JEEP XJ 1995 Service And Repair Manual

(11) Remove lock ball spring with pencil magnet
(Fig. 10).
(12) Remove shift head lock ball with pencil mag-
net (Fig. 11).
(13) Remove adapter housing bolts (Fig. 12).
Fig. 10 Removing/Installing Lock Ball Spring
Fig. 11 Removing/Installing Shift Head Lock Ball
Fig. 12 Adapter Housing Bolt Locations
JAX 15 MANUAL TRANSMISSION 21 - 39

(14) Loosen adapter/extension housing with rubber
mallet (Fig. 13).
(15) Remove housing after loosening it (Fig. 14)
(16) Remove adapter housing oil seal with a pry
tool (Fig. 15).GEAR CASE REMOVAL
(1) Remove bearing retainer bolts and remove re-
tainer (Fig. 16).
(2) Remove retainer oil seal with pry tool (Fig. 17).
(3) Remove input shaft bearing snap ring (Fig. 18).
Fig. 15 Removing Adapter Housing Seal
Fig. 13 Loosening Adapter Housing
Fig. 14 Adapter Housing Removal
Fig. 16 Front Bearing Retainer Removal
Fig. 17 Front Bearing Retainer Seal Location
Fig. 18 Removing Input Shaft Bearing Snap Ring
21 - 40 AX 15 MANUAL TRANSMISSIONJ

(4) Remove cluster gear front bearing snap ring
(Fig. 19).
(5) Loosen gear case by tapping it away from inter-
mediate plate with rubber mallet (Fig. 20).
(6) Remove gear case from geartrain and interme-
diate plate (Fig. 21).
(7) Remove speedometer gear snap ring and re-
move speedometer gear and spacer from output
shaft.
FIFTH GEAR AND SYNCHRO ASSEMBLY
REMOVAL
(1) Remove three lock ball plugs from intermediate
plate (Fig. 22).
(2) Remove three lock ball springs and lock balls
from intermediate plate with pencil magnet (Fig. 23).
(3) Mount intermediate plate and geartrain assem-
bly in vise as follows:
(a) Insert two spare bolts in one bottom bolt hole
in intermediate plate. Insert bolts from opposite
sides of plates (Fig. 24).(b) Install enough flat washers under each bolt
head to prevent bolts from touching (Fig. 24).
(c) Tape bolts and washers in place and mount
intermediate plate in vise (Fig. 24).
(d) Clamp vise jaws securely against bolt heads
(Fig. 24).Do not clamp vise jaws on intermedi-
ate plate. Clamp only on bolt heads.
Fig. 19 Removing Cluster Gear Front Bearing Snap
Ring
Fig. 20 Loosening Gear Case
Fig. 21 Gear Case Removal
Fig. 22 Lock Ball Plug Locations
JAX 15 MANUAL TRANSMISSION 21 - 41

(4) Remove fifth gear snap ring (Fig. 25). Retain
snap ring for assembly reference. It is a select fit
component.
(5) Remove E-ring that secures reverse shift arm
to fork (Fig. 26).
Fig. 24 Mounting Intermediate Plate And Geartrain In Vise
Fig. 23 Removing/Installing Lock Ball And Spring
Fig. 25 Fifth Gear Snap Ring Removal
Fig. 26 Reverse Shift Arm E-Ring Removal
21 - 42 AX 15 MANUAL TRANSMISSIONJ

(6) Remove bolts attaching reverse shift arm bracket
to intermediate plate. Then remove bracket (Fig. 27).
(7) Remove reverse shift arm and shoe (Fig. 28).
(8) Remove fifth gear shift fork set screw (Fig. 29).(9) Move fifth gear shift rail forward until it clears
shift fork.
(10) Remove fifth gear shift fork from synchro
sleeve (Fig. 30).
(11) Remove reverse shift rail and reverse shift
head as assembly (Fig. 31).
(12) Measure thrust clearance between counter
fifth gear and thrust ring with feeler gauge. Clear-
ance should be 0.10 to 0.40 mm (0.003 to 0.019 in.).
If clearance exceeds limits, gear and/or ring will have
to be replaced.
(13) Loosen fifth spline gear with standard two-jaw
puller (Fig. 32).Position puller jaws behind fifth
counter gear as shown.
(14) Remove fifth spline gear (Fig. 33).
(15) Remove fifth gear synchro ring (Fig. 34).
(16) Remove fifth gear synchro and sleeve assem-
bly (Fig. 35).
(17) Remove counter fifth gear thrust ring (Fig.
36).
(18) Remove thrust ring lock ball with pencil mag-
net (Fig. 37).
Fig. 27 Reverse Shift Arm Bracket Removal
Fig. 28 Reverse Shift Arm And Shoe Removal
Fig. 29 Fifth Gear Fork Set Screw Removal
Fig. 30 Fifth Gear Shift Fork Removal
Fig. 31 Reverse Shift Head And Rail Removal
JAX 15 MANUAL TRANSMISSION 21 - 43

Fig. 32 Loosening Fifth Spline Gear
Fig. 33 Fifth Spline Gear Removal
Fig. 34 Fifth Gear Synchro Ring Removal
Fig. 35 Counter Fifth Gear And Synchro Assembly
Removal
Fig. 36 Fifth Gear Thrust Ring Removal
Fig. 37 Thrust Ring Lock Ball Removal
21 - 44 AX 15 MANUAL TRANSMISSIONJ

(19) Remove bolts attaching output shaft rear
bearing retainer to intermediate plate (Fig. 38).
(20) Remove rear bearing retainer (Fig. 39).
(21) Remove reverse gear and shaft (Fig. 40).
SHIFT RAIL AND FORK REMOVAL
There are a total of five shift rails in the AX 15
transmission. The 1-2, 3-4, fifth gear and front re-
verse shift rails are shown in Figure 41.
Two shift rails are used for reverse gear range. The
front reverse rail is at the forward side of the inter-
mediate plate (Fig. 41). The short rear reverse rail
and reverse shift head are at the rear side of the in-
termediate plate.
It is not necessary to remove the shift rails if
they are in good condition. Only the shift forks
need be removed for access to the shafts and gears.
Fig. 38 Output Shaft Rear Bearing Retainer Bolt Removal
Fig. 39 Output Shaft Rear Bearing Retainer Removal
Fig. 40 Reverse Idler Gear And Shaft Removal
Fig. 41 Shift Rail Identification
JAX 15 MANUAL TRANSMISSION 21 - 45

(1) Remove fifth gear shift rail (Fig. 41). Catch lock
ball in your hand as rail comes out of intermediate plate.
(2) Remove 1-2 and 3-4 shift rail C-rings with two
screwdrivers of equal size and length (Fig. 42).
(3) Remove shift fork set screws (Fig. 43).
(4) Remove 3-4 shift rail from shift fork and inter-
mediate plate (Fig. 44).
(5) Remove 3-4 shift rail interlock plug from inter-
mediate plate with magnet (Fig. 45).(6) Remove 1-2 shift rail from shift fork and inter-
mediate plate (Fig. 46).
Fig. 42 Shift Rail C-Ring Removal
Fig. 43 Shift Fork Set Screw Removal
Fig. 44 Removing 3-4 Shift Rail
Fig. 45 Removing 3-4 Shift Rail Interlock Plug
Fig. 46 Removing 1-2 Shift Rail
21 - 46 AX 15 MANUAL TRANSMISSIONJ

(7) Remove 1-2 shift rail interlock pin from shift
rail (Fig. 47).
(8) Remove 1-2 shift rail interlock plug from inter-
mediate plate (Fig. 48).
(9) Lift reverse shift fork upward and remove fifth
gear shift rail lock ball (Fig. 49).(10) Remove 3-4 shift fork (Fig. 50).
(11) Remove 1-2 shift fork (Fig. 50).
(12) Remove reverse shift rail C-ring with two
equal length and size screwdrivers (Fig. 51).
(13) Remove reverse shift rail and fork (Fig. 52).
(14) Remove interlock pin from reverse shift rail
(Fig. 53).
(15) Position shift rails, shift forks, lock balls, in-
terlock plugs and interlock pins on the workbench in
order of removal. This will help in identifying compo-
nents during inspection and assembly.
OUTPUT SHAFT AND CLUSTER GEAR
REMOVAL
(1) Remove output shaft rear bearing snap ring
(Fig. 54).
(2) Remove cluster gear rear bearing snap ring
(Fig. 54).
Fig. 47 Removing 1-2 Shift Rail Interlock Pin
Fig. 48 Removing 1-2 Shift Rail Interlock Plug
Fig. 49 Fifth Gear Shift Rail Lock Ball Removal
Fig. 50 Shift Fork Removal
JAX 15 MANUAL TRANSMISSION 21 - 47

Fig. 51 Reverse Shift Rail C-Ring Removal
Fig. 52 Reverse Shift Rail And Fork Removal
Fig. 53 Reverse Shift Rail Interlock Pin Removal
Fig. 54 Removing Bearing Snap Rings
21 - 48 AX 15 MANUAL TRANSMISSIONJ