
and
CJ-6A
are equipped with the
same transmission, but with a remote control shift.
Models DJ-5 and DJ-6 are equipped with a similar

transmission,
however, the construction is
some­
what different because it is not designed to receive a transfer case for four-wheel drive.

For
DJ-5 and DJ-6 2WD vehicles, the trans­ mission repair procedures begin with Par. J-12.
J-2.
TRANSMISSION SHIFTING CONTROL
The
shift of the three-speed transmission is smooth

and
positive. The cane control lever shifts the trans­
mission gears direct from the shift control housing
mounted to the top side of the transmission housing.

The
remote control lever shifts the transmission
gears through remote control rods attached to the

adjusting
levers of the shift shafts protruding from the left side of the transmission housing. Poppet
balls and springs retain the transmission gears in mesh and an interlocking mechanism prevents
shifting into two gears at the same time.
J-3.
Transmission Remote Control Adjustment
•
Early
CJ-5A,
CJ-6A

First
disconnect the transmission shift rods from the remote control levers.
Check
for binding of
the remote control shaft on the steering column

and
make the necessary corrections to eliminate any binding condition.

If
the shift is not smooth and positive, first make

sure
the gears are in neutral position then remove
the shift rods at the transmission by removing
clevis pins, Fig. J-l No. 17, and slip a short piece
of snug fitting 34" [6,35 mm.] aligning rod, through
the gearshift levers and housing as shown in insert
drawing.

This
places the clutch and shift lever assemblies

in
the neutral position. Adjust the shift rod yokes
at the transmission end, so clevis pins can be in­ stalled freely without moving the shift levers on the
transmission after which remove alignment pin.
If
shifting from first to second is difficult or trans­
mission hangs in first gear, shorten the low and
reverse shift rod one
turn
at a time until the con­
dition is corrected. Usually three turns are re­

quired.

Should
the fault continue after completing the above adjustment, check further as outlined below.

First
remove the lubricating fitting. Use a narrow
feeler
gauge
which
will
enter the opening for the
lubricator
and check the clearance
between
the
faces of the shifting clutches.
This
clearance should
be .015" to .031", [W to W]
[0,397-0,794
mm.]. If
this clearance is greater the assembly must be removed for adjustment. The shift dog, which

engages
the clutch slots, should not have more than .009" [0,229 mm.] clearance in the slots. If the clear­
ance
between
the clutch
grooves
and cross pins is
too great,
these
parts must be replaced.
J-4.
Removal
of
Remote Control
m
Early
CJ-5A,
CJ-6A

•
Refer to Fig. J-l

To
remove the remote control the following pro­ cedure is
suggested:

a.
Remove shifting rods from the transmission

and
also from the steering remote control clutch levers. 239

'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL

J

10489

FIG.
J-2—THREE-SPEED
TRANSMISSION
— T90 1—
Main
Drive
Gear

2—
Main
Drive
Gear
Bearing
Retainer

3—
Main
Drive
Gear
Bearing
Retainer Oil
Seal
4—
Main
Drive
Gear
Snap
Ring

5—
Main
Drive
Gear
Bearing
Snap
Ring

6—
Main
Drive
Gear
Bearing
7—
Synchronizer
Shifting Plate
8—
Shift
Rail
Cap
9—
Shift
Rail—High
and Intermediate
10—
Shift
Rail
Poppet
Ball

11—
Shift
Rail
Poppet
Spring

12—
Shift
Fork—High
and Intermediate

13—
Control
Housing
14—
Control
Lever
Support
Spring

15—
Control
Lever
Housing Pin
16—
Control
Lever
Fulcrum
Ball

17—
Gear
Shift
Lever
18—
Shift
Fork—Low
and Reverse

19—
Sliding
Gear—Low
and Reverse
20—
Main
Shaft
Bearing
Adapter

21—
Main
Shaft
Bearing
22—
Main
Shaft
Washer

23—
Main
Shaft Nut
24—
Main
Shaft

25—
Idler
and Countershaft
Lock
Plate
26—
^Countershaft
Gear
Bearing
Rollers

2
7—Countershaft

28—
Countershaft
Thrust
Washer
Rear—Steel

29—
Countershaft
Thrust
Washer
Rear—Bronze

30—
Countershaft
Gears
31—
Transmission
Case

32—
Main
Shaft Second Speed
Gear
33—
Countershaft
Bearing
Spacer
34—
Synchronizer
Blocking
Ring

35—
Countershaft
Thrust
Washer
Front—Bronze

36—
Countershaft
Bearing
Washer

37—
Intermediate
and High Speed
Clutch
Sleeve

38—
Intermediate
and High
Clutch
Hub

39—
Synchronizer
Spring

40—
Intermediate
and High
Clutch
Hub
Snap
Ring

41—
Main
Shaft Pilot
Bearing
Roller

CJ-5A,
CJ-6A
models, remove the remote control

rods.

d.
Remove the set screw from the transfer case
shift lever pivot pin. Remove the pivot pin, shift

levers,
and shift lever springs. On models
CJ-5A,
and
CJ-6A
remove pivot pin cotter key and the

adjusting
rod attaching nut to remove shift lever.
See
Fig.
J-l.

e. If the vehicle is equipped with power take-off,
remove the shift lever plate screws and lift out the

lever.

f. Disconnect the front and
rear
propeller shafts
from
the transfer case, following the procedure de­

tailed
in Section
L.
Should the vehicle be equipped

with
power take-off, disconnect the transfer case end of the power take-off drive shaft.
g. Disconnect the
speedometer
cable at the transfer case.

h.
Disconnect the hand brake cable.
i.
Disconnect the clutch release cable at beilcrank
yoke end.
j.
Place
jacks
under the transmission and engine,
protecting the
engine
oil pan with a block of wood,
k.
Remove the nuts holding
rear
mounting to

frame
cross member.

I.
Remove the transfer case snubbing rubber bolt
nut at cross member.

m.
Remove
bolts
holding frame center cross mem­

ber
to frame side
rail
and remove cross member,
n.
Remove
bolts
holding transmission to flywheel
bellhousing.
o.
Force
transmission to right to
disengage
clutch
control
lever tube
ball
joint.

p.
Lower
jacks
under
engine
and transmission.

Slide
transmission and transfer case assemblies

toward
rear
of vehicle until the clutch shaft clears the flywheel housing.
q.
Lower
jack
under transmission. Remove trans­ mission and transfer case as an assembly from

under
the vehicle.

r.
For separation of the transmission and transfer
case, refer to Par. J-7. 241

'Jeep*
UNIVERSAL
SERIES'
SERVICE
MANUAL

lightly
on the end of the
mainshaft
to
loosen
the

gear
and
separate
the two
units.

J-8.
Disassembly
—
T90,
T86AA
®
Refer to Fig. J-5, J-7
a. If the transfer
case
is
attached,
separate
it from
the
transmission
as
outlined
in Par. J-7. b.
Remove
the
shift
housing
and
gasket
from the
top of the
transmission
case.
The
shift
housing
can
be
disassembled,
if
necessary,
at
this
point
by re­
moving
the
shift
rails and forks from the
shift

housing.
Use care not to
lose
the
poppet
balls
and
springs.

Note;
On
CJ-5
A
and
C
J-6A
models
equipped
with
side-shift
remote-control
transmission
it is
neces­

sary to
remove
the main drive
gear
before
the
shift

forks can be
removed.

e.
Remove
the
three
screws
and
washers
attaching
the
front
main drive
gear
bearing
retainer to the
transmission.
Remove
the retainer and
gasket,

d.
Remove
the two
socket-head
screws
from the
front
end of the
transmission
case.
These
screws

support
the oil
collector
inside
the
case.

Note:
The oil
collector
has
been
discontinued
in

late
production
transmission
assemblies.
11881

FIG.
J-6—MAIN
SHAFT
RETAINING
PLATE

13321

FIG.
J-7—T86AA
THREE-SPEED
TRANSMISSION
—
CANE
SHIFT

1—
Bearing
Retainer Screws
2—
Main
Drive Gear Bearing Retainer
3—
Bearing
Retainer Oil Seal

,
4—Bearing Snap Ring
5—
Main
Drive Gear Snap Ring 6—
Main
Drive Gear Bearing 7—
Front
Bearing Oil Retaining Washer
8—
Main
Drive Gear
9— Pilot Roller Bearing
10— Shift
Rail
Cap
11—
Poppet
Ball

12—
Poppet
Spring
13—
Lock
Washer
14— Shift Housing Bolt
15—
Control
Housing 16— Interlock Plunger
17— Shift Lever Spring
18— Shift Tower Gasket
19— Blocking Ring 20—
Clutch
Hub Snap Ring
21— Synchronizer Spring
22— Synchronizer Plate
23—
Clutch
Hub
24—
Clutch
Sleeve

25— High and Intermediate Clutch
Fork

26— Shift
Fork
Pin
27— High and Intermediate Shift
Rail

28— Second Speed Gear 29—
Main
Shaft
30—
Low
and Reverse Sliding Gear
31—
Low
and Reverse Shift
Fork

32—
Low
and Reverse Shift
Rail
33—
Bearing
Spacer
34—
—Rear
Bearing Adapter
35—Rear
Bearing 36—
Rear
Bearing Snap Ring
37— Nut
38—Washer 39—
Transfer
Case Drive Gear
40—Lock
Plate
41 —Countershaft
42—
Rear
Countershaft Thrust Washer
(steel)

43—
Rear
Countershaft Thrust Washer (bronze)
44— Countershaft Bearing Washer
45— Countershaft Bearing 46— Countershaft Center Bearing Spacer
47— Reverse Idler Gear Shaft
48— Reverse Idler Gear Bearing Washer
49— Reverse Idler Gear Roller Bearings 50— Reverse Idler Gear
51— Countershaft Gear 52— Countershaft Front Thrust Washer
53— Plug 54— Shift Lever
55—
Transmission
Case
56— Retainer Gasket 245

'Jeep*
UNIVERSAL
SERIES SERVICE
MANUAL

J
control
levers and remove arms. Remove the shift
levers and then remove the
sleeve,
poppet
balls,

spring,
and interlock pin.
Check
the oil seal care­
fully
for oil leakage and replace if necessary,
b.
If it is evident that a minimum clearance of .001" to .007" [0,025 a 0,178 mm.] cannot be
obtained
between
the end of the interlock
sleeve
and
the shift levers, even though the
longest
sleeve

has been installed, replace the existing
sleeve
with

an
Interlock Sleeve Service Kit.
When
assembling the interlock
sleeve
be sure that
the shift lever
poppet
spring works freely inside the

interlock
sleeve
and that the interlock pin is not
omitted from inside the spring.
If
the notched surfaces of the shifting lever are

dirty
or rough, they should be cleaned and
smoothed. If notched surfaces are scored or dam­
aged, the lever should be replaced.

Each
time an interlock
sleeve
or shift lever is
replaced,
check the clearance
between
the inter­

lock
sleeve
and the shift lever.
J-10.
Transmission
Inspection

a.
Wash the transmission case thoroughly inside
and
outside with cleaning solvent.

b.
Check
bearing and shaft bores. Inspect the case
for
cracks.
Check
the front and
rear
faces and dress
off any
burrs
with a fine
mill
file. If
cracks
are found

or
the bores are not true, replace the case.

c.
Clean
and inspect all gears and bronze blocking
rings for
cracks,
chipped or cracked teeth, or ex­cessive wear of the teeth.

d.
Inspect all bushings and bearings for wear or damage.
e.
Check
first and reverse sliding gear for freedom of movement on the mainshaft.

f.
Check
the clutch
sleeve
to see that it slides freely on the hub.

g.
Check
the condition of the bearing retainer oil

seal.

J-11.
Transmission
Reassembly
—
T90,
T86AA

•
Refer to Fig. J-5, J-7
Assemble the unit in the reverse order of disas­
sembly, noting the following points:

a.
Oil circulation is provided
between
the trans­ mission and transfer case by the addition of drilled
passages
between
the two units. The
rear
face of
the transmission case is drilled with two %" 11,11 mm],
holes
and two [6,35 mm.] holes.

The
front face of the transfer case is drilled with
two %"
[11,11
mm.]
holes
to register with
those

drilled
in the transmission case. When making re­
placement of either unit or case, it is important that
mating parts be installed, that is, if a transmission
case is drilled use a drilled transfer case. It is im­
portant that the correct gasket, having
openings
for
oil
passage, be used with the drilled cases.

b.
Position the reverse idler gear in the case and

install
the shaft using care that the slot at the shaft end is correctly aligned to receive the lock plate.
c. Assemble the spacer, six washers, and four countershaft
needle
bearings in the countershaft
gear hub, using special tool W-166 with loading

sleeve,
as shown in Fig. J-9 and J-10. Place the

spacer
inside the hub and insert the special tool in
the spacer. Place a washer at each end of the spacer

and
load a set of bearing rollers at each end.
Then

add
a washer, a set of bearing rollers, and finally
another washer at each end to complete the as­ sembly. Place the countershaft gear assembly in
the case but do not install the countershaft until
the mainshaft and main drive gear are installed.

d.
When assembling the mainshaft gears, the low

and
reverse sliding gear is installed with the shift
shoe
groove
toward the front of the transmission.
e. The sequence of assembly of the synchronizer

unit
is shown in Fig. J-4.
First
install the two springs in the high and intermediate clutch hub

with
the spring tension opposed. Place the right lipped end of one spring in a slot of the hub and
place the spring in the hub.
Turn
the hub around
and
make exactly the same installation with the other spring, starting with the same slot. In­

stall
the three synchronizer shifting plates in the
three
slots
in the hub with the smooth side of the
plates out. Hold the plates in position and slip the second and direct speed clutch
sleeve
over the hub

with
the long beveled
edge
toward the long part
of the clutch hub.
Install
the two blocking rings
one on each side of the hub.
Install
the completed
assembly on the mainshaft with the beveled
edge

of the clutch
sleeve
toward the front end of the
shaft.

f.
Install
main drive gear bearing
onto
the main
drive
gear shaft, using tool
KF-128A.

g.
When installing the mainshaft, use care that the
needle
bearing rollers in the main drive gear
are
correctly positioned. Use heavy grease to hold
them in position for assembly.

h.
The countershaft gear set, when assembled in
the case, should have .012" to .018" [0,305 a
0,457
mm.] end play.
This
clearance is obtained by selective thickness of the
rear
steel thrust washer

which
is available in .0555" and .0625"
[1,410
a 1,587 mm.] thickness.

After
installation of the front and
rear
bearing

retainers
on the mainshaft,
turn
the transmission over to allow the gears to mesh and also to permit alignment and installation of the countershaft.

i.
To install the countershaft gear set in the
case, first install the large bronze thrust washer
at the front of the case with the lip of the washer
entered in the slot of the case. Use heavy grease to hold this washer in position. Next, install the steel thrust washer at the
rear
of the case.
Start

the countershaft into the case just enough to hold
this washer in place. Align the slot in the counter­ shaft with the slot in the reverse idler gear shaft
to permit installation of the lock plate. Be sure the

thrust
washers are correctly positioned.
Then

position the bronze-faced washer against the
rear
end of the gear and place the gear in its running
position.
Tap
the countershaft through the counter­shaft gear set and the case, forcing out the special
tool W-166.

j.
Attach the transfer case to the transmission 247

'Jeep*
UNIVERSAL
SERIES SERVICE
MANUAL

reverse sliding gear on the shaft with the shifting

fork
groove
toward the rear.
e. Assemble the
second
speed
gear on the shaft
with the
teeth
which
engage
in the clutch
sleeve

toward the front of the case.
f.
Next,
assemble
the synchronizer unit. The as­ sembly
sequence
of the synchronizer is shown in

Fig.
J-12.
First
install the two springs in the high
and intermediate clutch hub. These springs must
be installed with the spring
tension
opposed.
Place the right lipped end of a spring in a
slot
of the
hub and place the spring in the hub.
Turn
the hub
around and make exactly the same installation
with the other spring starting with the same
slot.
Fig.
J-5. Install the three synchronized shifting

plates
in the three
slots
in the hub with the
smooth

side
of the
plates
out. Hold the
plates
in
position

and slip the
second
and direct
speed
clutch
sleeve
over the hub. Install the two blocking rings one
one each
side
of the hub.
g. Place
some
heavy
grease
in the main shaft
pilot and
position
the thirteen
needle
type
roller bearings.

h.
Install the main drive gear. If the bearing has

been
removed,
note
that the closed
side
is assembled
toward the inside of the case.

i.
Enter
the main shaft bearing in the case and

assemble
the shaft in position.

j.
Install the front bearing retainer. k. For
ease
in installing the countershaft, turn the
transmission case over to allow the gears to mesh.

With
the countershaft thrust washers correctly
positioned,
start the countershaft through the rear
of the case with the lock plate
slot
toward the rear
and the
slot
in alignment with the
slot
in the
12879

FIG.
J-13—T14A
THREE-SPEED
TRANSMISSION

1—
Retainer
Screws
2—
Main
Drive
Gear
Bearing Retainer
3—
Retainer
Gasket
4—
Oil
Seal 5— Snap Ring (small)
6— Snap Ring (large) 7—
Main
Drive
Gear
Bearing
8—
Oil
Retaining Washer (slinger)
9—
Main
Drive
Gear

10— Mainshaft Pilot Bearing Rollers
11—
Case

12— Nut
13—
Flatwasher

14— Spacer 15—
Bearing
Adapter
16— Snap Ring

17—
Mainshaft Bearing
18— Reverse
Gear

19— Snap Ring
20—
Low
Synchronizer Assembly 21— Synchronizer Blocking Ring 22—
Low
Gear

23— Mainshaft
24— Second
Gear

25— Synchronizer Blocking Ring
26—
Second-Third
Synchronizer Assembly
27— Synchronizer Blocking Ring
28— Snap Ring 29— Countershaft Front Thrust Washer (large)
30— Countershaft
Gear

31— Reverse Idler
Gear
Bearing Washer
32— Reverse Idler
Gear
Roller Bearings 33— Reverse Idler
Gear
34— Countershaft
Rear
Thrust Washer (small)
35— Countershaft Bearing Spacer Washer* 36— Reverse Idler Shaft
37— Countershaft Roller Bearings
38— Spacer Washer
39— Countershaft
40—
Lockplate

249