Jeep Cherokee (XJ): Diagnosis and testing. Removal and installation

Low lubricant level

A low transmission lubricant level is generally the result of a leak, inadequate lubricant fill, or an incorrect lubricant level check.

Leaks can occur at the mating surfaces of the gear case, intermediate plate and adaptor or extension housing, or from the front/rear seals. A suspected leak could also be the result of an overfill condition.

Leaks at the rear of the extension or adapter housing will be from the housing oil seals. Leaks at component mating surfaces will probably be the result of inadequate sealer, gaps in the sealer, incorrect bolt tightening, or use of a non-recommended sealer.

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 causing 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 recommendations 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 consequence of using non-recommended lubricants is noise, excessive wear, internal bind, and hard shifting.

Substantial lubricant leaks can result in gear, shift rail, synchro, and bearing damage. If a leak goes undetected for an extended period, the first indications of component damage are usually hard shifting and noise.

Component damage, incorrect clutch adjustment, or a damaged clutch pressure plate or disc are additional probable causes of increased shift effort. Incorrect adjustment or a worn/damaged pressure plate or disc can cause incorrect release. If the clutch problem is advanced, gear clash during shifts can result.

Worn or damaged synchro rings can cause gear clash when shifting into any forward gear. In some new or rebuilt transmissions, new synchro rings may tend to stick slightly causing hard or noisy shifts. In most cases, this condition will decline as the rings wear- in.

Transmission noise

Most manual transmissions make some noise during normal operation. Rotating gears generate a mild whine that is audible, but generally only at extreme speeds.

Severe, highly audible transmission noise is generally 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.

Transmission

REMOVAL

(1) Shift transmission into first or third gear.

(2) Raise and support vehicle on suitable safety stands.

(3) Support engine with adjustable jack stand.

Position wood block between jack and oil pan to avoid damaging pan.

(4) Remove crossmember/skid plate.

(5) Disconnect necessary exhaust system components.

(6) Remove skid plate, if equipped.

(7) Remove slave cylinder (Fig. 4) from clutch housing.

(8) Mark rear propeller shaft and rear axle yokes for installation alignment (Fig. 5).

Fig. 4 Slave Cylinder-Typical

1 - CLUTCH SLAVE CYLINDER

Fig. 5 Marking Propeller Shaft And Axle Yokes

1 - REFERENCE MARKS

(9) Mark front propeller shaft, axle, and transfer case yokes for installation alignment, if equipped.

(10) Remove propeller shaft(s).

(11) Unclip wire harnesses from transmission and transfer case, if equipped.

(12) Disconnect transfer case vent hose, if equipped.

(13) Disengage any wire connectors attached to transmission or transfer case, if equipped, components.

(14) Support transfer case, if equipped, with transmission jack.

(15) Secure transfer case, if equipped, to jack with safety chains.

(16) Disconnect transfer case shift linkage at transfer case, if equipped.

(17) Remove nuts attaching transfer case to transmission, if equipped.

(18) Remove transfer case, if equipped.

(19) Remove crankshaft position sensor (Fig. 6).

Fig. 6 Crankshaft Position Sensor -2.5 and 4.0L Engine

1 - ENGINE SPEED SENSOR
2 - GROMMET
3 - MOUNTING BOLT(S)
4 - LEFT REAR OF ENGINE
5 - TRANSMISSION

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

(20) Support engine with adjustable jack stand.

Position wood block between jack and oil pan to avoid damaging pan.

(21) Support transmission with transmission jack.

(22) Secure transmission to jack with safety chains.

(23) Disconnect rear cushion and bracket from transmission.

(24) Remove rear crossmember.

(25) Disconnect transmission shift lever as follows: (a) Lower transmission approximately 7-8 cm (3 in.) for access to shift lever.

(b) Reach up and around transmission case and unseat shift lever dust boot from transmission shift tower (Fig. 7). Move boot upward on shift lever for access to retainer that secures lever in shift tower.

(c) Reach up and around transmission case and press shift lever retainer downward with finger pressure. Turn retainer counterclockwise to release it.

(d) Lift lever and retainer out of shift tower (Fig.

7). Do not remove the shift lever from the floor console shifter boots. Leave the lever in place for transmission installation.

Fig. 7 Removing/Installing Shift Lever

1 - SHIFT LEVER RETAINER
2 - DUST BOOT
3 - SHIFT TOWER

(26) Remove clutch housing brace rod.

(27) Remove clutch housing-to-engine bolts.

(28) Pull transmission jack rearward until input shaft clears clutch. Then slide transmission out from under vehicle.

(29) Remove clutch release bearing, release fork, and retainer clip.

(30) Remove clutch housing from transmission (Fig. 8).

INSTALLATION

(1) Install clutch housing (Fig. 8) on transmission.

Tighten housing bolts to 46 N·m (34 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 transmission jack.

(5) Lightly lubricate pilot bearing and transmission input shaft splines with Mopart high temp grease.

(6) Raise transmission and align transmission input shaft and clutch disc splines. Then slide transmission into place.

(7) Install and tighten clutch housing-to-engine bolts to the appropriate torque: Be sure the housing is properly seated on engine block before tightening bolts.

•  Tighten 3/8" diameter bolts to 37 N·m (27 ft.lbs.).
•  Tighten 7/16" diameter bolts to 58 N·m (43 ft.lbs.).

Fig. 8 Clutch Housing

1 - HOUSING-TO-TRANSMISSION BOLTS (46 N·m/34 ft. lbs.)
2 - CLUTCH HOUSING
3 - TRANSMISSION

• Tighten M12 bolts to 75 N·m (55 ft.lbs.).

(8) Install clutch housing brace rod.

(9) Lower transmission approximately 7-8 cm (3 in.) for access to shift tower. Be sure transmission is in first or third gear.

(10) Reach up and around transmission and insert shift lever in shift tower. Press lever retainer downward and turn it clockwise to lock it in place. Then install lever dust boot on shift tower.

(11) Install rear crossmember. Tighten crossmember- to-frame bolts to 41 N·m (31 ft. lbs.) torque.

(12) Install fasteners to hold rear cushion and bracket to transmission. Then tighten transmissionto- rear support bolts/nuts to 54 N·m (40 ft. lbs.) torque.

(13) Remove support stands from engine and transmission.

(14) Install and connect crankshaft position sensor.

(15) Position transfer case on transmission jack, if equipped.

(16) Secure transfer case to jack with safety chains, if equipped.

(17) Raise transfer case, if equipped, and align transfer case input shaft to the transmission output shaft.

(18) Slide transfer case forward until case is seated on transmission, if necessary.

(19) Install nuts to attach transfer case to transmission, if equipped. Tighten transfer case-to-transmission nuts to 35 N·m (26 ft. lbs.) torque.

(20) Connect transfer case shift linkage at transfer case, if equipped.

(21) Connect transfer case vent hose, if equipped.

(22) Secure wire harnesses in clips/tie straps on 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 transmission or transfer case, if equipped, output shaft.

(25) Align marks on rear propeller shaft and rear axle yokes (Fig. 9).

Fig. 9 Align Propeller Shaft And Rear Axle Yokes Alignment Marks

1 - REFERENCE MARKS

(26) Install and tighten propeller shaft U-joint clamp bolts to 19 N·m (170 in. lbs.) torque.

(27) Align marks on front propeller shaft, axle, and transfer case yokes, if equipped.

(28) Install and tighten propeller shaft U-joint clamp bolts to 19 N·m (170 in. lbs.) torque.

(29) Install slave cylinder in clutch housing.

(30) Install skid plate, if equipped. Tighten bolts to 42 N·m (31 ft. lbs.) torque. Tighten stud nuts to 17 N·m (150 in. lbs.) torque.

(31) Fill transmission and transfer case, if equipped, with recommended lubricants. Refer to the Lubricant Recommendation sections of the appropriate component for correct fluid.

(32) Lower vehicle.

Front bearing retainer seal

REMOVAL

(1) Remove release bearing and lever from the transmission.

(2) Remove the bolts holding the front bearing retainer to the transmission case.

(3) Remove the front bearing retainer from the transmission case.

(4) Using a suitable pry tool, remove the front bearing retainer seal.

INSTALLATION

(1) Using Tool Handle C-4171 and Seal Installer 8211, install new seal in to the front bearing retainer (Fig. 10).

Fig. 10 Install Front Bearing Retainer Seal

1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 8211 (AX5) OR 8209 (AX15)

(2) Remove any residual gasket material from the sealing surfaces of the bearing retainer and the transmission case.

(3) Install new front bearing retainer gasket to the front bearing retainer.

(4) Install the front bearing retainer onto the transmission case.

(5) Install the bolts to hold the bearing retainer onto the transmission case.

(6) Tighten the bolts to 17 N·m (12 ft. lbs.).

(7) Install release bearing and lever onto the transmission.

Extension housing seal

REMOVAL

(1) Raise and support vehicle.

(2) Remove propeller shaft. Refer to Group 3, Differential and Driveline, for proper procedures.

(3) Using a suitable seal puller or screw with a slide hammer, remove the extension housing seal (Fig. 11).

Fig. 11 Remove Extension Housing Seal

1 - SLIDE HAMMER
2 - SEAL PULLER
3 - 2WD EXTENSION HOUSING

INSTALLATION

(1) Clean seal bore of extension housing of any residual sealer material from original seal.

(2) Using Tool Handle C-4171 and Seal Installer 8212, install new extension housing seal so that the seal is located 0 6 0.5 mm (0 6 0.02 in.) to the face of the extension housing (Fig. 12).

(3) Install propeller shaft. Refer to Group 3, Differential and Driveline, for proper procedures.

(4) Check and add fluid to transmission as necessary.

Refer to the Recommended Lubricant section for proper fluid requirements.

(5) Lower vehicle.

Adapter housing seal

REMOVAL

(1) Hoist and support vehicle.

(2) Remove transfer case.

(3) Using a suitable pry tool, or a slide hammer mounted screw, remove the adapter housing seal (Fig. 13).

Fig. 12 Install Extension Housing Seal

1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 8212
3 - EXTENSION HOUSING

Fig. 13 Remove Adapter Housing Seal

1 - ADAPTER HOUSING OIL SEAL

INSTALLATION

(1) Clean seal bore of adapter housing of any residual sealer material from original seal.

(2) Using Tool Handle C-4171 and Seal Installer 8208, install new seal so that the seal is located 0 6 0.2 mm (0 6 0.008 in.) to the seal bore face of adapter housing (Fig. 14).

(3) Install transfer case.

(4) Check and add fluid to transmission as necessary.

Refer to the Recommended Lubricant section for proper fluid requirements.

(5) Lower vehicle.

Fig. 14 Install Adapter Housing Seal

1 - SPECIAL TOOL 8208
2 - ADAPTER HOUSING
3 - SPECIAL TOOL C-4171