TJ TRANSMISSION AND TRANSFER CASE 21 - 1

TRANSMISSION AND TRANSFER CASE

CONTENTS

page page

AUTOMATIC TRANSMISSION—30/32RH . . . . . . 75 AX5 MANUAL TRANSMISSION . . . . . . . . . . . . . . 1

AX15 MANUAL TRANSMISSION . . . . . . . . . . . . 38 NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . 168

AX5 MANUAL TRANSMISSION

INDEX
page page

GENERAL INFORMATION DISASSEMBLY AND ASSEMBLY

AX5 MANUAL TRANSMISSION . . . . . . . . . . . . . . 1 ADAPTER/EXTENSION HOUSING AND
GEAR RATIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FRONT BEARING RETAINER . . . . . . . . . . . . . . 8
RECOMMENDED LUBRICANT . . . . . . . . . . . . . . . 2 COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 26
TRANSMISSION ASSEMBLY INFORMATION . . . . 2 INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 26
TRANSMISSION IDENTIFICATION . . . . . . . . . . . . 1 OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 28
DIAGNOSIS AND TESTING SEMI-SYNCHRONIZED REVERSE
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . .... 3 IDLER GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 32
LOW LUBRICANT LEVEL . . . . . . . . . . . . . . . .... 2 SHIFT MECHANISM AND GEARTRAIN . . . . . . . . 15
TRANSMISSION NOISE . . . . . . . . . . . . . . . . .... 4 CLEANING AND INSPECTION
REMOVAL AND INSTALLATION AX5 MANUAL TRANSMISSION
ADAPTER HOUSING SEAL . . . . . . . . . . . . . . . . . 7 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 33
EXTENSION HOUSING SEAL . . . . . . . . . . . . . . . 7 SPECIFICATIONS
FRONT BEARING RETAINER SEAL . . . . . . . . . . . 6 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIAL TOOLS
AX5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

GENERAL INFORMATION TRANSMISSION IDENTIFICATION

The AX5 identification code is on the bottom sur-
AX5 MANUAL TRANSMISSION face of the transmission case near the fill plug (Fig.
The AX5 is a five speed manual transmission with 2). The first number is year of manufacture. The sec-
fifth gear being the overdrive range. An adapter ond and third numbers indicate month of manufac-
housing is used to attach the transmission to the ture. The next series of numbers is the transmission
transfer case on 4-wheel drive applications. A stan- serial number.
dard style extension housing is used for the 2-wheel
drive applications. The shift mechanism is integral to
the transmission assembly and mounted in the shift
tower portion of the adapter/extension housing (Fig.
1).
21 - 2 TRANSMISSION AND TRANSFER CASE TJ
GENERAL INFORMATION (Continued)

Fig. 1 AX5 Manual Transmission

RECOMMENDED LUBRICANT
Recommended lubricant for AX5 transmissions is
Mopar� 75W–90, API Grade GL–3 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.
The fill plug is on the passenger side of the
adapter housing (Fig. 3). The drain plug is on the
bottom of the case.
Approximate dry fill lubricant capacity is:
• 3.3 liters (3.49 quarts) for 4–wheel drive applica-
tions.
• 3.5 liters (3.70 quarts) for 2–wheel drive applica-
tions.

TRANSMISSION ASSEMBLY INFORMATION

Lubricate the transmission components with
Mopar� 75W–90, GL 3 gear lubricant during assem-
bly. Use petroleum jelly to lubricate seal lips and/or
hold parts in place during installation.
Refer to (Fig. 4) during assembly for AX5 gear
Fig. 2 Transmission Identification assembly identification.
GEAR RATIOS
Gear ratios for the AX5 manual transmission are DIAGNOSIS AND TESTING
as follows:
• First gear: 3.93:1 LOW LUBRICANT LEVEL
• Second gear: 2.33:1 A low transmission lubricant level is generally the
• Third gear: 1.45:1 result of a leak, inadequate lubricant fill, or an incor-
• Fourth gear: 1.00:1 rect lubricant level check.
• Fifth gear: 0.85:1 Leaks can occur at the mating surfaces of the gear
• Reverse gear: 4.74:1 case, intermediate plate and adaptor or extension
TJ TRANSMISSION AND TRANSFER CASE 21 - 3
DIAGNOSIS AND TESTING (Continued)
A leak at the front of the transmission will be from
either the front bearing retainer or retainer seal.
Lubricant may be seen dripping from the clutch
housing after extended operation. If the leak is
severe, it may also contaminate the clutch disc caus-
ing the disc to slip, grab, and/or chatter.
A correct lubricant level check can only be made
when the vehicle is level. Also allow the lubricant to
settle for a minute or so before checking. These rec-
ommendations will ensure an accurate check and
avoid an underfill or overfill condition. Always check
the lubricant level after any addition of fluid to avoid
an incorrect lubricant level condition.

HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper, or contaminated lubricants. The con-
sequence of using non–recommended lubricants is
noise, excessive wear, internal bind, and hard shift-
Fig. 3 Fill Plug Location ing. Substantial lubricant leaks can result in gear,
housing, or from the front/rear seals. A suspected shift rail, synchro, and bearing damage. If a leak
leak could also be the result of an overfill condition. goes undetected for an extended period, the first indi-
Leaks at the rear of the extension or adapter hous- cations of component damage are usually hard shift-
ing will be from the housing oil seals. Leaks at com- ing and noise.
ponent mating surfaces will probably be the result of Component damage, incorrect clutch adjustment, or a
inadequate sealer, gaps in the sealer, incorrect bolt damaged clutch pressure plate or disc are additional
tightening, or use of a non–recommended sealer. probable causes of increased shift effort. Incorrect

Fig. 4 Geartrain Components

21 - 4 TRANSMISSION AND TRANSFER CASE TJ
DIAGNOSIS AND TESTING (Continued)
adjustment or a worn/damaged pressure plate or disc (11) Disengage any wire connectors attached to trans-
can cause incorrect release. If the clutch problem is mission or transfer case, if equipped, components.
advanced, gear clash during shifts can result. Worn or (12) Support transfer case, if equipped, with trans-
damaged synchro rings can cause gear clash when mission jack.
shifting into any forward gear. In some new or rebuilt (13) Secure transfer case, if equipped, to jack with
transmissions, new synchro rings may tend to stick safety chains.
slightly causing hard or noisy shifts. In most cases, this (14) Disconnect transfer case shift linkage at
condition will decline as the rings wear–in. transfer case, if equipped.
(15) Remove nuts attaching transfer case to trans-
TRANSMISSION NOISE mission, if equipped.
Most manual transmissions make some noise during nor- (16) Remove transfer case, if equipped.
mal operation. Rotating gears generate a mild whine that (17) Remove crankshaft position sensor (Fig. 6),
is audible, but generally only at extreme speeds. (Fig. 7).
Severe, highly audible transmission noise is gener-
ally the initial indicator of a lubricant problem.
Insufficient, improper, or contaminated lubricant will
promote rapid wear of gears, synchros, shift rails,
forks and bearings. The overheating caused by a
lubricant problem, can also lead to gear breakage.

REMOVAL AND INSTALLATION

TRANSMISSION
REMOVAL
(1) Shift transmission into first or third gear.
(2) Raise and support vehicle on suitable safety stands.
(3) Disconnect necessary exhaust system components.
(4) Remove skid plate, if equipped.
(5) Remove slave cylinder from clutch housing.
(6) Mark rear propeller shaft and rear axle yokes
for installation alignment (Fig. 5).

Fig. 6 Crankshaft Position Sensor—2.5L Engine

CAUTION: It is important that the crankshaft posi-
tion sensor be removed prior to transmission
removal. The sensor can easily be damaged if left
in place during removal operations.

(18) Support engine with adjustable jack stand.

Position wood block between jack and oil pan to
avoid damaging pan.
(19) Support transmission with transmission jack.
(20) Secure transmission to jack with safety
chains.
(21) Disconnect rear cushion and bracket from
Fig. 5 Marking Propeller Shaft And Axle Yokes transmission.
(7) Mark front propeller shaft, axle, and transfer (22) Remove rear crossmember.
case yokes for installation alignment, if equipped. (23) Disconnect transmission shift lever as follows:
(8) Remove propeller shaft(s). (a) Lower transmission–transfer case assembly
(9) Unclip wire harnesses from transmission and approximately 7–8 cm (3 in.) for access to shift lever.
transfer case, if equipped. (b) Reach up and around transmission case and
(10) Disconnect transfer case vent hose, if unseat shift lever dust boot from transmission shift
equipped. tower (Fig. 8). Move boot upward on shift lever for
access to retainer that secures lever in shift tower.
TJ TRANSMISSION AND TRANSFER CASE 21 - 5
REMOVAL AND INSTALLATION (Continued)
(28) Remove clutch housing from transmission
(Fig. 9).

Fig. 7 Crankshaft Position Sensor —4.0L Engine

(c) Reach up and around transmission case and
press shift lever retainer downward with finger pres-
sure. Turn retainer counterclockwise to release it.
(d) Lift lever and retainer out of shift tower (Fig.
8). Do not remove the shift lever from the floor con-
sole shifter boots. Leave the lever in place for
transmission installation.
Fig. 9 Clutch Housing
INSTALLATION
(1) Install clutch housing on transmission. Tighten
housing bolts to 37 N·m (27 ft. lbs.) torque.
(2) Lubricate contact surfaces of release fork pivot
ball stud and release fork with high temp grease.
(3) Install release bearing, fork, and retainer clip.
(4) Position and secure transmission on transmis-
sion jack.
(5) Lightly lubricate pilot bearing and transmis-
sion input shaft splines with Mopar� high temp
grease.
(6) Raise transmission and align transmission
input shaft and clutch disc splines. Then slide trans-
mission into place.
(7) Install and tighten clutch housing-to-engine
Fig. 8 Removing/Installing Shift Lever bolts to 38 N·m (28 ft. lbs.) torque (Fig. 9). Be sure
the housing is properly seated on engine block
(24) Remove clutch housing brace rod. before tightening bolts.
(25) Remove clutch housing-to-engine bolts. (8) Install clutch housing brace rod.
(26) Pull transmission jack rearward until input (9) Lower transmission approximately 7–8 cm (3
shaft clears clutch. Then slide transmission out from in.) for access to shift tower. Be sure transmission is
under vehicle. in first or third gear.
(27) Remove clutch release bearing, release fork, (10) Reach up and around transmission and insert
and retainer clip. shift lever in shift tower. Press lever retainer down-
21 - 6 TRANSMISSION AND TRANSFER CASE TJ
REMOVAL AND INSTALLATION (Continued)
ward and turn it clockwise to lock it in place. Then (30) Install skid plate, if equipped. Tighten bolts to
install lever dust boot on shift tower. 42 N·m (31 ft. lbs.) torque. Tighten stud nuts to 17
(11) Install rear crossmember. Tighten crossmem- N·m (150 in. lbs.) torque.
ber-to-frame bolts to 41 N·m (31 ft. lbs.) torque. (31) Fill transmission and transfer case, if
(12) Install fasteners to hold rear cushion and equipped, with recommended lubricants. Refer to the
bracket to transmission. Then tighten transmission-to- Lubricant Recommendation sections of the appropri-
rear support bolts/nuts to 45 N·m (33 ft. lbs.) torque. ate component for correct fluid.
(13) Remove support stands from engine and (32) Lower vehicle.
transmission.
(14) Install and connect crankshaft position sensor. FRONT BEARING RETAINER SEAL
(15) Position transfer case on transmission jack, if
equipped. REMOVAL
(16) Secure transfer case to jack with safety (1) Remove release bearing and lever from the
chains, if equipped. transmission.
(17) Raise transfer case, if equipped, and align transfer (2) Remove the bolts holding the front bearing
case input shaft to the transmission output shaft. retainer to the transmission case.
(18) Slide transfer case forward until case is (3) Remove the front bearing retainer from the
seated on transmission, if necessary. transmission case.
(19) Install nuts to attach transfer case to trans- (4) Using a suitable pry tool, remove the front
mission, if equipped. Tighten transfer case-to-trans- bearing retainer seal.
mission nuts to 35 N·m (26 ft. lbs.) torque.
(20) Connect transfer case shift linkage at transfer INSTALLATION
case, if equipped. (1) Using Tool Handle C-4171 and Seal Installer
(21) Connect transfer case vent hose, if equipped. 8211, install new seal in to the front bearing retainer
(22) Secure wire harnesses in clips/tie straps on (Fig. 11).
transmission and transfer case, if equipped.
(23) Engage wire connectors attached to all necessary
transmission or transfer case, if equipped, components.
(24) Install rear propeller shaft slip yoke to trans-
mission or transfer case, if equipped, output shaft.
(25) Align marks on rear propeller shaft and rear
axle yokes (Fig. 10).

Fig. 11 Install Front Bearing Retainer Seal

Fig. 10 Align Propeller Shaft And Rear Axle Yokes
(2) Remove any residual gasket material from the
Alignment Marks
sealing surfaces of the bearing retainer and the
(26) Install and tighten propeller shaft U–joint transmission case.
clamp bolts to 19 N·m (170 in. lbs.) torque. (3) Install new front bearing retainer gasket to the
(27) Align marks on front propeller shaft, axle, front bearing retainer.
and transfer case yokes, if equipped. (4) Install the front bearing retainer onto the
(28) Install and tighten propeller shaft U–joint transmission case.
clamp bolts to 19 N·m (170 in. lbs.) torque. (5) Install the bolts to hold the bearing retainer
(29) Install slave cylinder in clutch housing. onto the transmission case.
TJ TRANSMISSION AND TRANSFER CASE 21 - 7
REMOVAL AND INSTALLATION (Continued)
(6) Tighten the bolts to 17 N·m (12 ft. lbs.). (5) Lower vehicle.
(7) Install release bearing and lever onto the
transmission. ADAPTER HOUSING SEAL
EXTENSION HOUSING SEAL REMOVAL
REMOVAL (1) Hoist and support vehicle.
(1) Raise and support vehicle. (2) Remove transfer case.
(2) Remove propeller shaft. Refer to Group 3, Dif- (3) Using a suitable pry tool, or a slide hammer
ferential and Driveline, for proper procedures. mounted screw, remove the adapter housing seal
(3) Using a suitable seal puller or screw with a slide (Fig. 14).
hammer, remove the extension housing seal (Fig. 12).

Fig. 14 Remove Adapter Housing Seal

Fig. 12 Remove Extension Housing Seal
INSTALLATION
INSTALLATION (1) Clean seal bore of adapter housing of any
(1) Clean seal bore of extension housing of any residual sealer material from original seal.
residual sealer material from original seal. (2) Using Tool Handle C-4171 and Seal Installer
(2) Using Tool Handle C-4171 and Seal Installer 8208, install new seal so that the seal is located 0 �
8212, install new extension housing seal so that the 0.2 mm (0 � 0.008 in.) to the seal bore face of
seal is located 0 � 0.5 mm (0 � 0.02 in.) to the face adapter housing (Fig. 15).
of the extension housing (Fig. 13).

Fig. 13 Install Extension Housing Seal

(3) Install propeller shaft. Refer to Group 3, Differ-
ential and Driveline, for proper procedures.
(4) Check and add fluid to transmission as neces-
sary. Refer to the Recommended Lubricant section for
proper fluid requirements. Fig. 15 Install Adapter Housing Seal
21 - 8 TRANSMISSION AND TRANSFER CASE TJ
REMOVAL AND INSTALLATION (Continued)
(3) Install transfer case. (8) Remove detent ball plug (Fig. 19).
(4) Check and add fluid to transmission as neces- (9) Remove detent spring and ball with pencil
sary. Refer to the Recommended Lubricant section for magnet (Fig. 20), (Fig. 21).
proper fluid requirements.
(5) Lower vehicle.

DISASSEMBLY AND ASSEMBLY

ADAPTER/EXTENSION HOUSING AND FRONT
BEARING RETAINER
DISASSEMBLY
(1) Drain transmission lubricant, if necessary.
(2) Remove release bearing and lever.
(3) Remove clutch housing bolts and remove hous-
ing (Fig. 18).
(4) Remove vehicle speed sensor and speedometer
adapter, if necessary.
(5) Remove bolts holding shift tower to transmis-
sion case.
(6) Remove shift tower from transmission case
(Fig. 16).
(7) Remove shift tower gasket from shift tower or
transmission case (Fig. 17).

Fig. 18 Clutch Housing

Fig. 16 Remove Shift Tower

Fig. 19 Remove Detent Ball Plug

(10) Remove shift arm retainer bolt (Fig. 22).
(11) Remove shift arm restrictor pins (Fig. 23).
(12) Remove shift lever shaft plug (Fig. 24).
(13) Remove shifter shaft with large magnet (Fig. 25).
Fig. 17 Remove Shift Tower Gasket (14) Remove the shift arm from the adapter housing.
TJ TRANSMISSION AND TRANSFER CASE 21 - 9
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 23 Shift Arm Rstrictor Pins

Fig. 20 Remove Detent Spring

Fig. 21 Remove Detent Ball Fig. 24 Removing Shift Lever Shaft Plug

Fig. 22 Shift Arm Retainer Bolt Removal Fig. 25 Remove Shifter Shaft
21 - 10 TRANSMISSION AND TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(15) Remove adapter/extension housing bolts.
(16) Loosen adapter/extension housing by tapping
it loose with plastic mallet (Fig. 26).
(17) Remove adapter/extension housing (Fig. 27).

Fig. 28 Speedometer Drive Gear Assembly

Fig. 26 Loosen Adapter/Extension Housing

Fig. 29 Remove Front Bearing Retainer

Fig. 27 Remove Adapter/Extension Housing–Typical

(18) On 4x2 transmissions;
(a) Remove speedometer gear retaining snap-
ring from output shaft.
(b) Remove speedometer gear from output shaft
and remove speedometer gear lock ball from output
shaft.
(c) Remove speedometer drive gear locating
snap-ring (Fig. 28).
(19) Remove the bolts holding the front bearing
retainer to the transmission case.
(20) Remove the bearing retainer from transmis- Fig. 30 Remove Input Shaft Bearing Snap-ring
sion case (Fig. 29).
ASSEMBLY
(21) Remove input shaft bearing snap-ring (Fig. 30).
(1) Remove any residual sealer from transmission case,
(22) Remove countershaft front bearing snap-ring.
intermediate plate, and adapter/extension housing.
(23) Separate intermediate plate and transmission case
(2) Apply a 1/8 to 3/16 inch wide bead of Threeb-
by tapping them loose with plastic mallet (Fig. 31).
ond� Liquid Gasket TB1281, P/N 83504038, as
(24) Separate the intermediate plate from the
shown, making sure to keep sealer bead to inside of
transmission case (Fig. 32).
bolt holes (Fig. 33).
TJ TRANSMISSION AND TRANSFER CASE 21 - 11
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 31 Separate Intermediate Plate and Fig. 34 Install Transmission Gear Case to the
Transmission Case Intermediate Plate
(4) Install new front bearing snap rings (Fig. 35).

Fig. 32 Remove Intermediate Plate from

Transmission Case
(3) Align geartrain and shift rails with mating
holes in transmission case and install transmission
case to the intermediate plate (Fig. 34). Verify that
the transmission case is seated on the intermediate
plate locating pins.

Fig. 35 Install Front Bearing Snap-rings

Fig. 33 Apply Sealer to Transmission Gear Case

21 - 12 TRANSMISSION AND TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(5) Install front bearing retainer gasket to front
bearing retainer.
(6) Install the front bearing retainer (Fig. 36) and
tighten bolts to 17 N·m (12 ft. lbs.).

Fig. 38 Install Adapter/Extension Housing–Typical

Fig. 36 Install Front Bearing Retainer

(7) On 4x2 transmissions;
(a) Install speedometer drive gear locating snap-
ring (Fig. 37).
(b) Install speedometer gear lock ball in output shaft
and install speedometer gear onto output shaft.
(c) Install speedometer gear retaining snap-ring
onto output shaft.
(8) Apply a 1/8 to 3/16 inch wide bead of Threeb-
ond� Liquid Gasket TB1281, P/N 83504038, to seal-
ing surface of adapter/extension housing, making
sure to keep sealer bead to inside of bolt holes.
(9) Install adapter or extension housing on inter- Fig. 39 Position Shift Arm in Adapter or Extension
mediate plate (Fig. 38). Tighten housing bolts to 34 Housing
N·m (25 ft. lbs.) torque. (11) Start shifter arm shaft in hole in back of
(10) Position shift arm in shifter tower opening of adapter or extension housing. Align shift arm and
adapter or extension housing (Fig. 39). Be sure that shifter arm shaft and insert shifter arm shaft
the shifter arm is engaged into the shift rails. through the shifter arm and into the forward portion
of the adapter or extension housing (Fig. 40).
(12) Rotate the shifter arm shaft until the hole in
the shift arm is aligned with the hole in the shaft.
(13) Install the shift arm retainer bolt and tighten
to 38 N·m (28 ft. lbs.) (Fig. 41).

Fig. 37 Speedometer Drive Gear Assembly

TJ TRANSMISSION AND TRANSFER CASE 21 - 13
DISASSEMBLY AND ASSEMBLY (Continued)
(14) Install and tighten shifter arm shaft plug to
18 N·m (13 ft. lbs.) torque (Fig. 42).

Fig. 42 Shifter Arm Shaft Plug Installation

Fig. 40 Install Shifter Arm Shaft (15) Install shift restrictor pins in shift tower and
tighten to 27 N·m (20 ft. lbs.) (Fig. 43).

Fig. 41 Install Shift Arm Retainer Bolt

Fig. 43 Install Shifter Restrictor Pins
(16) Install shift detent ball in detent opening of
case (Fig. 44).
(17) Install detent spring in case (Fig. 45).
21 - 14 TRANSMISSION AND TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(18) Install detent plug and tighten to 19 N·m (14
ft. lbs.) (Fig. 46).

Fig. 46 Install Detent Ball Plug

Fig. 44 Install Detent Ball

Fig. 47 Install Shift Tower

Fig. 45 Install Detent Spring

(19) Install shift tower gasket onto shift tower.
(20) Install the shift tower oil deflector and gasket
onto the adapter or extension housing.
(21) Install shift tower onto transmission case
(Fig. 47).
(22) Install bolts to hold shift tower to transmission
case. Tighten tower bolts to 18 N·m (13 ft. lbs.) torque.
(23) Install new metal o-ring onto the backup lamp
switch.
(24) Install backup lamp switch (Fig. 48). Tighten
switch to 44 N·m (32.5 ft. lbs.) torque.
(25) Install new seal in adapter/extension housing.
(26) Install vehicle speed sensor, if necessary.
(27) Install clutch housing, release bearing, release
fork and retainer clip. Fig. 48 Install Backup Lamp Switch
TJ TRANSMISSION AND TRANSFER CASE 21 - 15
DISASSEMBLY AND ASSEMBLY (Continued)
SHIFT MECHANISM AND GEARTRAIN (3) Remove bolt holding fifth gear shift fork to
shift rail (Fig. 51).
DISASSEMBLY
(1) Install suitable bolts and washers in intermedi-
ate plate (Fig. 49). Then clamp plate and gear assem-
bly in vise. Use enough washers to prevent bolts
from touching. Also be sure vise jaws are clamped on
bolt heads.

Fig. 51 Remove Shift Fork Retainer Bolt

(4) Remove fifth gear blocker ring from counter-
shaft assembly with Puller L-4407 (Fig. 52).

Fig. 49 Positioning Intermediate Plate In Vise

(2) Remove countershaft fifth gear retaining snap-
ring (Fig. 50).

Fig. 52 Remove Fifth Gear Blocker Ring

Fig. 50 Remove Fifth Gear Snap-ring

21 - 16 TRANSMISSION AND TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(5) Remove fifth gear synchro ring (Fig. 53).
(6) Remove the countershaft fifth gear assembly
from countershaft (Fig. 54).

Fig. 55 Remove Fifth Gear Thrust Ring

Fig. 53 Remove Fifth Gear Synchro Ring

Fig. 56 Remove Fifth Gear Thrust Ring Lock Ball

(11) Remove bolts holding output shaft rear bear-
ing retainer to the intermediate plate and remove
Fig. 54 Remove Fifth Gear and Synchro Assembly retainer (Fig. 58).
(7) Remove fifth gear thrust ring from counter-
shaft (Fig. 55).
(8) Remove fifth gear thrust ring lock ball from
countershaft (Fig. 56).

NOTE: There are many lock balls, check balls,

interlock balls, and interlock pins used in various
places in the transmission. Whenever a pin or ball
is removed, it should be identified in such a way
that it can be reinstalled in the same location from
which it was removed.

(9) Remove bolt holding reverse idler gear shaft

lock plate to the intermediate plate.
(10) Remove reverse idler gear shaft and reverse
idler gear assembly (Fig. 57).

NOTE: Be sure to retrieve the pin and compression Fig. 57 Remove Reverse Idler Shaft
spring from the reverse idler shaft.
TJ TRANSMISSION AND TRANSFER CASE 21 - 17
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 58 Remove Output Shaft Rear Bearing Retainer

(12) Remove bolts holding 1–2 and 3–4 shift forks
to the shift rails (Fig. 59) and discard bolts.
(13) Remove bolts holding reverse shift arm
bracket to intermediate plate (Fig. 60).

Fig. 60 Remove Reverse Shift Arm Bracket Bolts

Fig. 59 Remove Shift Fork To Shift Rail Bolts

(14) Remove snap-ring holding output shaft rear
bearing into the intermediate plate (Fig. 61).
(15) Remove countershaft rear bearing snap-ring.
(16) With aid of an assistant, support the main- Fig. 61 Remove Output Shaft Rear Bearing
shaft and countershaft. Tap on the rear of the main- Snap-ring
shaft and countershaft with a suitable plastic mallet.
This will release the countershaft from the counter-
shaft rear bearing and the mainshaft rear bearing
from the intermediate plate. The countershaft will
release from the countershaft bearing first and can
be removed by moving the countershaft rearward and
downward (Fig. 62).
21 - 18 TRANSMISSION AND TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(17) Remove the mainshaft by moving the main-
shaft forward until the mainshaft rear bearing is
clear of the intermediate plate and then rotating the
mainshaft downward out of the shift forks (Fig. 63).

Fig. 62 Remove Countershaft and Countershaft

Rear Bearing
Fig. 64 Remove 3–4 Shift Fork

Fig. 63 Remove Mainshaft

Fig. 65 Remove 1–2 Shift Fork
(18) Remove the 3–4 shift fork from the 3–4 shift
rail (Fig. 64). (21) Remove threaded plugs from intermediate plate.
(19) Remove the snap-ring from near the end of Then remove lock ball and spring from plug holes with
the 1–2 shift rail to allow the removal of the 1–2 pencil magnet (Fig. 66). Note that the bottom spring is
shift fork. shorter in length than the other two springs.
(20) Remove the 1–2 shift fork from the 1–2 and (22) Remove the intermediate plate from the vise,
the 3–4 shift rails (Fig. 65). rotate the plate 180°, and reinstall the plate in the vise
using the same bolt and washer mounting set-up.
TJ TRANSMISSION AND TRANSFER CASE 21 - 19
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 68 Remove Fifth Gear Check Ball

Fig. 66 Remove Lock Ball And Spring

CAUTION: The interlock balls and pins are different
sizes and shapes. Be sure to correctly identify
which position an item is removed from to ensure
that it is reinstalled in the same location.

(23) Remove fifth gear shift rail (Fig. 67). Fig. 69 Remove Reverse Shift Head And Rail
Assembly
(27) Remove reverse shift rail and reverse shift
fork and arm assembly from intermediate plate (Fig.
70).

Fig. 67 Remove Fifth Gear Shift Rail

(24) Remove fifth gear check ball (Fig. 68) and
interlock pin.
(25) Remove reverse shift head and rail assembly
(Fig. 69).
(26) Remove snap-ring holding reverse shift rail
into intermediate plate. Fig. 70 Remove Reverse Shift Rail
21 - 20 TRANSMISSION AND TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(28) Remove interlock pin from reverse shift rail (30) Remove snap-ring on 3–4 shift rail.
(Fig. 71). (31) Remove 1–2 shift rail from intermediate plate.
(32) Remove interlock pin from 1–2 shift rail (Fig.
73).

Fig. 71 Remove Interlock Pin From Reverse Shift

Rail
(29) Remove reverse elongated check ball (Fig. 72).

Fig. 73 Remove 1–2 Shift Rail Interlock Pin

(33) Remove 1–2 shift rail elongated check ball
from intermediate plate (Fig. 74).
(34) Remove 3–4 shift rail from intermediate plate.

Fig. 72 Remove Reverse Check Ball Fig. 74 Remove 1–2 Check Ball
TJ TRANSMISSION AND TRANSFER CASE 21 - 21
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 75 Shift Rail Components

ASSEMBLY (3) Install the interlock pin into the 1–2 shift rail
Refer to (Fig. 75) while assembling and installing (Fig. 77).
the shift rail components. Also, verify that all shift (4) Install the 1–2 shift rail into the intermediate plate.
rail components are in their neutral position when
installing the check balls and interlock pins.
(1) Install the 3–4 shift rail into the intermediate plate.
(2) Install the 1–2 elongated check ball into the
intermediate plate (Fig. 76).

Fig. 77 Install 1–2 Shift Rail Interlock Pin

Fig. 76 Install 1–2 Check Ball

21 - 22 TRANSMISSION AND TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(5) Install snap-ring onto 3–4 shift rail.
(6) Install the reverse check ball into the interme-
diate plate (Fig. 78).

Fig. 80 Install Reverse Arm Bracket to Fork

(9) Install reverse shift rail into intermediate plate
and position reverse arm bracket to intermediate
plate (Fig. 81).

Fig. 78 Install Reverse Check Ball

(7) Install the interlock pin into the reverse shift
rail (Fig. 79).
(8) Assemble the reverse arm bracket to the
reverse fork (Fig. 80).

Fig. 81 Install Reverse Shift Rail

(10) Install snap-ring onto reverse shift rail (Fig. 82).

Fig. 79 Install Reverse Interlock Pin

Fig. 82 Install Reverse Snap-ring

TJ TRANSMISSION AND TRANSFER CASE 21 - 23
DISASSEMBLY AND ASSEMBLY (Continued)
(11) Install reverse shift head and rail assembly
into the intermediate plate.
(12) Install the fifth gear interlock ball and check
ball (Fig. 83).

Fig. 85 Install 1–2 Shift Fork

Fig. 83 Install Fifth Gear Check Ball

(13) Install fifth gear shift rail (Fig. 84).

Fig. 84 Install Fifth Gear Shift Rail

(14) Remove the intermediate plate from the vise,
rotate the plate 180°, and reinstall the plate in the vise Fig. 86 Install 3–4 Shift Fork
using the same bolt and washer mounting set-up. the appropriate synchronizer sleeves. The mainshaft
(15) Install the shift rail detent balls in the inter- rear bearing will be started in the intermediate plate
mediate plate. but not fully driven in at this point.
(16) Install the shift rail detent springs in the (22) While an assistant supports the mainshaft,
intermediate plate. Note that the bottom detent align rear of countershaft with inner race of counter-
spring is shorter than the others. shaft rear bearing.
(17) Install the shift rail detent plugs in the inter- (23) Raise countershaft upward until gears mesh
mediate plate. with the mating gears on the mainshaft.
(18) Install the 1–2 shift fork onto the 1–2 and 3–4 (24) Using a suitable rubber mallet, tap on the
shift rails (Fig. 85). input shaft and the front of the countershaft equally
(19) Install the snap-ring onto the 1–2 shift rail. to install the mainshaft rear bearing into the inter-
(20) Install the 3–4 shift fork onto the 3–4 shift mediate plate and the rear of the countershaft into
rail (Fig. 86). the rear countershaft bearing. It may be necessary to
(21) Install mainshaft into the intermediate plate occasionally hold the countershaft into the intermedi-
by guiding the output shaft through opening in inter- ate plate and tap the countershaft rear bearing onto
mediate plate until the shift forks are aligned with the countershaft and into the intermediate plate.
21 - 24 TRANSMISSION AND TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(25) Install snap-rings onto the rear mainshaft and
countershaft bearings.
(26) Install the bolts to hold the reverse shift arm
bracket to the intermediate plate.
(27) Install new bolts to hold the shift forks to the
shift rails (Fig. 87).

Fig. 88 Reverse Shift Arm Position

Fig. 87 Install Shift Fork Bolts

(28) Position the mainshaft rear bearing retainer
over the output shaft and onto the intermediate
plate.
(29) Install new bolts to hold the bearing retainer
to the intermediate plate.
(30) Move the reverse shift arm into the reverse
gear position. The reverse gear position is with the
arm moved away from the intermediate plate (Fig.
88).
(31) Install the reverse idler gear assembly into
position on the mainshaft and reverse shift arm. Fig. 89 Install Compression Spring And Pin
(32) Install the compression spring and pin into
the reverse idler gear shaft (Fig. 89).
(33) Install the reverse idler shaft through the
intermediate plate and reverse idler gear assembly
(Fig. 90) until the idler shaft pin contacts the gear
assembly. Make sure that the notched cut-out in the
idler shaft is to the rear of the transmission.
(34) Align the pin with the alignment notch in the
reverse idler gear assembly (Fig. 91). The alignment
notch in the reverse idler gear race/hub is a small
relief cut above one of the main longitudinal slots. Be
sure that the pin is aligned with the proper slot, the
opposite slot has an oil drain hole which the pin will
drop into. The assembly will then be locked onto the
shaft and will need to be disassembled in order to be
removed.
Fig. 90 Install Reverse Idler Shaft
TJ TRANSMISSION AND TRANSFER CASE 21 - 25
DISASSEMBLY AND ASSEMBLY (Continued)
(35) Depress compression spring and pin in (40) Install the fifth gear thrust ring onto the
reverse idler gear shaft (Fig. 92). countershaft and over the lock ball (Fig. 94).

Fig. 91 Align Idler Shaft Pin Fig. 93 Install Fifth Gear Thrust Ring Lock Ball

Fig. 92 Depress Pin In Reverse Idler Gear Shaft Fig. 94 Install Fifth Gear Thrust Ring
(36) Install the reverse idler gear shaft the (41) Install fifth gear shift fork to the countershaft
remainder of the way through the reverse idler gear fifth gear assembly.
assembly. (42) Install the countershaft fifth gear bearings
(37) Position the reverse idler gear shaft lock plate into the countershaft fifth gear assembly.
onto the intermediate plate. (43) Position the countershaft fifth gear assembly
(38) Install a new bolt to hold the idler gear shaft on the countershaft. Ensure that the fifth gear fork is
lock plate to the intermediate plate. installed onto the fifth gear shift rail.
(39) Install the fifth gear thrust ring lock ball to (44) Install the fifth gear synchro ring.
the countershaft (Fig. 93).
21 - 26 TRANSMISSION AND TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(45) Position the fifth gear blocker ring onto the
countershaft.
(46) Using a suitable mallet and spacer, tap the
fifth gear blocker ring onto the countershaft.
(47) Install new bolt to hold fifth gear shift fork to
the fifth gear shift rail (Fig. 95).

Fig. 96 Countershaft Front Bearing Snap-ring

(4) Select the thickest snap-ring that will fit into
the snap-ring groove of the countershaft (Fig. 96).
Fig. 95 Install Fifth Gear Retainer Bolt (5) Install snap-ring to hold countershaft front
(48) Measure countershaft fifth gear thrust clear- bearing onto countershaft.
ance.
(49) Select a snap-ring so that the thrust clearance INPUT SHAFT
is 0.10–0.30 mm (0.004–0.010 in.).
DISASSEMBLY
(50) Install snap-ring to hold fifth gear blocker
(1) Verify that the 3–4 synchronizer is in the neu-
ring onto countershaft.
tral position.
(51) Remove intermediate plate from vise and
(2) Separate input shaft from output shaft (Fig.
remove bolts and washers from intermediate.
97). Note that the output shaft pilot bearing is an
uncaged roller type bearing.
COUNTERSHAFT
DISASSEMBLY
(1) Remove select fit snap-ring holding the coun-
tershaft front bearing onto the countershaft (Fig. 96).
(2) Using Bearing Splitter P-334, a suitable spacer
on center of countershaft, and a shop press, remove
the countershaft front bearing from the countershaft.

ASSEMBLY
(1) Remove any nicks or burrs on countershaft hub
with fine emery or crocus cloth.
(2) Position countershaft front bearing on end of
countershaft.
(3) Using Special Tool 8109 and a shop press,
press bearing onto countershaft.

Fig. 97 Separate Input and Output Shafts

TJ TRANSMISSION AND TRANSFER CASE 21 - 27
DISASSEMBLY AND ASSEMBLY (Continued)
(3) Remove the output shaft pilot bearing rollers
from the input shaft and the output shaft.
(4) Remove the fourth gear synchronizer ring from
the input shaft (Fig. 98).

Fig. 98 Input Shaft Components

(5) Remove the select fit snap-ring holding the
input shaft bearing onto the input shaft.
(6) Using Bearing Splitter P-334 and a shop press,
remove the bearing from the input shaft.

ASSEMBLY
(1) Position input shaft bearing onto input shaft.
(2) Using Driver L-4507, drive bearing onto input
shaft.
(3) Select the thickest snap-ring that will fit into
the snap-ring groove of the input shaft (Fig. 99).
(4) Lubricate output shaft pilot bearing bore of
input shaft with petroleum jelly.

Fig. 99 Select Input Shaft Bearing Snap-ring

21 - 28 TRANSMISSION AND TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(5) Install output shaft pilot bearing rollers in (3) Remove output shaft fifth gear snap ring with
input shaft bore (Fig. 100). Ensure to use sufficient two screwdrivers (Fig. 102).
petroleum jelly to hold rollers in position.

Fig. 100 Install Output Shaft Pilot Bearing Rollers

(6) Install the fourth gear synchronizer ring onto Fig. 102 Remove Fifth Gear Snap-ring
the input shaft. (4) Using Bearing Splitter P-334 or suitable press
(7) Install input shaft to output shaft. Use care plates positioned under first gear, press fifth gear,
when mating the two shafts not to displace any out- rear bearing, first gear, and first gear bearing inner
put shaft pilot bearing rollers. race off output shaft (Fig. 103).
OUTPUT SHAFT
DISASSEMBLY
(1) Remove input shaft and output shaft pilot
bearing rollers from output shaft.
(2) Measure and note thrust clearance of output
shaft gears (Fig. 101). Clearance should be 0.10 –
0.25 mm (0.004 – 0.010 in.).

Fig. 103 Remove Fifth Gear, First Gear Bearing, And

Race
(5) Remove first gear needle roller bearing from
Fig. 101 Check Output Shaft Gear Thrust Clearance output shaft.
TJ TRANSMISSION AND TRANSFER CASE 21 - 29
DISASSEMBLY AND ASSEMBLY (Continued)
(6) Remove first gear bearing inner race lock ball (10) Remove select fit snap-ring holding the 3–4
with pencil magnet (Fig. 104). synchronizer onto the output shaft (Fig. 106).

Fig. 104 Remove First Gear Bearing Inner Race Fig. 106 Remove 3–4 Synchronizer Snap Ring
Lock Ball (11) Using Bearing Splitter P-334 or suitable press
(7) Remove first gear synchronizer ring. plates positioned under third gear, press the 3–4 syn-
(8) Using Bearing Splitter P-334 or suitable press chronizer and third gear from output shaft (Fig. 107).
plates positioned under second gear, press 1–2 syn-
chronizer, reverse gear, and second gear from output
shaft (Fig. 105).

Fig. 107 Remove 3–4 Synchronizer And Third Gear

(12) Remove third gear needle roller bearing from
output shaft or gear.
Fig. 105 Remove Second Gear, Reverse Gear, And
1–2 Synchronizer ASSEMBLY
(1) Lubricate transmission components with speci-
(9) Remove second gear needle roller bearing from
fied gear lubricant.
the output shaft or second gear.
21 - 30 TRANSMISSION AND TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(2) If necessary, assemble 1–2 and 3–4 synchro-
nizer hubs, sleeves, springs and key inserts (Fig.
108).

Fig. 109 Select 3–4 Synchronizer Snap-ring

Fig. 108 Synchronizer Identification

(3) Install third gear needle bearing onto the out-
put shaft.
(4) Install third gear over bearing and onto output
shaft flange.
(5) Install third gear synchronizer ring to third
gear.
(6) Position the 3–4 synchronizer onto the output
shaft.
(7) Using Adapter 6747-1A and a shop press, press
the 3–4 synchronizer onto the output shaft.
(8) Select the thickest snap-ring that will fit into
the snap-ring groove of the output shaft (Fig. 109).
(9) Install snap-ring to hold 3–4 synchronizer onto
output shaft.
(10) Verify third gear thrust clearance with feeler
Fig. 110 Check Third Gear Clearance
gauge (Fig. 110). Clearance should be 0.10 – 0.25 mm
(0.004 – 0.010 in.). If clearance is out of specification, (12) Install second gear over bearing and onto out-
refer to Cleaning and Inspection section within this put shaft flange.
group. (13) Install second gear synchronizer ring onto sec-
(11) Install second gear needle bearing onto output ond gear.
shaft. (14) Position 1–2 synchronizer assembly onto
splines of output shaft.
TJ TRANSMISSION AND TRANSFER CASE 21 - 31
DISASSEMBLY AND ASSEMBLY (Continued)
(15) Using Driver MD-998805, Adapter 6747-1A,
and a shop press, press the 1–2 synchronizer onto
the output shaft.
(16) Install first gear synchronizer ring into 1–2
synchronizer.
(17) Install first gear bearing inner race lock ball
in output shaft (Fig. 111).

Fig. 112 First Gear Components

Fig. 111 Install First Gear Bearing Inner Race Lock

Ball
(18) Install first gear needle bearing onto output
shaft (Fig. 112).
(19) Install first gear onto output shaft and over
bearing.
(20) Install first gear bearing inner race onto out- Fig. 113 Check First–Second Gear Thrust Clearance
put shaft and inside first gear bearing. Rotate bear-
(25) Position fifth gear onto output shaft with the
ing race until race installs over lock ball.
gear’s short shoulder toward the rear of shaft.
(21) Position output shaft rear bearing onto output
Ensure that the gear and output shaft splines are
shaft. Ensure that the snap ring groove in bearing
aligned.
outer race is toward rear of output shaft.
(26) Using Adapter 6747-1A, Driver L-4507, and a
(22) Using Driver L-4507 and suitable mallet,
shop press, press fifth gear onto output shaft.
drive bearing onto output shaft.
(27) Select the thickest snap-ring that will fit into
(23) Install snap-ring onto output shaft rear bear-
the snap-ring groove of the output shaft (Fig. 114).
ing outer race.
(28) Install snap-ring to hold fifth gear onto output
(24) Check first–second gear thrust clearance (Fig.
shaft.
113). Standard clearance is 0.10 – 0.25 mm (0.004 –
0.010 in.). If clearance is out of specification, refer to
Cleaning and Inspection section within this group.
21 - 32 TRANSMISSION AND TRANSFER CASE TJ
DISASSEMBLY AND ASSEMBLY (Continued)

SEMI-SYNCHRONIZED REVERSE IDLER GEAR

DISASSEMBLY
(1) Remove snap-ring holding the reverse idler
gear onto the reverse idler gear hub/race (Fig. 115).
(2) Remove the plate washer from the reverse idler
gear hub/race (Fig. 116).

Fig. 115 Remove Reverse Idler Gear Snap-ring

Fig. 116 Remove Reverse Idler Gear Plate Washer

(3) Remove the reverse idler gear from the reverse
idler gear hub/race (Fig. 117).
(4) Remove the reverse idler gear synchronizer
ring from the reverse idler gear hub/race (Fig. 118).
ASSEMBLY
(1) Install the reverse idler gear synchronizer ring
onto the reverse idler gear hub/race. Apply a film of
75W-90 GL-3 transmission oil to the contact surface
of the synchronizer ring prior to assembly.
(2) Install the reverse idler gear onto the reverse idler
gear hub/race. Apply a film of 75W-90 GL-3 transmission
oil to the reverse idler gear bushing prior to assembly-
.Verify that the teeth on the synchronizer ring are properly
engaged into the recesses of the reverse idler gear.
Fig. 114 Select/Install Fifth Gear Snap Ring (3) Install the plate washer over the reverse idler
gear hub/race and onto the reverse idler gear.
TJ TRANSMISSION AND TRANSFER CASE 21 - 33
DISASSEMBLY AND ASSEMBLY (Continued)
GEAR CASE, ADAPTER/EXTENSION HOUSING,
INTERMEDIATE PLATE
Clean the case, housing, and intermediate plate
with solvent and dry with compressed air. Replace
the case if cracked, porous, or if any of the bearing
and gear bores are damaged.
Inspect the threads in the case, housing, and plate.
Minor thread damage can be repaired with steel thread
inserts, if necessary. Do not attempt to repair any threads
which show evidence of cracks around the threaded hole.

OUTPUT SHAFT
Check thickness of the output shaft and inner
bearing race flanges with a micrometer or vernier
calipers (Fig. 119).
Fig. 117 Remove Reverse Idler Gear

Fig. 118 Remove Reverse Idler Gear Synchronizer Ring

(4) Install the snap-ring to hold the reerse idler
gear onto the reverse idler hub/race.
CLEANING AND INSPECTION
AX5 MANUAL TRANSMISSION COMPONENTS
GENERAL INFORMATION
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. Fig. 119 Check Shaft And Bearing Race Flange Thickness
Never use compressed air on the bearings. This could cause
• Minimum thickness for shaft flange is 4.80 mm
severe damage to the bearing roller and race surfaces.
(0.189 in.)
If output shaft or inner race flange thickness is
• Minimum thickness for first gear bearing inner
within specification but any gear thrust clearance is
race flange is 3.99 mm (0.157 in.)
out of specification, replace the necessary gear and
Measure diameter of the output shaft journal sur-
gear needle bearing as an assembly.
faces with a micrometer. Replace the shaft if either of
these surfaces are worn beyond specified limits.
• Second gear surface minimum diameter is
37.964 mm (1.495 in.)
• Third gear surface minimum diameter is 34.984
mm (1.377 in.)
Measure diameter of the first gear bearing inner
race. Minimum diameter is 38.985 mm (1.535 in.).
21 - 34 TRANSMISSION AND TRANSFER CASE TJ
CLEANING AND INSPECTION (Continued)
Measure output shaft runout with a dial indicator (Fig.
120). Runout should not exceed 0.05 mm (0.002 in.).

Fig. 120 Check Output Shaft Runout

Fig. 121 Check Gear–To–Race Clearance
Replace output shaft or first gear inner bearing
race if measurement of any surface is out of specifi-
cation. Do not attempt to repair out of specification
components.

COUNTERSHAFT
Inspect the countershaft gear teeth. Replace the
countershaft if any teeth are worn or damaged.
Inspect the bearing surfaces and replace shaft if any
surface shows damage or wear.
Check condition of the countershaft front bearing.
Replace the bearing if worn, noisy, or damaged.

GEAR AND SYNCHRONIZER

Install the needle bearing and inner race in the
first gear. Then check oil clearance between the gear
and inner race (Fig. 121). Clearance should be 0.009
– 0.032 mm (0.0004 – 0.0013 in.).
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. 122). Oil clearance for all three
gears is 0.009 – 0.0013 mm (0.0004 – 0.0013 in.). Fig. 122 Check Gear–To–Shaft Oil Clearance
Check synchronizer ring wear (Fig. 123). 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. 124). Replace the fork if
clearance exceeds 1.0 mm (0.039 in.).
(1) Inspect all mainshaft gear teeth. Replace any
gear which shows any worn or damaged teeth.
TJ TRANSMISSION AND TRANSFER CASE 21 - 35
CLEANING AND INSPECTION (Continued)
SPECIFICATIONS
TORQUE

DESCRIPTION TORQUE
Plugs, Access . . . . . . . . . . . . . . . . .19 N·m (14 ft.lbs.)
Bolts, Adapter Housing . . . . . . . . .34 N·m (25 ft.lbs.)
Switch, Back-up Light. . . . . . . . .44 N·m (32.5 ft.lbs.)
Plugs, Drain and Fill . . . . . . . . .44 N·m (32.5 ft.lbs.)
Bolts, Front Bearing Retainer . . . .17 N·m (12 ft.lbs.)
Plugs, Interlock and Detent . . . . . .19 N·m (14 ft.lbs.)
Screws, Propeller Shaft Clamp . . . . . . . . .16–23 N·m
(140–200 in.lbs.)
Bolts, Rear Mount to Transmission . . . . . .33–60 N·m
(24–44 ft.lbs.)
Nut, Rear Mount Clevis . . . . . . . . . . . . . .54–75 N·m
(40–55 ft.lbs.)
Nuts, Rear Mount to Crossmember . . . . . .33–49 N·m
(24–36 ft.lbs.)
Pins, Restrictor . . . . . . . . . . . . . .27.4 N·m (20 ft.lbs.)
Fig. 123 Check Synchronizer Ring Wear Bolts, Reverse Shift Arm Bracket . . . . . . . . . .18 N·m
(13 ft.lbs.)
Screw, Shift Arm Set . . . . . . . . . . .38 N·m (28 ft.lbs.)
Screws, Shift Fork Set . . . . . . . . . .20 N·m (15 ft.lbs.)
Nut, Shift Knob. . . . . . . . . . . . . . . . . . . . .20–34 N·m
(15–25 ft.lbs.)
Screws, Shifter Floor Cover . . . . . . . . . . . . .2–3 N·m
(17–30 in.lbs.)
Bolts, Shift Tower . . . . . . . . . . . . .18 N·m (13 ft.lbs.)
Nuts, Transfer Case Mounting . . . . . . . . .30–41 N·m
(22–30 ft.lbs.)

Fig. 124 Check Fork–To–Hub Clearance

21 - 36 TRANSMISSION AND TRANSFER CASE TJ

SPECIAL TOOLS
AX5

8211 Installer, Seal

C-3339 Dial Indicator Set

8212 Installer, Seal

C-3995-A Installer, Extension Housing Seal

8208 Installer, Seal

C-4171 Handle, Universal Tool

P-334 Splitter, Bearing
TJ TRANSMISSION AND TRANSFER CASE 21 - 37
SPECIAL TOOLS (Continued)

8109 Cup, Installer

L-4507 Tube, Driver

6747–1A Adapter, Fixture

MD-998805 Installer, Seal