front JEEP CHEROKEE 1994 Service Repair Manual

PUMP REPLACEMENT
REMOVAL
(1) Remove and cap pressure and return lines from
pump. Refer to Pressure and Return Line Replace-
ment in this section.
(2) Remove belt tension, turn tensioner clock-wise
and slip belt off pulley (Fig. 6).
(3) Remove the screws retaining front bracket and
pump to the rear bracket (Fig. 7, 8).(4) Remove screws that attach the front bracket to
the rear bracket (Fig. 9).
(5) Remove pump from bracket.
To remove the rear bracket from engine, the air
conditioning compressor and bracket must be re-
moved first. Refer to Group 24, Heating and Air Con-
ditioning for removal procedures.
(6) Remove fan from pulley and hub on rear
bracket.
(7) Remove 4 screws attaching the rear bracket to
block (Fig. 10, 11).
(8) Remove bracket from engine.
INSTALLATION
(1) Install the rear bracket to engine. Install
screws finger tight.
Fig. 6 Belt Tensioner
Fig. 7 Pump Mounting Screw Removal/Installation
Fig. 8 Power Steering Pump Mounting
Fig. 9 Front Bracket
JSTEERING 19 - 71

(2) Tighten front screws to 48 Nzm (35 ft. lbs.)
torque. Tighten side screw to 48 Nzm (35 ft. lbs.)
torque. It is important to torque the front screws
FIRST and the side screw LAST. This will prevent
the bracket from twisting or distorting.
(3) Install fan to pulley and hub. Tighten the nuts
to 27 Nzm (20 ft. lbs.) torque.
(4) Install air conditioning bracket and compressor
to engine. Refer to Group 24, Heating and Air Condi-
tioning for installation procedures.(5) Loose assemble screws through front bracket,
pump and into rear bracket.
(6) Install screws that attach the front bracket to
the rear bracket (Fig. 8). Tighten the screws to 27
Nzm (20 ft. lbs.) torque (Fig. 7).
(7) Install belt, turn tensioner clockwise and slip
belt onto pulley (Fig. 6).
(8) Install pressure and return lines to pump. Re-
fer to Pressure and Return Line Replacement in this
section.
(9) After installation, add power steering fluid, in-
spect and test for fluid leaks. Refer to Power Steering
PumpÐInitial Operation.
Fig. 11 Rear Bracket (Side View)Fig. 10 Rear Bracket (Front View)
19 - 72 STEERINGJ

(Fig. 2). The first number is year of manufacture.
The second and third numbers indicate month of
manufacture. The next series of numbers is the
transmission serial number.
GEAR RATIOS
AX 4 and AX 5 gear ratios are as follows:
²First gear: 3.93:1
²Second gear: 2.33:1
²Third gear: 1.45:1
²Fourth gear: 1.00:1
²Fifth gear (AX 5): 0.85:1
²Reverse gear: 4.74:1
SHIFT PATTERN
The AX 4/5 first through fourth gear shift pattern
is in a conventional H configuration. On the AX 5,
fifth gear is up and to the right and reverse gear is
down and to the right (Fig. 3).
RECOMMENDED LUBRICANT
Recommended lubricant for AX 4/5 transmissions
is Mopar 75W-90, API Grade GL-5 gear lubricant, or
equivalent SAE rated gear lubricant.
Correct lubricant fill level is to the bottom edge of
the fill plug hole. The fill plug is at the passenger
side of the adapter housing Fig. 4). The drain plug is
at the bottom of the case.
Approximate dry fill lubricant capacity is 3.3 liters
(3.5 qts.).
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 adaptor 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.
Fig. 2 Transmission Identification
Fig. 3 Shift PatternÐAX 4/5 Transmission
Fig. 4 Fill Plug Location
21 - 2 AX 4/5 MANUAL TRANSMISSIONJ

(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

(7) Remove shift lever shaft plug (Fig. 12). Then
pull shaft out with large magnet.
(8) Remove adapter housing bolts.
(9) Remove adapter housing by tapping it loose
with plastic mallet.
(10) Remove front bearing snap rings (Fig. 13).
(11) Remove front bearing retainer and intermedi-
ate plate by tapping them loose with plastic mallet
(Fig. 14).
SHIFT MECHANISM DISASSEMBLY
(1) Install two clutch housing bolts and spare
washers in intermediate plate (Fig. 15). Then clamp
plate and gear assembly in vise.Use enough wash-
ers to prevent bolts from touching. Also be sure
vise jaws are clamped on bolt heads (Fig. 15).
Fig. 15 Positioning Intermediate Plate In Vise
Fig. 12 Removing Shift Lever Shaft Plug
Fig. 13 Removing Bearing Retainer Snap Ring
Fig. 14 Removing Bearing Retainer And
Intermediate Plate
21 - 6 AX 4/5 MANUAL TRANSMISSIONJ

each ring and gear with feeler gauge. Replace ring if
clearance exceeds 2.0 mm (0.078 in.).
Check shift fork-to-synchronizer hub clearance
with a feeler gauge (Fig. 49). Replace the fork if
clearance exceeds 1.0 mm (0.039 in.).
TRANSMISSION ASSEMBLY AND ADJUSTMENT
Lubricate the transmission components with Mopar
75W-90, GL 5 gear lubricant during assembly. Use
petroleum jelly to lubricate seal lips and/or hold
parts in place during installation. Refer to the
Counter Gear Comparison Chart (Fig. 102) during
assembly for AX 4/5 gear differences.
ASSEMBLING OUTPUT SHAFT, INPUT SHAFT
AND COUNTER GEAR
(1) If front bearing was removed from input shaft,
press new bearing on shaft (Fig. 50).
Fig. 50 Installing Front Bearing And Snap Ring
Fig. 48 Checking Synchronizer Ring Wear
Fig. 49 Checking Fork-To-Hub Clearance
JAX 4/5 MANUAL TRANSMISSION 21 - 15

(2) Secure front bearing with thickest snap ring
that will fit in groove (Fig. 50).
(3) Press front bearing on counter gear. Secure
bearing with thickest snap ring that will fit in ring
groove (Fig. 51).
(4) Install new oil seals in front bearing retainer
and adapter (Fig. 52). Bearing retainer seal depth is
11.2 - 12.1 mm (0.441 - 0.480 in.).(5) Install reverse shaft and shaft retaining pin in
adapter. Then install access hole plug with torx bit
(Fig. 53).
(6) Lubricate transmission components with speci-
fied gear lubricant.
(7) Assemble 1-2 and 3-4 synchronizer hubs,
sleeves, springs and key inserts (Fig. 54).
Fig. 51 Installing Counter Gear Front Bearing And Snap Ring
Fig. 52 Oil Seal Installation
Fig. 53 Installing Reverse Shaft Pin
Fig. 54 Synchronizer Identification
21 - 16 AX 4/5 MANUAL TRANSMISSIONJ

(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