lock JEEP CHEROKEE 1995 Service Repair Manual

(9) Verify third gear thrust clearance with feeler
gauge (Fig. 49). 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. 50).
(11) Install first gear lock ball in output shaft (Fig.
51).
(12) Assemble first gear, synchronizer ring, gear
needle bearing and inner race (Fig. 52). Then install
assembly on output shaft.Rotate inner race until
aligned with locking ball.(13) Press rear bearing on shaft (Fig. 52). Snap
ring groove in bearing goes toward rear. Use screw-
driver to hold inner race in position when installing
bearing (Fig. 53).
(14) Install snap ring on rear bearing.
Fig. 49 Checking Third Gear Clearance
Fig. 50 Installing Second Gear And Synchronizer
Fig. 51 Installing First Gear And Lock Ball
Fig. 52 Assembling First Gear Components
JAX 4/5 MANUAL TRANSMISSION 21 - 19

(21) Install counter gear in intermediate plate (Fig.
59).
(22) Install rear bearing snap ring and install
bearing retainer (Fig. 60). Tighten retainer screws to
18 Nzm (13 ft. lbs.) torque.(23) Install reverse shift arm (Fig. 61). Tighten at-
taching bolt to 18 Nzm (13 ft. lbs.) torque.
(24) Install lock ball, spacer and needle bearing
(Fig. 62) on counter shaft.
(25) On AX 5, assemble counter fifth gear and syn-
chro components (Figs. 42 and 62).
Fig. 59 Counter Gear Installation
Fig. 60 Installing Bearing Retainer And Snap Ring
Fig. 61 Installing Reverse Shift Fork
Fig. 62 Counter Fifth Gear And Synchronizer
Assembly (AX 5)
21 - 22 AX 4/5 MANUAL TRANSMISSIONJ

(26) On AX 5, install assembled gear and synchro-
nizer on counter shaft (Fig. 63).
(27) Install remaining synchronizer ring and spline
fifth gear (Fig. 64). 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. 20).
(29) On AX 4, install oil slinger and lock nut on
counter gear (Fig. 42).
(30) On AX 5, install fifth gear snap ring (Fig. 65).
(31) Disengage 1-2 and 3-4 synchronizer sleeves.
(32) On AX 5, check counter fifth gear thrust clear-
ance (Fig. 66). Standard clearance is 0.10 - 0.30 mm
(0.004 - 0.010 in.). Adjust clearance with different
thickness snap ring if necessary.
Fig. 65 Checking Fifth Gear Thrust Clearance (AX 5)
Fig. 63 Fifth Gear And Synchronizer Installation (AX 5)
Fig. 64 Installing Fifth Gear (AX 5)
JAX 4/5 MANUAL TRANSMISSION 21 - 23

SHIFT MECHANISM ASSEMBLY AND
INSTALLATION
When assembling the shift mechanism, refer
to Figure 66 for component details and loca-
tion.
(1) Install reverse shift arm. Then seat shift fork
in bracket (Fig. 67).
(2) Install reverse idler gear on shaft. Then install
shaft and gear in intermediate plate (Fig. 68). 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. 69).
(4) Coat shift rail interlock pins and balls with lib-
eral quantity of petroleum jelly to hold them in place.
(5) Refer to Figure 70 for interlock ball and pin po-
sitions during following assembly steps.
Fig. 68 Installing Reverse Idler Gear And Shaft
Fig. 69 Installing No. 2 Shift Rail and Shift Forks
Fig. 67 Installing Reverse Shift Arm
JAX 4/5 MANUAL TRANSMISSION 21 - 25

Fig. 70 Interlock Ball And Pin Position
21 - 26 AX 4/5 MANUAL TRANSMISSIONJ

(6) Insert first interlock pin in intermediate plate
(Fig. 71). Use pencil magnet and screwdriver to in-
stall pin.
(7) Install smaller diameter interlock pin in No. 1
rail (Fig. 72).(8) Slide No. 1 rail through 1-2 shift fork (Fig. 73).
(9) Install largest interlock pin between Nos. 1 and
3 shift rails (Fig. 74).
Fig. 71 Installing First Interlock Pin
Fig. 72 Installing Interlock Pin In No. 1 Shift Rail
Fig. 73 Installing No. 1 Shift Rail
Fig. 74 Installing 1-3 Shift Rail Interlock Pin
JAX 4/5 MANUAL TRANSMISSION 21 - 27

(10) Install interlock pin in No. 3 shift rail (Fig.
75).
(11) Slide No. 3 rail into reverse shift head (Fig.
76).(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. 77).
(14) Install reverse shift head lock ball with screw-
driver and pencil magnet (Fig. 78).
Fig. 75 Installing No. 3 Shift Rail Interlock Pin
Fig. 76 Installing No. 3 Shift Rail
Fig. 77 Installing Reverse Shift Head
Fig. 78 Installing Reverse Shift Head Lock Ball
21 - 28 AX 4/5 MANUAL TRANSMISSIONJ

(15) Shift fifth gear synchronizer sleeve rearward
to lock it (Fig. 79).
(16) On AX 5, install fifth-reverse shift fork in syn-
chronizer sleeve. Then slide No. 4 shift rail into fork
(Fig. 80).(17) Install shift rail lock ball with pencil magnet
and screwdriver (Fig. 81).
(18) Check interlock operation as follows: Move No.
1 shift rail rearward to first gear position. Interlock
operation is OK if remaining shift rails did not move.
(19) Install new shift fork pins (Fig. 82).
Fig. 79 Locking Fifth Synchronizer
Fig. 80 Fifth-Reverse Shift Fork Installation
Fig. 81 Lock Ball Installation
Fig. 82 Installing Shift Fork Pins
JAX 4/5 MANUAL TRANSMISSION 21 - 29

(20) Install new shift rail C-rings (Fig. 83).
(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. 84).
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. 85).
(4) Install new front bearing snap ring (Fig. 86).
Fig. 83 Installing Shift Rail C-Rings
Fig. 84 Installing Lock Ball Plugs
Fig. 85 Installing Transmission Case
Fig. 86 Installing Front Bearing Snap Ring
21 - 30 AX 4/5 MANUAL TRANSMISSIONJ

(5) Install new gasket on front bearing retainer
and install retainer on case (Fig. 87).
(6) Install adapter or extension housing on inter-
mediate plate (Fig. 88). Tighten housing bolts to 37
Nzm (27 ft. lbs.) torque.
(7) Install shift arm (Fig. 88).(8) Install shift arm lock plate with pliers (Fig. 89).
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. 90).
Fig. 87 Installing Front Bearing Retainer
Fig. 88 Installing Adapter Housing And Shift Arm
Fig. 89 Shift Arm Lock Plate Installation
Fig. 90 Shaft Plug Installation
JAX 4/5 MANUAL TRANSMISSION 21 - 31