remote control JEEP CJ 1953 Service Manual
[x] Cancel search | Manufacturer: JEEP, Model Year: 1953, Model line: CJ, Model: JEEP CJ 1953Pages: 376, PDF Size: 19.96 MB
Page 239 of 376
'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL
J
THREE-SPEED
TRANSMISSION
Contents
SUBJECT
PAR.
GENERAL
J-l
TRANSMISSION
SHIFTING
CONTROL.
. J-2
TRANSMISSION
REMOTE
CONTROL
ADJUSTMENT
J-3
REMOTE
CONTROL
DISASSEMBLY
J-4
REMOTE
CONTROL
REASSEMBLY.
. . . . J-5
TRANSMISSION
REMOVAL
J-6
SEPARATING
TRANSMISSION
AND
TRANSFER
CASE
J-7
SUBJECT
PAR.
DISASSEMBLY
OF
CANE
SHIFT
TRANSMISSION
J-8, J-12, J-16
Transmission
Cleaning and
Inspection J-10, J-18
Transmission
Interlocking Sleeve Inspection J-9
REASSEMBLY
OF
CANE
SHIFT
TRANSMISSION
J-ll,
J-14, J-19
SERVICE
DIAGNOSIS
J-20
TRANSMISSION
SPECIFICATIONS
J-21
J-1.
GENERAL
A
three speed synchromesh transmission is standard
equipment on all 'Jeep' Universal vehicles.
The
models T90 and T96 transmissions are used
with
the
Hurricane
F4 engine, and models
T86AA
and
T14A transmissions are used with the Daunt
less
V-6 engine. All model transmissions are similar
in
design with exception of the T14A which is a
fully
synchronized (all forward gears) transmission
with
helical drive gears throughout.
The
transmission assembly is attached to the
rear
face of the flywheel bell housing and is supported on a rubber insulator at the frame center cross member which forms the
rear
engine
support.
All
4-wheel-drive vehicles are equipped with a
transfer
case attached to the
rear
of the transmission.
Transfer
case service and repair procedures
are
described in Section
K.
Models
CJ-5A,
and
CJ-6A
are equipped with the
same transmission, but with a remote control shift.
Models DJ-5 and DJ-6 are equipped with a similar
transmission,
however, the construction is
some
what different because it is not designed to receive a transfer case for four-wheel drive.
For
DJ-5 and DJ-6 2WD vehicles, the trans mission repair procedures begin with Par. J-12.
J-2.
TRANSMISSION SHIFTING CONTROL
The
shift of the three-speed transmission is smooth
and
positive. The cane control lever shifts the trans
mission gears direct from the shift control housing
mounted to the top side of the transmission housing.
The
remote control lever shifts the transmission
gears through remote control rods attached to the
adjusting
levers of the shift shafts protruding from the left side of the transmission housing. Poppet
balls and springs retain the transmission gears in mesh and an interlocking mechanism prevents
shifting into two gears at the same time.
J-3.
Transmission Remote Control Adjustment
•
Early
CJ-5A,
CJ-6A
First
disconnect the transmission shift rods from the remote control levers.
Check
for binding of
the remote control shaft on the steering column
and
make the necessary corrections to eliminate any binding condition.
If
the shift is not smooth and positive, first make
sure
the gears are in neutral position then remove
the shift rods at the transmission by removing
clevis pins, Fig. J-l No. 17, and slip a short piece
of snug fitting 34" [6,35 mm.] aligning rod, through
the gearshift levers and housing as shown in insert
drawing.
This
places the clutch and shift lever assemblies
in
the neutral position. Adjust the shift rod yokes
at the transmission end, so clevis pins can be in stalled freely without moving the shift levers on the
transmission after which remove alignment pin.
If
shifting from first to second is difficult or trans
mission hangs in first gear, shorten the low and
reverse shift rod one
turn
at a time until the con
dition is corrected. Usually three turns are re
quired.
Should
the fault continue after completing the above adjustment, check further as outlined below.
First
remove the lubricating fitting. Use a narrow
feeler
gauge
which
will
enter the opening for the
lubricator
and check the clearance
between
the
faces of the shifting clutches.
This
clearance should
be .015" to .031", [W to W]
[0,397-0,794
mm.]. If
this clearance is greater the assembly must be removed for adjustment. The shift dog, which
engages
the clutch slots, should not have more than .009" [0,229 mm.] clearance in the slots. If the clear
ance
between
the clutch
grooves
and cross pins is
too great,
these
parts must be replaced.
J-4.
Removal
of
Remote Control
m
Early
CJ-5A,
CJ-6A
•
Refer to Fig. J-l
To
remove the remote control the following pro cedure is
suggested:
a.
Remove shifting rods from the transmission
and
also from the steering remote control clutch levers. 239
Page 240 of 376
THREE-SPEED
TRANSMISSION
FIG.
J-l—TRANSMISSION
REMOTE
CONTROL
CJ-5
A,
CJ-6A
1— Stop Screw
2—
Bias
Spring
3—
Gearshift
Lever
4—
Lever
Ball
5—
Steering
Wheel 6—
Horn
Button 7—
Column
and Bearing
8—
End
Huts
9—
Shift
Rod
Ends
10—
Shift
Rod
11—
Shift
Rod
12—
Cross-Shift
Bracket
13—
Control
Shaft
14—
Lubrication
Fitting
15—
Lever
and
Clutch
16—
Adjusting
Yoke
17—
Aligning
Rod 11706
b.
Remove gearshift lever fulcrum pin and the
gearshift lever.
c.
Remove plates on the toe board at the steer
ing
post.
d.
Remove two screws holding remote control
housing to the steering
post
and lift the housing
from
the positioning pin.
e.
Remove the assembly down through the floor
pan.
f. Remove the lower clutch and shift lever from the housing by turning counterclockwise.
g. Remove upper clutch and shift lever in the same
manner.
h. Wash all parts in a suitable cleaning solution.
J-5.
Reassembly of
Remote
Control
•
Refer to
Fig.
J-l
Check
clearance of shift dog which
engages
in slot
of clutches, and if found to be greater than .009" [0,229 mm.] clearance, replace the worn parts.
Assemble upper clutch lever assembly in housing
making
sure that the alignment
hole
in the housing
faces toward the engine.
Turn
the upper lever as
sembly in as far as it
will
go and then back off one
full
turn
until the
hole
in the clutch lever aligns
with
hole
in the housing.
Assemble the lower clutch lever assembly in hous ing until faces of clutches contact then back off
not more than one-half
turn
which should bring
the aligning
hole
in the lever in line with the
hole
in
the housing. If the one-half
turn
does
not bring
the alignment
hole
in proper position, it
will
be
necessary to grind off (square with axis not to exceed .015") [0,397 mm.] the face of the lower
clutch;
in other words, backing off not more than
one-half
turn
from face to face contact
gives
the
proper
clearance of .015" to .031"
[0,397-0,794
mm.]
between
the two clutches.
Assemble the unit to the steering
post
in reverse
order
of dismantling and adjust remote control
rods.
After
assembly, if the shift dog catches on the
edge
of the slot in the clutch when moving the lever up
and
down, disconnect the shift rod at the
transmission
end and either lengthen or shorten it
slightly to correct this condition.
J-6.
TRANSMISSION
REMOVAL
The
following repair procedures given in Par. J-7
through J-ll for the standard
3-speed
transmission
apply
in general to all models listed. Minor dif
ferences
between
models that affect the procedure
are
noted. Procedure for the optional
4-speed
transmission
begins
with Section
J-l.
Removal
is as follows:
a.
Drain
the transmission and transfer case. Re place the
drain
plugs.
b.
Remove the floor pan inspection plate.
c.
Remove the shift lever and shift housing as sembly and its gasket from the transmission. On 240
Page 241 of 376
'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL
J
10489
FIG.
J-2—THREE-SPEED
TRANSMISSION
— T90 1—
Main
Drive
Gear
2—
Main
Drive
Gear
Bearing
Retainer
3—
Main
Drive
Gear
Bearing
Retainer Oil
Seal
4—
Main
Drive
Gear
Snap
Ring
5—
Main
Drive
Gear
Bearing
Snap
Ring
6—
Main
Drive
Gear
Bearing
7—
Synchronizer
Shifting Plate
8—
Shift
Rail
Cap
9—
Shift
Rail—High
and Intermediate
10—
Shift
Rail
Poppet
Ball
11—
Shift
Rail
Poppet
Spring
12—
Shift
Fork—High
and Intermediate
13—
Control
Housing
14—
Control
Lever
Support
Spring
15—
Control
Lever
Housing Pin
16—
Control
Lever
Fulcrum
Ball
17—
Gear
Shift
Lever
18—
Shift
Fork—Low
and Reverse
19—
Sliding
Gear—Low
and Reverse
20—
Main
Shaft
Bearing
Adapter
21—
Main
Shaft
Bearing
22—
Main
Shaft
Washer
23—
Main
Shaft Nut
24—
Main
Shaft
25—
Idler
and Countershaft
Lock
Plate
26—
^Countershaft
Gear
Bearing
Rollers
2
7—Countershaft
28—
Countershaft
Thrust
Washer
Rear—Steel
29—
Countershaft
Thrust
Washer
Rear—Bronze
30—
Countershaft
Gears
31—
Transmission
Case
32—
Main
Shaft Second Speed
Gear
33—
Countershaft
Bearing
Spacer
34—
Synchronizer
Blocking
Ring
35—
Countershaft
Thrust
Washer
Front—Bronze
36—
Countershaft
Bearing
Washer
37—
Intermediate
and High Speed
Clutch
Sleeve
38—
Intermediate
and High
Clutch
Hub
39—
Synchronizer
Spring
40—
Intermediate
and High
Clutch
Hub
Snap
Ring
41—
Main
Shaft Pilot
Bearing
Roller
CJ-5A,
CJ-6A
models, remove the remote control
rods.
d.
Remove the set screw from the transfer case
shift lever pivot pin. Remove the pivot pin, shift
levers,
and shift lever springs. On models
CJ-5A,
and
CJ-6A
remove pivot pin cotter key and the
adjusting
rod attaching nut to remove shift lever.
See
Fig.
J-l.
e. If the vehicle is equipped with power take-off,
remove the shift lever plate screws and lift out the
lever.
f. Disconnect the front and
rear
propeller shafts
from
the transfer case, following the procedure de
tailed
in Section
L.
Should the vehicle be equipped
with
power take-off, disconnect the transfer case end of the power take-off drive shaft.
g. Disconnect the
speedometer
cable at the transfer case.
h.
Disconnect the hand brake cable.
i.
Disconnect the clutch release cable at beilcrank
yoke end.
j.
Place
jacks
under the transmission and engine,
protecting the
engine
oil pan with a block of wood,
k.
Remove the nuts holding
rear
mounting to
frame
cross member.
I.
Remove the transfer case snubbing rubber bolt
nut at cross member.
m.
Remove
bolts
holding frame center cross mem
ber
to frame side
rail
and remove cross member,
n.
Remove
bolts
holding transmission to flywheel
bellhousing.
o.
Force
transmission to right to
disengage
clutch
control
lever tube
ball
joint.
p.
Lower
jacks
under
engine
and transmission.
Slide
transmission and transfer case assemblies
toward
rear
of vehicle until the clutch shaft clears the flywheel housing.
q.
Lower
jack
under transmission. Remove trans mission and transfer case as an assembly from
under
the vehicle.
r.
For separation of the transmission and transfer
case, refer to Par. J-7. 241
Page 245 of 376
'Jeep*
UNIVERSAL
SERIES'
SERVICE
MANUAL
lightly
on the end of the
mainshaft
to
loosen
the
gear
and
separate
the two
units.
J-8.
Disassembly
—
T90,
T86AA
®
Refer to Fig. J-5, J-7
a. If the transfer
case
is
attached,
separate
it from
the
transmission
as
outlined
in Par. J-7. b.
Remove
the
shift
housing
and
gasket
from the
top of the
transmission
case.
The
shift
housing
can
be
disassembled,
if
necessary,
at
this
point
by re
moving
the
shift
rails and forks from the
shift
housing.
Use care not to
lose
the
poppet
balls
and
springs.
Note;
On
CJ-5
A
and
C
J-6A
models
equipped
with
side-shift
remote-control
transmission
it is
neces
sary to
remove
the main drive
gear
before
the
shift
forks can be
removed.
e.
Remove
the
three
screws
and
washers
attaching
the
front
main drive
gear
bearing
retainer to the
transmission.
Remove
the retainer and
gasket,
d.
Remove
the two
socket-head
screws
from the
front
end of the
transmission
case.
These
screws
support
the oil
collector
inside
the
case.
Note:
The oil
collector
has
been
discontinued
in
late
production
transmission
assemblies.
11881
FIG.
J-6—MAIN
SHAFT
RETAINING
PLATE
13321
FIG.
J-7—T86AA
THREE-SPEED
TRANSMISSION
—
CANE
SHIFT
1—
Bearing
Retainer Screws
2—
Main
Drive Gear Bearing Retainer
3—
Bearing
Retainer Oil Seal
,
4—Bearing Snap Ring
5—
Main
Drive Gear Snap Ring 6—
Main
Drive Gear Bearing 7—
Front
Bearing Oil Retaining Washer
8—
Main
Drive Gear
9— Pilot Roller Bearing
10— Shift
Rail
Cap
11—
Poppet
Ball
12—
Poppet
Spring
13—
Lock
Washer
14— Shift Housing Bolt
15—
Control
Housing 16— Interlock Plunger
17— Shift Lever Spring
18— Shift Tower Gasket
19— Blocking Ring 20—
Clutch
Hub Snap Ring
21— Synchronizer Spring
22— Synchronizer Plate
23—
Clutch
Hub
24—
Clutch
Sleeve
25— High and Intermediate Clutch
Fork
26— Shift
Fork
Pin
27— High and Intermediate Shift
Rail
28— Second Speed Gear 29—
Main
Shaft
30—
Low
and Reverse Sliding Gear
31—
Low
and Reverse Shift
Fork
32—
Low
and Reverse Shift
Rail
33—
Bearing
Spacer
34—
—Rear
Bearing Adapter
35—Rear
Bearing 36—
Rear
Bearing Snap Ring
37— Nut
38—Washer 39—
Transfer
Case Drive Gear
40—Lock
Plate
41 —Countershaft
42—
Rear
Countershaft Thrust Washer
(steel)
43—
Rear
Countershaft Thrust Washer (bronze)
44— Countershaft Bearing Washer
45— Countershaft Bearing 46— Countershaft Center Bearing Spacer
47— Reverse Idler Gear Shaft
48— Reverse Idler Gear Bearing Washer
49— Reverse Idler Gear Roller Bearings 50— Reverse Idler Gear
51— Countershaft Gear 52— Countershaft Front Thrust Washer
53— Plug 54— Shift Lever
55—
Transmission
Case
56— Retainer Gasket 245
Page 246 of 376
J
THREE-SPEED
TRANSMISSION
FIG.
J-8—SHAFT
LOCK
PLATE
e. Tap lightly on the front end of the countershaft
to loosen the lock plate. Remove the lock plate
from
slots cut in the
rear
ends of the countershaft
and
reverse idler shaft. Refer to Fig. J-8.
f. Using special tool No. W-166 or a brass drift,
drive
the countershaft toward the
rear
of the case
and
remove it. The countershaft gear set
will
drop
to the bottom of the transmission case. If the
special
tool is used, the needle bearing rollers
will
remain
in the countershaft gear hub and the gears
and
bearings may later be removed as an assembly.
g. Remove the mainshaft
rear
bearing adapter.
h.
Remove the mainshaft and gears from the case.
The
mainshaft assembly with the gears
still
in place
may
be removed through the
rear
bearing adapter
opening. Do not
lose
pilot roller bearing when
separating
shafts.
i.
On
early production transmissions drive the main
drive
gear into the case enough to remove the oil
collector. Remove the oil collector from the trans
mission case.
j.
Remove the main drive gear,
k.
Remove the countershaft gear set and the three
thrust
washers. Remove the washers, needle bear
ing rollers, and spacer from the assembly. 1, Remove the reverse idler shaft and gear by
driving
the shaft into the case using a brass drift,
m.
This
completes the disassembly of the trans
mission on
those
models with a cane shift,
n.
On
CJ-5
A
and
CJ-6 A
models equipped with a
remote shift transmission, inspect the poppet and
interlock
assembly which floats between the shift
lever assemblies described in Par. J-9.
FIG.
J-9—COUNTERSHAFT GEAR BEARING ARBOR
FIG.
J-l0—COUNTERSHAFT BEARING SPACERS J-9-
Transmission Interlocking Sleeve
I
inspection
a.
The interlock
sleeve
and poppet assembly should be carefully checked. Should the assembly
be too long, it
will
be impossible to shift gears and
if
it is too short, it
will
fail
to function as an inter
lock
to prevent shifting into two gears at one time.
Locate
the intermediate-and-high control arm for
second gear position. Use a feeler
gauge
to measure
the clearance between the ends of the interlock
sleeve
and the notched surface of each shift lever
as shown in Fig.
J-l
1.
Clearance
must be from .001" to .007" [0,025 a
0,178 mm.] on each side of the interlock sleeve.
To
obtain correct clearance, interlock
sleeves
are
available
for selective fit.
The
different lengths can be identified by a letter at the end.
1.287"
[3,269 cm.] — etched C
1.291"
[3,279 cm.] — etched B
1.295"
[3,289 cm.] — etched A
1.299"
[3,299 cm.] — no
mark
1.303"
[3,309 cm.] — etched D
Should
an interlock
sleeve
need replacing, proceed
as follows:
Where
necessary drive out the taper retaining pins
from
the bottom of the shift lever bosses. Remove
the nuts, lock washers, and flat washers from the
4
FIG.
J-l 1—INTERLOCK
SLEEVE
CLEARANCE
246