JEEP CHEROKEE 1994 Service Repair Manual

(20) Install input shaft on output shaft.
(21) Install counter gear in intermediate plate (Fig.
66).
(22) Install rear bearing snap ring and install
bearing retainer (Fig. 67). Tighten retainer screws to
18 Nzm (13 ft. lbs.) torque.(23) Install reverse shift arm (Fig. 68). Tighten at-
taching bolt to 18 Nzm (13 ft. lbs.) torque.
(24) Install lock ball, spacer and needle bearing
(Fig. 69) on counter shaft.
(25) On AX 5, assemble counter fifth gear and syn-
chro components (Figs. 69 and 104).
Fig. 66 Installing Counter Gear
Fig. 67 Installing Bearing Retainer And Snap Ring
Fig. 68 Installing Reverse Shift Fork
Fig. 69 Counter Fifth Gear And Synchronizer
AssemblyÐAX 5
21 - 20 AX 4/5 MANUAL TRANSMISSIONJ

(26) On AX 5, install assembled gear and synchro-
nizer on counter shaft (Fig. 70).
(27) Install remaining synchronizer ring and spline
fifth gear (Fig. 71). Use length of pipe to tap gear
into place.
(28) Shift 1-2 and 3-4 synchronizer sleeves into
gear to lock output shaft and counter gear (Fig. 28).
(29) On AX 4, install oil slinger and lock nut on
counter gear (Fig. 104).
(30) On AX 5, install fifth gear snap ring (Fig. 72).
(31) Disengage 1-2 and 3-4 synchronizer sleeves.
(32) On AX 5, check counter fifth gear thrust
clearance (Fig. 72). Standard clearance is 0.10 - 0.30
mm (0.004 - 0.010 in.). Adjust clearance with differ-
ent thickness snap ring if necessary.
SHIFT MECHANISM ASSEMBLY AND
INSTALLATION
When assembling the shift mechanism, refer to
Figure 73 for component details and location.
Fig. 70 Fifth Gear And Synchronizer
InstallationÐAX 5
Fig. 71 Installing Fifth GearÐAX 5
Fig. 72 Fifth Gear Thrust ClearanceÐAX 5
JAX 4/5 MANUAL TRANSMISSION 21 - 21

Fig. 73 Shift Components
21 - 22 AX 4/5 MANUAL TRANSMISSIONJ

(1) Install reverse shift arm. Then seat shift fork
in bracket (Fig. 74).
(2) Install reverse idler gear on shaft. Then install
shaft and gear in intermediate plate (Fig. 75). Install
shaft lock plate and tighten attaching bolt to 18 Nzm
(13 ft. lbs.) torque.
(3) Install 1-2 and 3-4 shift forks in synchronizer
sleeves. Then slide No. 2 shift rail through interme-
diate plate and into forks (Fig. 76).
(4) Coat shift rail interlock pins and balls with lib-
eral quantity petroleum jelly to hold them in place.
(5) Refer to Figure 77 for interlock ball and pin po-
sitions during following assembly steps.
Fig. 75 Installing Reverse Idler Gear And Shaft
Fig. 76 Installing No. 2 Shift Rail and Shift Forks
Fig. 74 Installing Reverse Shift Arm
JAX 4/5 MANUAL TRANSMISSION 21 - 23

Fig. 77 Interlock Ball And Pin Position
21 - 24 AX 4/5 MANUAL TRANSMISSIONJ

(6) Insert first interlock pin in intermediate plate
(Fig. 78). Use pencil magnet and screwdriver to in-
stall pin.
(7) Install smaller diameter interlock pin in No. 1
rail (Fig. 79).(8) Slide No. 1 rail through 1-2 shift fork (Fig. 80).
(9) Install largest interlock pin between Nos. 1 and
3 shift rails (Fig. 81).
Fig. 78 Installing First Interlock Pin
Fig. 79 Installing Interlock Pin In No. 1 Shift Rail
Fig. 80 Installing No. 1 Shift Rail
Fig. 81 Installing 1-3 Shift Rail Interlock Pin
JAX 4/5 MANUAL TRANSMISSION 21 - 25

(10) Install interlock pin in No. 3 shift rail (Fig.
82).
(11) Slide No. 3 rail into reverse shift head (Fig.
83).
(12) Assemble reverse shift head and No. 5 shift
rail.(13) Install No. 5 shift rail in intermediate plate
and engage shift head on No. 3 shift rail (Fig. 84).
(14) Install reverse shift head lock ball with screw-
driver and pencil magnet (Fig. 85).
Fig. 82 Installing No. 3 Shift Rail Interlock Pin
Fig. 83 Installing No. 3 Shift Rail
Fig. 84 Installing Reverse Shift Head
Fig. 85 Installing Reverse Shift Head Lock Ball
21 - 26 AX 4/5 MANUAL TRANSMISSIONJ

(15) Shift fifth gear synchronizer sleeve rearward
to lock it (Fig. 86).
(16) On AX 5, install fifth-reverse shift fork in
synchronizer sleeve. Then slide No. 4 shift rail into
fork (Fig. 87).(17) Install shift rail lock ball with pencil magnet
and screwdriver (Fig. 88).
(18) Check interlock operation as follows: Move
No. 1 shift rail rearward to first gear position. Inter-
lock operation is OK if remaining shift rails did not
move.
(19) Install new shift fork pins (Fig. 89).
Fig. 86 Locking Fifth Synchronizer
Fig. 87 Fifth-Reverse Shift Fork Installation
Fig. 88 Lock Ball Installation
Fig. 89 Installing Shift Fork Pins
JAX 4/5 MANUAL TRANSMISSION 21 - 27

(20) Install new shift rail C-rings (Fig. 90).
(21) Apply sealer to threads of lock ball plugs.
(22) Install lock balls and springs in intermediate
plate.Short spring goes in top hole of interme-
diate plate.
(23) Install lock ball and spring plugs (Fig. 91).
Tighten plugs to 19 Nzm (14 ft. lbs.) torque.ASSEMBLING GEARTRAIN AND
TRANSMISSION CASE
(1) Remove intermediate plate from vise.
(2) Install new gaskets on intermediate plate.
(3) Install transmission case on intermediate plate
(Fig. 92).
(4) Install new front bearing snap ring (Fig. 93).
Fig. 92 Installing Transmission Case
Fig. 93 Installing Front Bearing Snap Ring
Fig. 90 Installing Shift Rail C-Rings
Fig. 91 Installing Lock Ball Plugs
21 - 28 AX 4/5 MANUAL TRANSMISSIONJ

(5) Install new gasket on front bearing retainer
and install retainer on case (Fig. 94).
(6) Install adapter or extension housing on inter-
mediate plate (Fig. 95). Tighten housing bolts to 37
Nzm (27 ft. lbs.) torque.
(7) Install shift arm (Fig. 95).(8) Install shift arm lock plate with pliers (Fig. 96).
Then install and tighten lock plate set bolt to 38 Nzm
(28 ft. lbs.) torque.
(9) Install and tighten shaft plug to 18 Nzm (13 ft.
lbs.) torque (Fig. 97).
Fig. 94 Installing Front Bearing Retainer
Fig. 95 Installing Adapter Housing And Shift Arm
Fig. 96 Shift Arm Lock Plate Installation
Fig. 97 Shaft Plug Installation
JAX 4/5 MANUAL TRANSMISSION 21 - 29