lock JEEP CHEROKEE 1994 Service Repair Manual

(6) Remove No. 4 shift rail, fifth gear and No. 3
shift fork (Fig. 20).
(7) Pull No. 5 shift rail and shift head out of plate
(Fig. 21).
(8) Remove shift rail No.3.Catch interlock pins
as rail is removed (Fig. 22).
(9) Remove No. 1 shift rail and interlock pin (Fig.
23).
(10) Remove shift rail No. 2 and shift forks 1 and 2
(Fig. 24).
Fig. 20 Removing No. 4 Shift Rail And Fifth Gear
Shift Fork
Fig. 21 Removing No. 5 Shift Rail And Shift Head
Fig. 22 Removing No. 3 Shift Rail And Interlock Pin
Fig, 23 Removing No. 1 Shift Rail And Interlock Pin
Fig. 24 Removing Shift Forks And No. 2 Shift Rail
21 - 8 AX 4/5 MANUAL TRANSMISSIONJ

(11) Remove reverse idler gear and shaft (Fig. 25).
(12) Remove reverse shift arm and fork (Fig. 26).MAINSHAFT DISASSEMBLY
(1) On AX 5, measure fifth counter gear thrust
clearance with feeler gauge (Fig. 27). Clearance
should be 0.10 - 0.30 mm (0.004 - 0.012 in.).
(2) Engage two synchro sleeves to lock mainshaft
gears (Fig. 28).
Fig. 25 Removing Reverse Idler Gear And Shaft
Fig. 26 Reverse Shift Arm Removal
Fig. 27 Measuring Counter Fifth Gear Thrust
Clearance
Fig. 28 Locking Mainshaft Gears
JAX 4/5 MANUAL TRANSMISSION 21 - 9

(3) On AX 4, remove counter gear nut and oil
slinger. On AX 5, remove select fit snap ring that se-
cures fifth spline gear and counter fifth gear on shaft
(Fig. 29).
(4) Remove fifth spline gear, synchronizer and
counter fifth gear with two-jaw puller (Fig. 30).(5) Remove spacer and remove lock ball with pen-
cil magnet (Fig. 31).
(6) Remove reverse shift arm bracket (Fig. 32).
Fig. 29 Removing Fifth Gear Snap Ring
Fig. 30 Removing Fifth Gear Assembly
Fig. 31 Spacer And Lock Ball Removal
Fig. 32 Removing Reverse Shift Arm Bracket
21 - 10 AX 4/5 MANUAL TRANSMISSIONJ

(13) Remove output shaft fifth gear snap ring with
two screwdrivers (Fig. 37).
(14) Press fifth gear, rear bearing, first gear and
inner race off output shaft (Fig. 38).(15) Remove needle roller bearing.
(16) Remove synchronizer ring.
(17) Remove synchronizer lock ball with pencil
magnet (Fig. 39).
(18) Press 1-2 synchronizer and second gear off
output shaft (Fig. 40).
(19) Remove needle roller bearing from the shaft
or second gear.
Fig. 37 Removing Fifth Gear Snap Ring
Fig. 38 Removing Fifth Gear And First Gear Bearing
And Race
Fig. 39 Synchronizer Lock Ball Removal
Fig. 40 1-2 Synchronizer And Second Gear Removal
21 - 12 AX 4/5 MANUAL TRANSMISSIONJ

(8) Assemble and install third gear, needle bear-
ing, synchronizer ring, 3-4 synchronizer and snap
ring on output shaft (Fig. 55). Use thickest snap ring
that fits in shaft groove.
(9) Verify third gear thrust clearance with feeler
gauge (Fig. 56). Clearance should be 0.10 - 0.25 mm
(0.004 - 0.010 in.).(10) Assemble second gear, gear needle bearing,
synchronizer ring and 1-2 synchronizer. Then press
assembly on output shaft (Fig. 57).
(11) Install first gear lock ball in output shaft (Fig.
58).
Fig. 55 Installing Third Gear And 3-4 Synchronizer
Fig. 56 Checking Third Gear Clearance
Fig. 57 Installing Second Gear And Synchronizer
Fig. 58 Installing First Gear And Lock Ball
JAX 4/5 MANUAL TRANSMISSION 21 - 17

(12) Assemble first gear, synchronizer ring, gear
needle bearing and inner race (Fig. 59). Then install
assembly on output shaft.Rotate inner race until
aligned with locking ball.
(13) Press rear bearing on shaft (Fig. 59). Snap
ring groove in bearing goes toward rear. Use screw-
driver to hold inner race in position when installing
bearing (Fig. 60).
(14) Install snap ring on rear bearing.(15) Check first-second gear thrust clearance (Fig.
61). Standard clearance is 0.10 - 0.25 mm (0.004 -
0.010 in.).
(16) Press fifth gear on output shaft (Fig. 62).
(17) Install fifth gear snap ring (Fig. 63). Use
thickest snap ring that will fit in shaft groove.
Fig. 59 First Gear Assembly
Fig. 60 Installing Output Shaft Rear Bearing
Fig. 61 Checking First-Second Gear Clearance
Fig. 62 Installing Output Shaft Fifth Gear
21 - 18 AX 4/5 MANUAL TRANSMISSIONJ

(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

(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