JEEP XJ 1995 Service And Repair Manual

(10) Remove shift rail No. 2 and shift forks 1 and 2
(Fig. 16).
(11) Remove reverse idler gear and shaft (Fig. 17).(12) Remove reverse shift arm and fork (Fig. 18).
MAINSHAFT DISASSEMBLY
(1) On AX 5, measure fifth counter gear thrust
clearance with feeler gauge (Fig. 19). Clearance
should be 0.10-0.30 mm (0.004-0.012 in.).
Fig. 16 Removing Shift Forks And No. 2 Shift Rail
Fig. 17 Removing Reverse Idler Gear And Shaft
Fig. 18 Reverse Shift Arm Removal
Fig. 19 Measuring Counter Fifth Gear Thrust
Clearance
JAX 4/5 MANUAL TRANSMISSION 21 - 9

(2) Engage two synchro sleeves to lock mainshaft
gears (Fig. 20).
(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. 21).(4) Remove fifth spline gear, synchronizer and
counter fifth gear with 2-, or 3-jaw puller (Fig. 22).
(5) Remove spacer and remove lock ball with pencil
magnet (Fig. 23).
Fig. 20 Locking Mainshaft Gears
Fig. 21 Removing Fifth Gear Snap Ring
Fig. 22 Removing Fifth Gear Assembly
Fig. 23 Spacer And Lock Ball Removal
21 - 10 AX 4/5 MANUAL TRANSMISSIONJ

(6) Remove reverse shift arm bracket (Fig. 24).
(7) Remove rear bearing retainer bolts with appro-
priate size torx bit and remove retainer (Fig. 25).(8) Remove rear bearing snap ring (Fig. 26).
(9) Tap intermediate plate with plastic mallet and
pull output shaft-counter gear assemblies out of plate
(Fig. 27).
(10) Remove rear bearing from intermediate plate.
(11) Remove input shaft and shaft roller bearings
from output shaft.
Fig. 24 Removing Reverse Shift Arm Bracket
Fig. 25 Removing Rear Bearing Retainer
Fig. 26 Removing Rear Bearing Snap Ring
Fig. 27 Removing Counter Gear And Output Shaft
JAX 4/5 MANUAL TRANSMISSION 21 - 11

(12) Measure thrust clearance of output shaft
gears (Fig. 28). Clearance should be 0.10 - 0.25 mm
(0.004 - 0.010 in.).
(13) Remove output shaft fifth gear snap ring with
two screwdrivers (Fig. 29).(14) Press fifth gear, rear bearing, first gear and
inner race off output shaft (Fig. 30).
(15) Remove needle roller bearing.
(16) Remove synchronizer ring.
(17) Remove synchronizer lock ball with pencil
magnet (Fig. 31).
Fig. 28 Checking Output Shaft Gear Thrust
Clearance
Fig. 29 Removing Fifth Gear Snap Ring
Fig. 30 Removing Fifth Gear And First Gear Bearing
And Race
Fig. 31 Synchronizer Lock Ball Removal
21 - 12 AX 4/5 MANUAL TRANSMISSIONJ

(18) Press 1-2 synchronizer and second gear off
output shaft (Fig. 32).
(19) Remove needle roller bearing from the shaft
or second gear.
(20) Remove 3-4 synchronizer snap ring (Fig. 33).
(21) Press 3-4 synchronizer and third gear off shaft
(Fig. 34).
(22) Remove needle roller bearing from shaft or
gear.
CLEANING AND INSPECTION
Clean the transmission components in solvent. Dry
the cases, gears, shift mechanism and shafts with
compressed air.Dry the bearings with clean, dry
shop towels only. Never use compressed air on
the bearings. This could cause severe damage
to the bearing roller and race surfaces.
Inspect the transmission case. Replace the case if
cracked, porous, or if any of the bearing and gear
bores are damaged.
Check thickness of the output shaft and inner bearing
race flanges with a micrometer or vernier calipers (Fig. 35).
²Minimum thickness for shaft flange is 4.8 mm
(0.189 in.)
²Minimum thickness for bearing race flange is 3.99
mm (0.157 in.)
Measure diameter of the output shaft journal sur-
faces with a micrometer (Fig. 36). Replace the shaft
if either of these surfaces are worn beyond specified
limits.
²Second gear surface minimum diameter is 37.96
mm (1.495 in.)
²Third gear surface minimum diameter is 34.98
mm (1.377 in.)
Measure output shaft runout with a dial indicator
(Fig. 37). Runout should not exceed 0.05 mm (0.002
in.).
Install the needle bearing and inner race in the
first gear. Then check oil clearance between the gear
and inner race (Fig. 38). Clearance should be 0.009 -
0.032 mm (0.0004 - 0.0013 in.).
Fig. 32 Second Gear And 1-2 Synchronizer Removal
Fig. 33 Removing 3-4 Synchronizer Snap Ring
Fig. 34 Removing 3-4 Synchronizer And Third Gear
JAX 4/5 MANUAL TRANSMISSION 21 - 13

Fig. 35 Checking Shaft And Bearing Race Flange
Thickness
Fig. 36 Checking Shaft And Race Diameters
Fig. 37 Checking Output Shaft Runout
Fig. 38 Checking Gear-To-Race Clearance
21 - 14 AX 4/5 MANUAL TRANSMISSIONJ

Install the needle bearings and the second, third
and counter fifth gears on the output shaft. Then
check oil clearance between the gears and shaft with
a dial indicator (Fig. 39). Oil clearance for all three
gears is 0.009 - 0.0013 mm (0.0004 - 0.0013 in.).
Check synchronizer ring wear (Fig. 40). Insert each
ring in matching gear. Measure clearance between
each ring and gear with feeler gauge. Replace ring if
clearance exceeds 2.0 mm (0.078 in.).Check shift fork-to-synchronizer hub clearance with
a feeler gauge (Fig. 41). Replace the fork if clearance
exceeds 1.0 mm (0.039 in.).
Fig. 39 Checking Gear-To-Shaft Oil Clearance
Fig. 40 Checking Synchronizer Ring Wear
Fig. 41 Checking Fork-To-Hub Clearance
JAX 4/5 MANUAL TRANSMISSION 21 - 15

TRANSMISSION ASSEMBLY AND ADJUSTMENT
Lubricate the transmission components with Mopar
75W-90, GL 5 gear lubricant during assembly. Use
petroleum jelly to lubricate seal lips and/or hold
parts in place during installation.
Refer to the Counter Gear Comparison Chart
(Fig. 42) during assembly for AX 4/5 gear differ-
ences.
Fig. 42 Counter Gear Components
21 - 16 AX 4/5 MANUAL TRANSMISSIONJ

ASSEMBLING OUTPUT SHAFT, INPUT SHAFT
AND COUNTER GEAR
(1) If front bearing was removed from input shaft,
press new bearing on shaft (Fig. 43).(2) Secure front bearing with thickest snap ring
that will fit in groove (Fig. 43).
(3) Press front bearing on counter gear. Secure
bearing with thickest snap ring that will fit in ring
groove (Fig. 44).
(4) Install new oil seals in front bearing retainer
and adapter (Fig. 45). Bearing retainer seal depth is
11.2 - 12.1 mm (0.441 - 0.480 in.).
(5) Install reverse shaft and shaft retaining pin in
adapter. Then install access hole plug with torx bit
(Fig. 46).
(6) Lubricate transmission components with speci-
fied gear lubricant.
(7) Assemble 1-2 and 3-4 synchronizer hubs,
sleeves, springs and key inserts (Fig. 47).
(8) Assemble and install third gear, needle bearing,
synchronizer ring, 3-4 synchronizer and snap ring on
output shaft (Fig. 48). Use thickest snap ring that
fits in shaft groove.
Fig. 43 Installing Front Bearing And Snap Ring
Fig. 44 Installing Counter Gear Front Bearing And
Snap Ring
JAX 4/5 MANUAL TRANSMISSION 21 - 17

Fig. 45 Oil Seal Installation
Fig. 46 Installing Reverse Shaft Pin
Fig. 47 Synchronizer Identification
Fig. 48 Installing Third Gear And 3-4 Synchronizer
21 - 18 AX 4/5 MANUAL TRANSMISSIONJ