lock JEEP CHEROKEE 1995 Service Repair Manual

(10) Install lock ball and spring in housing. Then
apply sealer to ball plug and install plug (Fig. 91).
Tighten plug to 19 Nzm (14 ft. lbs.) torque.
(11) Install reverse pins in housing (Fig. 92).
Tighten pins to 27 Nzm (20 ft. lbs.) torque.(12) Install shift tower and new gasket on housing
(Fig. 93). Tighten tower bolts to 18 Nzm (13 ft. lbs.)
torque.
(13) Install backup lamp switch (Fig. 93). Tighten
switch to 37 Nzm (27 ft. lbs.) torque.
(14) On 2-wheel drive models, install new seal in
extension housing (Fig. 94).
(15) Install vehicle speed sensor. Refer to proce-
dure in In-Vehicle Service section.
(16) Install clutch housing, release bearing, release
fork and retainer clip.
Fig. 91 Installing Ball Plug
Fig. 92 Install Reverse Pins
Fig. 93 Installing Shift Tower And Backup Lamp
Switch
Fig. 94 Extension Housing Seal InstallationÐ2WD
Models
21 - 32 AX 4/5 MANUAL TRANSMISSIONJ

The first number is year of manufacture. The sec-
ond and third numbers indicate month of manufac-
ture. The next series of numbers is the transmission
serial number.
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 level is from the bottom edge, to
no more than 6 mm (1/4 in.) below the bottom edge of
the fill plug hole.
Approximate dry fill 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
AX 15 gear ratios are:
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 incor-
rect 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 usually 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 housing
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
Fig. 3 AX 15 Shift Pattern
Fig. 4 Fill Plug Location
Fig. 5 Drain Plug/Backup Light Switch Location
21 - 34 AX 15 MANUAL TRANSMISSIONJ

(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.
(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. 2). Then remove both
shafts.
(12) Remove crankshaft position sensor (Fig. 4).
(13) Disconnect transmission and transfer case
vent hoses.
(14) Remove slave cylinder from clutch housing.
(15) Remove wire harnesses from clips/tie straps
on transmission and transfer case.
(16) Support transmission-transfer case assembly
with transmission jack. Secure assembly to jack with
safety chains.
(17) Reposition adjustable jack stand under engine.
Be sure to place wood block between jack and oil
pan.
(18) Remove clutch housing brace rod.
(19) Remove clutch housing-to-engine bolts and re-
move transmission-transfer case assembly.
(20) Remove bolts attaching transmission to trans-
fer case and separate components.
(21) Remove release bearing, fork and retainer
clip.
(22) Remove clutch housing from transmission.
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, 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.
Fig. 2 Removing/Installing Shift Lever
Fig. 3 Marking Propeller Shaft And Axle Yoke
Fig. 4 Crankshaft Position Sensor Location
21 - 36 AX 15 MANUAL TRANSMISSIONJ

(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) Install and connect crankshaft position sensor.
(10) Align and install transfer case on transmis-
sion. Tighten transfer case attaching nuts to 35 Nzm
(26 ft. lbs.) torque.
(11) Connect transfer case vacuum and vent hoses.
(12) Install and connect transfer case shift linkage.
Check and adjust linkage if necessary.
(13) Secure wire harnesses to clips/tie straps on
transmission and transfer case.
(14) Connect backup light switch wires.
(15) Install clutch slave cylinder.
(16) Connect vehicle speed sensor 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 HOUSING REMOVAL
(1) Remove release bearing, release lever and re-
lease fork from clutch housing. Then remove clutch
housing from transmission.
(2) Remove backup light switch. Then remove
drain plug (Fig. 1) and drain transmission lubricant
into pan.
(3) Remove shift tower bolts and remove tower
from adapter or extension housing (Fig. 2).
(4) Remove gasket from shift tower (Fig. 3).
Fig. 1 Drain Plug And Backup Light Switch Location
Fig. 2 Shift Tower Removal/Installation
Fig. 3 Shift Tower Gasket Removal/Installation
JAX 15 MANUAL TRANSMISSION 21 - 37

(5) Remove shift arm retainer bolt (Fig. 4).
(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. 4 Shift Arm Retainer Bolt Removal/Installation
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
21 - 38 AX 15 MANUAL TRANSMISSIONJ

(11) Remove lock ball spring with pencil magnet
(Fig. 10).
(12) Remove shift head lock ball with pencil mag-
net (Fig. 11).
(13) Remove adapter 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
JAX 15 MANUAL TRANSMISSION 21 - 39

(4) Remove cluster gear front bearing snap ring
(Fig. 19).
(5) Loosen gear case by tapping it away from inter-
mediate plate with rubber mallet (Fig. 20).
(6) Remove gear case from geartrain and interme-
diate plate (Fig. 21).
(7) Remove speedometer gear snap ring and re-
move speedometer gear and spacer from output
shaft.
FIFTH GEAR AND SYNCHRO ASSEMBLY
REMOVAL
(1) Remove three lock ball plugs from intermediate
plate (Fig. 22).
(2) Remove three lock ball springs and lock balls
from intermediate plate with pencil magnet (Fig. 23).
(3) Mount intermediate plate and geartrain assem-
bly in vise as follows:
(a) Insert two spare bolts in one bottom bolt hole
in intermediate plate. Insert bolts from opposite
sides of plates (Fig. 24).(b) Install enough flat washers under each bolt
head to prevent bolts from touching (Fig. 24).
(c) Tape bolts and washers in place and mount
intermediate plate in vise (Fig. 24).
(d) Clamp vise jaws securely against bolt heads
(Fig. 24).Do not clamp vise jaws on intermedi-
ate plate. Clamp only on bolt heads.
Fig. 19 Removing Cluster Gear Front Bearing Snap
Ring
Fig. 20 Loosening Gear Case
Fig. 21 Gear Case Removal
Fig. 22 Lock Ball Plug Locations
JAX 15 MANUAL TRANSMISSION 21 - 41

(4) Remove fifth gear snap ring (Fig. 25). Retain
snap ring for assembly reference. It is a select fit
component.
(5) Remove E-ring that secures reverse shift arm
to fork (Fig. 26).
Fig. 24 Mounting Intermediate Plate And Geartrain In Vise
Fig. 23 Removing/Installing Lock Ball And Spring
Fig. 25 Fifth Gear Snap Ring Removal
Fig. 26 Reverse Shift Arm E-Ring Removal
21 - 42 AX 15 MANUAL TRANSMISSIONJ

(6) Remove bolts attaching reverse shift arm bracket
to intermediate plate. Then remove bracket (Fig. 27).
(7) Remove reverse shift arm and shoe (Fig. 28).
(8) Remove fifth gear shift fork set screw (Fig. 29).(9) Move fifth gear shift rail forward until it clears
shift fork.
(10) Remove fifth gear shift fork from synchro
sleeve (Fig. 30).
(11) Remove reverse shift rail and reverse shift
head as assembly (Fig. 31).
(12) Measure thrust clearance between counter
fifth gear and thrust ring with feeler gauge. Clear-
ance should be 0.10 to 0.40 mm (0.003 to 0.019 in.).
If clearance exceeds limits, gear and/or ring will have
to be replaced.
(13) Loosen fifth spline gear with standard two-jaw
puller (Fig. 32).Position puller jaws behind fifth
counter gear as shown.
(14) Remove fifth spline gear (Fig. 33).
(15) Remove fifth gear synchro ring (Fig. 34).
(16) Remove fifth gear synchro and sleeve assem-
bly (Fig. 35).
(17) Remove counter fifth gear thrust ring (Fig.
36).
(18) Remove thrust ring lock ball with pencil mag-
net (Fig. 37).
Fig. 27 Reverse Shift Arm Bracket Removal
Fig. 28 Reverse Shift Arm And Shoe Removal
Fig. 29 Fifth Gear Fork Set Screw Removal
Fig. 30 Fifth Gear Shift Fork Removal
Fig. 31 Reverse Shift Head And Rail Removal
JAX 15 MANUAL TRANSMISSION 21 - 43

Fig. 32 Loosening Fifth Spline Gear
Fig. 33 Fifth Spline Gear Removal
Fig. 34 Fifth Gear Synchro Ring Removal
Fig. 35 Counter Fifth Gear And Synchro Assembly
Removal
Fig. 36 Fifth Gear Thrust Ring Removal
Fig. 37 Thrust Ring Lock Ball Removal
21 - 44 AX 15 MANUAL TRANSMISSIONJ