Jeep Cherokee (XJ): Countershaft. Input shaft. Output shaft

Countershaft

DISASSEMBLY

(1) Remove select fit snap-ring holding the countershaft front bearing onto the countershaft (Fig. 95).

(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.

Fig. 95 Countershaft Front Bearing Snap-ring

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.

(4) Select the thickest snap-ring that will fit into the snap-ring groove of the countershaft (Fig. 95).

(5) Install snap-ring to hold countershaft front bearing onto countershaft.

Input shaft

DISASSEMBLY

(1) Verify that the 3-4 synchronizer is in the neutral position.

(2) Separate input shaft from output shaft (Fig.

96). Note that the output shaft pilot bearing is an uncaged roller type bearing.

(3) Remove the output shaft pilot bearing rollers from the input shaft and the output shaft.

Fig. 96 Separate Input and Output Shafts

1 - INPUT SHAFT ASSEMBLY
2 - OUTPUT SHAFT AND GEAR ASSEMBLY

(4) Remove the fourth gear synchronizer ring from the input shaft (Fig. 97).

Fig. 97 Input Shaft Components

1 - BEARING
2 - SYNCHRO RING
3 - INPUT SHAFT
4 - BEARING SNAP RING

(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. 98).

(4) Lubricate output shaft pilot bearing bore of input shaft with petroleum jelly.

Fig. 98 Select Input Shaft Bearing Snap-ring

(5) Install output shaft pilot bearing rollers in input shaft bore (Fig. 99). Ensure to use sufficient petroleum jelly to hold rollers in position.

Fig. 99 Install Output Shaft Pilot Bearing Rollers

1 - INPUT SHAFT
2 - BEARING ROLLERS

(6) Install the fourth gear synchronizer ring onto the input shaft.

(7) Install input shaft to output shaft. Use care when mating the two shafts not to displace any output shaft pilot bearing rollers.

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. 100). Clearance should be 0.10 - 0.25 mm (0.004 - 0.010 in.).

Fig. 100 Check Output Shaft Gear Thrust Clearance

(3) Remove output shaft fifth gear snap ring with two screwdrivers (Fig. 101).

Fig. 101 Remove Fifth Gear Snap-ring

1 - SNAP RING

(4) Using Bearing Splitter P-334 or suitable press plates positioned under first gear, press fifth gear, rear bearing, first gear, and first gear bearing inner race off output shaft (Fig. 102).

(5) Remove first gear needle roller bearing from output shaft.

(6) Remove first gear bearing inner race lock ball with pencil magnet (Fig. 103).

(7) Remove first gear synchronizer ring.

(8) Using Bearing Splitter P-334 or suitable press plates positioned under second gear, press 1-2 synchronizer, reverse gear, and second gear from output shaft (Fig. 104).

(9) Remove second gear needle roller bearing from the output shaft or second gear.

(10) Remove select fit snap-ring holding the 3-4 synchronizer onto the output shaft (Fig. 105).

(11) Using Bearing Splitter P-334 or suitable press plates positioned under third gear, press the 3-4 synchronizer and third gear from output shaft (Fig. 106).

(12) Remove third gear needle roller bearing from output shaft or gear.

Fig. 102 Remove Fifth Gear, First Gear Bearing, And Race

1 - PRESS RAM
2 - OUTPUT SHAFT
3 - FIRST-FIFTH GEAR-BEARING ASSEMBLY

Fig. 103 Remove First Gear Bearing Inner Race Lock Ball

1 - LOCK BALL
2 - PENCIL MAGNET

Fig. 104 Remove Second Gear, Reverse Gear, And 1-2 Synchronizer

1 - PRESS RAM
2 - SECOND GEAR
3 - 1-2 SYNCHRONIZER HUB

Fig. 105 Remove 3-4 Synchronizer Snap Ring

1 - 3-4 SYNCHRONIZER SNAP RING

Fig. 106 Remove 3-4 Synchronizer And Third Gear

1 - 3-4 SYNCHRONIZER
2 - THIRD GEAR

ASSEMBLY

TRANSMISSION ASSEMBLY INFORMATION

Lubricate the transmission components with Mopart 75W-90, GL 3 gear lubricant during assembly.

Use petroleum jelly to lubricate seal lips and/or hold parts in place during installation.

Refer to (Fig. 107) during assembly for AX5 gear assembly identification.

(1) Lubricate transmission components with specified gear lubricant.

(2) If necessary, assemble 1-2 and 3-4 synchronizer hubs, sleeves, springs and key inserts (Fig.

108).

(3) Install third gear needle bearing onto the output 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.

Fig. 107 Geartrain Components

1 - SNAP RING
2 - FIFTH GEAR
3 - COUNTER GEAR
4 - BEARING
5 - LOCK BALL
6 - SYNCHRO HUB/SLEEVE
7 - SNAP RING
8 - SPACER
9 - COUNTER 5TH GEAR
10 - SYNCHRO RING
11 - 5TH SPLINE GEAR
12 - SNAP RING

(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 gauge (Fig. 110). Clearance should be 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.

(11) Install second gear needle bearing onto output shaft.

(12) Install second gear over bearing and onto output shaft flange.

(13) Install second gear synchronizer ring onto second gear.

(14) Position 1-2 synchronizer assembly onto splines of output shaft.

(15) Using Driver MD-998805, Adapter 6747-1A, and a shop press, press the 1-2 synchronizer onto the output shaft.

Fig. 108 Synchronizer Identification

1 - SLEEVES
2 - HUBS

Fig. 109 Select 3-4 Synchronizer Snap-ring

(16) Install first gear synchronizer ring into 1-2 synchronizer.

(17) Install first gear bearing inner race lock ball in output shaft (Fig. 111).

(18) Install first gear needle bearing onto output shaft (Fig. 112).

Fig. 110 Check Third Gear Clear

1 - FEELER GAUGE
2 - THIRD GEAR

Fig. 111 Install First Gear Bearing Inner Race Lock Ball

1 - FIRST GEAR LOCK BALL

(19) Install first gear onto output shaft and over bearing.

(20) Install first gear bearing inner race onto output shaft and inside first gear bearing. Rotate bearing race until race installs over lock ball.

(21) Position output shaft rear bearing onto output shaft. Ensure that the snap ring groove in bearing outer race is toward rear of output shaft.

(22) Using Driver L-4507 and suitable mallet, drive bearing onto output shaft.

(23) Install snap-ring onto output shaft rear bearing outer race.

Fig. 112 First Gear Components

1 - REAR BEARING
2 - INNER RACE
3 - FIRST GEAR
4 - NEEDLE BEARING
5 - FIRST GEAR LOCK BALL

(24) Check first-second gear thrust clearance (Fig.

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.

Fig. 113 Check First-Second Gear Thrust Clearance

(25) Position fifth gear onto output shaft with the gear's short shoulder toward the rear of shaft.

Ensure that the gear and output shaft splines are aligned.

(26) Using Adapter 6747-1A, Driver L-4507, and a shop press, press fifth gear onto output shaft.

(27) Select the thickest snap-ring that will fit into the snap-ring groove of the output shaft (Fig. 114).

Fig. 114 Select/Install Fifth Gear Snap Ring

(28) Install snap-ring to hold fifth gear onto output shaft.