lock JEEP CHEROKEE 1995 Service Repair Manual

(1) Remove fifth gear shift rail (Fig. 41). Catch lock
ball in your hand as rail comes out of intermediate plate.
(2) Remove 1-2 and 3-4 shift rail C-rings with two
screwdrivers of equal size and length (Fig. 42).
(3) Remove shift fork set screws (Fig. 43).
(4) Remove 3-4 shift rail from shift fork and inter-
mediate plate (Fig. 44).
(5) Remove 3-4 shift rail interlock plug from inter-
mediate plate with magnet (Fig. 45).(6) Remove 1-2 shift rail from shift fork and inter-
mediate plate (Fig. 46).
Fig. 42 Shift Rail C-Ring Removal
Fig. 43 Shift Fork Set Screw Removal
Fig. 44 Removing 3-4 Shift Rail
Fig. 45 Removing 3-4 Shift Rail Interlock Plug
Fig. 46 Removing 1-2 Shift Rail
21 - 46 AX 15 MANUAL TRANSMISSIONJ

(7) Remove 1-2 shift rail interlock pin from shift
rail (Fig. 47).
(8) Remove 1-2 shift rail interlock plug from inter-
mediate plate (Fig. 48).
(9) Lift reverse shift fork upward and remove fifth
gear shift rail lock ball (Fig. 49).(10) Remove 3-4 shift fork (Fig. 50).
(11) Remove 1-2 shift fork (Fig. 50).
(12) Remove reverse shift rail C-ring with two
equal length and size screwdrivers (Fig. 51).
(13) Remove reverse shift rail and fork (Fig. 52).
(14) Remove interlock pin from reverse shift rail
(Fig. 53).
(15) Position shift rails, shift forks, lock balls, in-
terlock plugs and interlock pins on the workbench in
order of removal. This will help in identifying compo-
nents during inspection and assembly.
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).
Fig. 47 Removing 1-2 Shift Rail Interlock Pin
Fig. 48 Removing 1-2 Shift Rail Interlock Plug
Fig. 49 Fifth Gear Shift Rail Lock Ball Removal
Fig. 50 Shift Fork Removal
JAX 15 MANUAL TRANSMISSION 21 - 47

Fig. 51 Reverse Shift Rail C-Ring Removal
Fig. 52 Reverse Shift Rail And Fork Removal
Fig. 53 Reverse Shift Rail Interlock Pin Removal
Fig. 54 Removing Bearing Snap Rings
21 - 48 AX 15 MANUAL TRANSMISSIONJ

(5) Remove first/reverse hub snap ring (Fig. 63).
(6) Remove synchro ring.
(7) Press reverse gear and first/reverse hub off
shaft as assembly.
(8) Remove remaining synchro ring and second
gear and bearing (Fig. 63).
(9) Remove snap ring at front of output shaft (Fig.
63).
(10) Press 3-4 hub and sleeve off output shaft as
assembly (Fig. 63).
(11) Remove synchro ring.
(12) Remove third gear and needle bearing (Fig.
63).
TRANSMISSION CLEANING AND INSPECTION
Clean the transmission components in solvent.
Then dry the cases, gears, shift mechanism and
shafts with compressed air.Dry the bearings with
clean, dry shop towels only. Never use com-
pressed air on the bearings. This could damage
the bearing rollers.
Replace components that are obviously worn,
cracked, chipped or damaged.
Inspect the transmission case. Replace the case if
cracked or porous or if any of the bearing and gear
bores are damaged.
Output Shaft Inspection
Measure thickness of the output shaft flange with
a micrometer (Fig. 64). Minimum allowable flange
thickness is 4.70 mm (0.185 in).
If shaft flange thickness is OK but previously
measured second/third gear thrust clearance
was incorrect (Fig. 62), replace the necessary
gear and needle bearing as an assembly.
Check diameter of the first, second and third gear
bearing surfaces of the output shaft (Fig. 64). Mini-
mum allowable diameters are:
²38.86 mm (1.529 in.) for first gear surface
²46.86 mm (1.844 in.) for second gear surface
²37.86 mm (1.490 in.) for third gear surface
Check output shaft runout with V-blocks and a dial
indicator (Fig. 64). Maximum allowable runout is
0.06 mm (0.0024 in.).
Replace the output shaft if any surface measured
fails to meet stated tolerance.
Cluster Gear Inspection
Inspect the cluster gear teeth. Replace the gear if
any teeth are worn or damaged or if the bearing sur-
faces are damaged.
Check diameter of the cluster gear journal with a
micrometer (Fig. 65). Minimum allowable diameter is
27.860 mm (1.096 in.).
Check condition of the cluster gear front bearing.
Replace the bearing if worn, noisy, or damaged.
Fig. 64 Checking Output Shaft Tolerances
Fig. 65 Checking Cluster Gear Journal Diameter
JAX 15 MANUAL TRANSMISSION 21 - 51

(23) Install input shaft on output shaft (Fig. 59).
Be sure output shaft hub is fully seated in pilot bear-
ing.
OUTPUT SHAFT AND CLUSTER GEAR
INSTALLATION
(1) Mount intermediate plate in vise (Fig. 24).
(2) Lubricate cluster gear journal and rear bearing
with petroleum jelly or gear lubricant.
(3) Install cluster gear rear bearing in intermedi-
ate plate (Fig. 81). Be sure snap ring groove in bear-
ing is rearward as shown.
(4) Start cluster gear into bearing (Fig. 57). Then
hold bearing and push gear into place. Use plastic or
rawhide mallet to seat bearing if necessary.
(5) Start output shaft rear bearing in intermediate
plate. Push shaft rearward and tap intermediate
plate with mallet to seat bearing.
(6) Install snap rings on cluster and output shaft
rearbearings only (Fig. 82). Do not install front
bearing snap rings at this time.
(7) Install reverse idler gear and shaft (Fig. 83).(8) Position rear bearing retainer over output shaft
and rear bearing.Be sure bearing retainer tab is
engaged in reverse idler shaft notch (Fig. 84).
(9) Install and tighten rear bearing retainer bolts
to 18 Nzm (13 ft-lbs).
SHIFT RAIL AND FORK INSTALLATION
The shift rail interlock pins, balls and plugs must
be installed in the correct sequence for proper shift-
ing. Refer to the installation diagram (Fig. 85) during
assembly.
Coat the intermediate plate shift rail bores
and the interlock balls, pins and plugs with a
thick covering of petroleum jelly before assem-
bly. The jelly will hold the interlock compo-
nents in place making installation easier. Use a
pencil magnet to hold and insert the interlocks.
Then use a small screwdriver to push the inter-
lock components into place.
(1) Coat reverse rail interlock pin with petroleum
jelly and install pin in rail (Fig. 86).
(2) Install reverse shift rail in intermediate plate
(Fig. 87).
Fig. 81 Installing Cluster Gear Rear Bearing
Fig. 82 Installing Rear Bearing Snap Rings
Fig. 83 Installing Reverse Idler Gear And Shaft
Fig. 84 Installing Rear Bearing Retainer
21 - 56 AX 15 MANUAL TRANSMISSIONJ

(3) Install reverse shift rail C-ring (Fig. 51).
Fig. 85 Shift Rail Ball-Plug-Pin Position
Fig. 86 Installing Reverse Shift Rail Interlock Pin
Fig. 87 Installing Reverse Shift Rail And Fork
JAX 15 MANUAL TRANSMISSION 21 - 57

(4) Position 1-2 and 3-4 shift forks in synchro
sleeves (Fig. 88).
(5) Coat reverse rail lock ball with petroleum jelly.
Then tilt reverse shift fork upward and insert ball in
intermediate plate (Fig. 89).
(6) Coat 1-2 shift rail interlock plug with petro-
leum jelly and install it in intermediate plate bore
(Fig. 90).
(7) Coat 1-2 shift rail interlock pin with petroleum
jelly and insert it in shift rail (Fig. 91).(8) Install 1-2 shift rail in intermediate plate and
1-2 fork (Fig. 92).
Fig. 88 Shift Fork Installation
Fig. 89 Installing Reverse Shift Rail Lock Ball
Fig. 90 Installing 1-2 Shift Rail Interlock Plug
Fig. 91 Installing 1-2 Shift Rail Interlock Pin
Fig. 92 Installing 1-2 Shift Rail
21 - 58 AX 15 MANUAL TRANSMISSIONJ

(9) Coat 3-4 shift rail interlock plug with petro-
leum jelly and install plug in intermediate plate (Fig.
93).
(10) Install 3-4 shift rail in intermediate plate and
in both shift forks (Fig. 94).
(11) Verify that none of the interlock balls, plugs,
or pins were displaced during shift rail installation.
(12) Install and tighten shift fork setscrews to 20
Nzm (14 ft. lbs.) torque (Fig. 95).
(13) Install 1-2 and 3-4 shift rail C-rings (Fig. 96).
(14) Insert fifth gear shift rail through reverse
shift fork.Then slide rail into intermediate plate
just far enough to secure interlock ball. Do not
fully install shift rail at this time.
FIFTH-REVERSE GEAR AND SHIFT
COMPONENT INSTALLATION
(1) Install thrust ring lock ball in cluster gear jour-
nal (Fig. 97). Use petroleum jelly to hold ball in
place.
Fig. 93 Installing 3-4 Shift Rail Interlock Plug
Fig. 94 Installing 3-4 Shift Rail
Fig. 95 Installing Shift Fork Set Screws
Fig. 96 Installing Shift Rail C-Rings
Fig. 97 Installing Thrust Ring Lock Ball
JAX 15 MANUAL TRANSMISSION 21 - 59

(2) Install fifth gear thrust ring (Fig. 98). Be sure
thrust ring notch fits over lock ball.
(3) Assemble counter fifth gear, synchro sleeve, in-
serts and insert springs (Fig. 99).
(4) Lubricate two-piece bearing with petroleum
jelly and install it in counter fifth gear (Fig. 100).
(5) Install counter fifth gear and synchro assembly
on cluster gear journal (Fig. 101).
(6) Install synchro ring in synchro sleeve (Fig.
102).
Fig. 98 Installing Fifth Gear Thrust Ring
Fig. 99 Assembling Fifth Gear And Synchro
Assembly
Fig. 100 Installing Counter Fifth Gear Bearing
Fig. 101 Installing Counter Fifth Gear And Sleeve
Fig. 102 Installing Fifth Gear Synchro Ring
21 - 60 AX 15 MANUAL TRANSMISSIONJ

(7) Install fifth spline gear on cluster journal (Fig.
103). Tap spline gear into place with plastic mallet if
necessary.
(8) Install fifth gear selective snap ring (Fig. 104).
Use thickest snap ring that will fit in shaft groove.
(9) Install reverse shift head and rail (Fig. 105).
Then install lock ball in shift head.
(10) Position fifth gear shift fork in synchro sleeve
(Fig. 106).(11) Install fifth gear shift rail (Fig. 107). Slide rail
through fork, shift head, intermediate plate and re-
verse shift fork. Be sure interlock ball is not dis-
placed during installation.
Fig. 103 Installing Fifth Spline Gear
Fig. 104 Installing Fifth Gear Snap Ring
Fig. 105 Installing Reverse Shift Head And Rail
Fig. 106 Fifth Gear Shift Fork Installation
Fig. 107 Fifth Gear Shift Rail Installation
JAX 15 MANUAL TRANSMISSION 21 - 61