light JEEP CHEROKEE 1994 Service Repair Manual

(6) Remove slave cylinder from clutch housing.
(7) Disconnect transmission shift lever as follows:
(a) Lower transmission-transfer case assembly ap-
proximately 7-8 cm (3 in.) for access to shift lever.
(b) Reach up and around transmission case and
unseat shift lever dust boot from transmission shift
tower (Fig. 6). Move boot upward on shift lever for
access to retainer that secures lever in shift tower.
(c) Reach up and around transmission case and
press shift lever retainer downward with your fin-
gers. Turn retainer counterclockwise to release it.
(d) Lift lever and retainer out of shift tower (Fig.
6).Do not remove the shift lever from the
floorpan boots. Leave the lever in place for
later transmission installation.
(8) Mark front and rear propeller shafts for instal-
lation alignment (Fig. 7). Then remove shafts.
(9) Remove crankshaft position position sensor (Fig.
8).
(10) Disconnect vehicle speed sensor wires.
(11) Disconnect transmission and transfer case
vent hoses.(12) Disconnect clutch master cylinder hydraulic
line from concentric bearing inlet line (Fig. 8).
(13) Support transmission-transfer case assembly
with a transmission jack. Secure assembly to jack
with safety chains.
(14) Remove clutch housing brace rod on 4-cylinder
models.
(15) Remove clutch housing-to-engine bolts and re-
move transmission-transfer case assembly.
(16) Remove bolts attaching transmission to trans-
fer case and separate components.
(17) Remove release bearing, fork and retainer clip.
(18) Remove clutch housing.
TRANSMISSION INSTALLATION
(1) Install clutch housing on transmission. Tighten
housing bolts to 37 Nzm (27 ft. lbs.) torque.
(2) Lubricate contact surfaces of release fork pivot
ball stud and release fork with high temp grease.
Then install release bearing, fork and retainer clip.
(3) Mount transmission on transmission jack.
(4) Lightly lubricate pilot bearing and transmis-
sion input shaft splines with Mopar high tempera-
ture grease.
(5) Align transmission input shaft and clutch disc
splines and install transmission.
(6) Install and tighten clutch housing-to-engine
bolts to 38 Nzm (28 ft. lbs.) torque.Be sure the
housing is properly seated on engine block be-
fore tightening bolts.
(7) Lower transmission approximately 7-8 cm (3
in.) for access to shift tower. Be sure transmission is
in first or third gear.
(8) Reach up and around transmission and insert
shift lever in shift tower. Press lever retainer down-
ward and turn it clockwise to lock it in place. Then
install lever dust boot on shift tower.
(9) Install slave cylinder in clutch housing.
(10) Connect engine timing sensor wires.
(11) Remove jack from under transmission and
mount transfer case on jack.Fig. 6 Removing/Installing Shift Lever
Fig. 7 Marking Propeller Shaft And Axle Yokes
Fig. 8 Hydraulic Line And Timing Sensor Location
21 - 4 AX 4/5 MANUAL TRANSMISSIONJ

(12) Align transfer case and transmission shafts
and install transfer case. Tighten transfer case-to-
transmission nuts/bolts to 35 Nzm (26 ft. lbs.) torque.
(13) Remove jack stand from under engine and re-
position jack under transmission. Then remove trans-
mission jack.
(14) Connect transfer case vent hose and shift link-
age. Check and adjust linkage if necessary.
(15) Connect transmission and transfer case vent
hoses.
(16) Connect backup light switch wires.
(17) Connect vehicle speed sensor wires.
(18) Install and connect crankshaft position sensor
if equipped.
(19) Install rear crossmember, or skid plate (Fig. 5).
On XJ, tighten crossmember-to-frame bolts to 41 Nzm
(31 ft. lbs.) torque. Then tighten transmission-to-rear
support bolts/nuts to 45 Nzm (33 ft. lbs.) torque. On YJ,
tighten bolts/nuts to indicated torque (Fig. 5).
(20) Align and install front/rear propeller shafts.
Tighten shaft U-joint clamp bolts to 19 Nzm (170 in.
lbs.) torque.
(21) On XJ, install skid plate, if removed. Tighten
bolts to 42 Nzm (31 ft. lbs.) torque. Tighten stud nuts
to 17 Nzm (150 in. lbs.) torque.
(22) Top off transmission and transfer case lubri-
cant levels.
(23) Lower vehicle.
TRANSMISSION DISASSEMBLY AND OVERHAUL
ADAPTER HOUSING AND FRONT BEARING
RETAINER REMOVAL
(1) Drain transmission lubricant.
(2) Remove concentric bearing.
(3) Remove clutch housing bolts and remove housing.
(4) On 2-wheel drive models, remove vehicle speed
sensor, speedometer adapter and speedometer driven
gear. Then remove extension housing seal (Fig. 9).(5) Remove detent spring and ball. Remove detent
plug (Fig. 10) and remove detent spring and ball
with pencil magnet.
(6) Remove shift arm set bolt (Fig. 11) and remove
bolt and lockplate.
Fig. 10 Detent Ball Plug Location
Fig. 11 Set Bolt Removal
Fig. 9 Removing 2-Wheel Drive Extension Housing Seal
JAX 4/5 MANUAL TRANSMISSION 21 - 5

TRANSMISSION SHIFT PATTERN
The AX 15 shift pattern is shown in Figure 3. First
and second and third and fourth gear ranges are in
line for improved shifting. Fifth and reverse gear
ranges are also in line at the extreme right of the
pattern (Fig. 3).
The AX 15 is equipped with a reverse lockout
mechanism. The shift lever must be moved through
the Neutral detent before making a shift to reverse.
TRANSMISSION LUBRICANT
Recommended lubricant for AX 15 transmissions is
Mopar 75W-90, API Grade GL-5 gear lubricant, or
equivalent.
Correct lubricant refill or top-off level is to the bot-
tom edge of the fill plug hole.
Lubricant capacity is:
²3.10 liters (3.27 qts.) in 4-wheel drive models.
²3.15 liters (3.32 qts.) in 2-wheel drive models.
TRANSMISSION SWITCH AND PLUG LOCATIONS
The fill plug is at the driver side of the gear case
(Fig. 4).
The drain plug and backup light switch are on the
passenger side of the gear case (Fig. 5).
TRANSMISSION GEAR RATIOS
The transmission gear ratios are as follows:
First gear - 3.83:1
Second gear - 2.33:1
Third gear - 1.44:1
Fourth gear - 1.00:1
Fifth gear - 0.79:1
Reverse - 4.22:1
SERVICE DIAGNOSIS
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill, or an in-
correct lubricant level check.
Leaks can occur at the mating surfaces of the gear
case, intermediate plate and adapter or extension
housing, or from the front/rear seals. A suspected
leak could also be the result of an overfill condition.
Leaks at the rear of the extension or adapter hous-
ing will be from the housing oil seals. Leaks at com-
ponent mating surfaces will probably be the result of
inadequate sealer, gaps in the sealer, incorrect bolt
tightening, or use of a non-recommended sealer.
A leak at the front of the transmission will be from
either the front bearing retainer or retainer seal. Lu-
bricant may be seen dripping from the clutch hous-
ing after extended operation. If the leak is severe, it
may also contaminate the clutch disc causing slip,
grab and chatter.
Transmissions filled from air or electrically pow-
ered lubricant containers can be underfilled. This
generally happens when the container delivery mech-
anism is improperly calibrated. Always check the lu-
bricant level after filling to avoid an under fill
condition.
A correct lubricant level check can only be made
when the vehicle is level; use a drive-on hoist to en-
sure this. Also allow the lubricant to settle for a
Fig. 3 AX 15 Shift Pattern
Fig. 4 Fill Plug Location
Fig. 5 Drain Plug And Backup Light Switch Location
JAX 15 MANUAL TRANSMISSION 21 - 33

minute or so before checking. These recommenda-
tions will ensure an accurate check and avoid an un-
der-or-overfill condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants, compo-
nent damage, incorrect clutch adjustment, or by a
damaged clutch pressure plate or disc.
Substantial lubricant leaks can result in gear, shift
rail, synchro and bearing damage. If a leak goes un-
detected for an extended period, the first indications
of a problem are usually hard shifting and noise.
Incorrect or contaminated lubricants can also con-
tribute to hard shifting. The consequence of using
non-recommended lubricants is noise, excessive wear,
internal bind and hard shifting.
Improper clutch release is a frequent cause of hard
shifting. Incorrect adjustment or a worn, damaged
pressure plate or disc can cause incorrect release. If
the clutch problem is advanced, gear clash during
shifts can result.
Worn or damaged synchro rings can cause gear
clash when shifting into any forward gear. In some
new or rebuilt transmissions, new synchro rings may
tend to stick slightly causing hard or noisy shifts. In
most cases, this condition will decline as the rings
wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears can generate a
mild whine that may only be audible at extreme
speeds.
Severe, obviously audible transmission noise is
generally the result of a lubricant problem. Insuffi-
cient, improper, or contaminated lubricant can pro-
mote rapid wear of gears, synchros, shift rails, forks
and bearings. The overheating caused by a lubricant
problem, can also lead to gear breakage.
TRANSMISSION REMOVALÐAX 15
(1) Shift transmission into first or third gear.
(2) Raise vehicle on a hoist.
(3) Disconnect necessary exhaust system compo-
nents.
(4) Support transmission with adjustable jack
stand.
(5) Disconnect rear cushion and mounting bracket
from transmission, or transfer case (Fig. 1).
(6) On XJ, remove rear crossmember. On YJ, re-
move skid plate (Fig. 1).
(7) Disconnect transmission shift linkage, speed-
ometer cable, transfer case vacuum lines and clutch
hydraulic lines.
(8) Lower transmission-transfer case assembly no
more than 7.6 cm (3 in.) for access to shift lever.
Fig. 1 Rear Mount Components (YJ Shown)
21 - 34 AX 15 MANUAL TRANSMISSIONJ

(9) Reach up and around transmission case and
unseat shift lever dust boot from transmission shift
tower (Fig. 2). Move boot upward on shift lever for
access to lever retainer.
(10) Disengage shift lever as follows:
(a) Reach up and around transmission case and
press shift lever retainer downward with your fin-
gers.
(b) Turn retainer counterclockwise to release it.
(c) Lift lever and retainer out of shift tower (Fig.
2).It is not necessary to remove shift lever
from floorpan boot. Simply leave lever in
place for later installation.
(11) Mark front and rear propeller shafts for in-
stallation alignment (Fig. 3). Then remove both
shafts.
(12) Remove crankshaft position/engine timing sen-
sor (Fig. 4).
(13) Disconnect transmission and transfer case
vent hoses.
(14) Remove slave cylinder from clutch housing.(15) Support transmission-transfer case assembly
with transmission jack. Secure assembly to jack with
safety chains.
(16) Reposition adjustable jack stand under engine.
Be sure to place wood block between jack and oil
pan.
(17) Remove clutch housing brace rod.
(18) Remove clutch housing-to-engine bolts and re-
move transmission-transfer case assembly.
(19) Remove bolts attaching transmission to trans-
fer case and separate components.
(20) Remove release bearing, fork and retainer
clip.
(21) Remove clutch housing from transmission.
TRANSMISSION INSTALLATIONÐAX 15
(1) Install clutch housing on transmission. Tighten
housing bolts to 37 Nzm (27 ft-lbs) torque.
(2) Lubricate contact surfaces of release fork, lever
and pivot ball stud. Then install bearing, fork and
clip in clutch housing.
(3) Mount transmission on transmission jack. Se-
cure transmission with safety chains.
(4) Lightly lubricate pilot bearing and transmis-
sion input shaft splines with Mopar high tempera-
ture grease.
(5) Align transmission input shaft and clutch disc
splines and install transmission.
(6) Install and tighten clutch housing-to-engine
bolts to 38 Nzm (28 ft. lbs.) torque.Be sure housing
is properly seated on engine before tightening
bolts.
(7) Lower transmission no more than 7.6 cm (3 in.)
for access to the shift tower.
(8) Reach up and around the transmission and in-
sert shift lever in shift tower. Press lever retainer
downward and turn it clockwise to lock it in place.
Then install lever dust boot on shift tower.
(9) Connect engine timing sensor.
Fig. 2 Removing/Installing Shift Lever
Fig. 3 Marking Propeller Shaft And Axle Yoke
Fig. 4 Timing Sensor Location
JAX 15 MANUAL TRANSMISSION 21 - 35

(10) Remove jack from under transmission and
mount transfer case on jack.
(11) Align transfer case and transmission shafts
and install transfer case. Tighten transfer case-to-
transmission nuts/bolts to 35 Nzm (26 ft. lbs.) torque.
(12) Move jack stand from under engine and repo-
sition it under transmission. Then remove transmis-
sion jack.
(13) Connect transfer case vacuum hoses and link-
age. Check and adjust linkage if necessary.
(14) Connect transmission and transfer case vent
hoses and backup light switch wires.
(15) Install clutch sleeve cylinder.
(16) Connect vehicle speed sensor and wires.
(17) On XJ, install rear crossmember and attach
cushion and bracket. Tighten crossmember-to-frame
bolts to 41 Nzm (30 ft. lbs.) torque. Tighten transmis-
sion-to-rear cushion and bracket bolts/nuts to 45 Nzm
(33 ft. lbs.) torque.
(18) On YJ, install rear cushion and bracket and
skid plate. Tighten attaching bolts/nuts to indicated
torque (Fig. 1).
(19) Align and install front/rear propeller shafts.
Tighten shaft U-joint clamp bolts to 19 Nzm (170 in.
lbs.) torque.
(20) On XJ, install skid plate if removed. Tighten
bolts to 42 Nzm (31 ft. lbs.) torque. Tighten stud nuts
to 17 Nzm (150 in. lbs.) torque.
(21) Top off transmission and transfer lubricant
levels.
(22) Remove supports and lower vehicle.
TRANSMISSION DISASSEMBLY AND OVERHAUL
ADAPTER/EXTENSION HOUSING REMOVAL
(1) Remove release bearing, fork, retainer clip and
clutch housing from transmission. Also remove shift
lever if not previously removed.
(2) On 2-wheel drive models, remove extension
housing seal (Fig. 1).(3) Remove shift tower bolts and remove tower
from adapter or extension housing (Fig. 2).
(4) Remove gasket from shift tower (Fig. 3).
(5) Remove shift arm retainer bolt (Fig. 4).
Fig. 1 Removing Extension Housing Seal
Fig. 2 Shift Tower Removal/Installation
Fig. 3 Shift Tower Gasket Removal/Installation
Fig. 4 Shift Arm Retainer Bolt Removal/Installation
21 - 36 AX 15 MANUAL TRANSMISSIONJ

(6) Loosen and remove restrictor pins (Fig. 5).
(7) Remove shift arm shaft plug (Fig. 6).
(8) Remove shift arm shaft with large magnet (Fig.
7).(9) Remove shift arm (Fig. 8).
(10) Remove plug for reverse shift head lock ball.
Plug is at right side of adapter housing near backup
light switch (Fig. 9).
Fig. 5 Removing/Installing Restrictor Pins
Fig. 6 Removing/Installing Shift Lever Shaft Plug
Fig. 7 Removing/Installing Shift Lever Shaft
Fig. 8 Shift Arm Removal/Installation
Fig. 9 Removing/Installing Lock Ball Plug
JAX 15 MANUAL TRANSMISSION 21 - 37

(11) Remove lock ball spring with pencil magnet
(Fig. 10).
(12) Remove shift head lock ball with pencil mag-
net (Fig. 11).
(13) Remove backup light switch from adapter/ex-
tension housing.
(14) On 2-wheel drive models, remove distance
sensor, speedometer adapter and driven gear if not
removed previously.
(15) Remove adapter/extension 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
21 - 38 AX 15 MANUAL TRANSMISSIONJ

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).
(3) Tap end of output shaft with mallet to unseat
and start rear bearing out of intermediate plate (Fig.
55).(4) Remove output shaft by rocking it lightly until
rear bearing comes out of intermediate plate (Fig.
56).
(5) Remove cluster gear by pulling it straight out
of rear bearing (Fig. 57).
(6) Remove cluster gear rear bearing from inter-
mediate plate (Fig. 58).
(7) Remove input shaft from output shaft (Fig. 59).
(8) Remove output shaft pilot bearing from input
shaft (Fig. 60).
(9) Remove synchro ring from input shaft (Fig. 61).
Fig. 51 Removing Reverse Shift Rail C-Ring
Fig. 52 Removing Reverse Shift Rail And Fork
Fig. 53 Removing Reverse Shift Rail Interlock Pin
Fig. 54 Removing Bearing Snap Rings
JAX 15 MANUAL TRANSMISSION 21 - 47

(27) Install and tighten shift arm shaft access plug
to 19 Nzm (14 ft. lbs.) torque (Fig. 126).
(28) Position new shift tower gasket on adapter
housing (Fig 127).
(29) Install shift tower (Fig. 128). Tighten tower
attaching bolts to 18 Nzm (13 ft. lbs.) torque.
(30) Install new gasket on backup light switch and
install switch. Tighten switch to 37 Nzm (27 ft. lbs.)
torque.
(31) Install new washer on drain plug. Then install
and tighten plug to 37 Nzm (27 ft. lbs.) torque.
(32) If transmission will be filled with gear lubri-
cant before installation, place transmission in a levelposition. Then fill with Mopar 75W-90, grade GL-5
gear lubricant. Correct fill level is to bottom edge of
fill plug hole.
(33) Install new washer on fill plug. Then install
and tighten plug to 37 Nzm (27 ft. lbs.) torque.
(34) Install clutch housing and release bearing
components.
(35) On 2-wheel drive models, install new seal in
extension housing with suitable size installer tool
(Fig. 129). Lubricate seal lips with petroleum jelly
before installation.
(36) On 2-wheel drive models, install speedometer
driven gear (if removed), and vehicle speed sensor.
Fig. 126 Access Plug Installation
Fig. 127 Shift Tower Gasket Installation
Fig. 128 Shift Tower Installation
Fig. 129 Installing Extension Housing SealÐ2WD
Models
JAX 15 MANUAL TRANSMISSION 21 - 65