Jeep XJ. Manual — part 373
(32) Install the compression spring and pin into
the reverse idler gear shaft (Fig. 88).
(33) Install the reverse idler shaft through the
intermediate plate and reverse idler gear assembly
(Fig. 89) 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. 90). 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.
(35) Depress
compression
spring
and
pin
in
reverse idler gear shaft (Fig. 91).
(36) Install
the
reverse
idler
gear
shaft
the
remainder of the way through the reverse idler gear
assembly.
Fig. 87 Reverse Shift Arm Position
1 – REVERSE SHIFT ARM
2 – INTERMEDIATE PLATE
Fig. 88 Install Compression Spring And Pin
1 – REVERSE IDLER GEAR SHAFT
2 – PIN
3 – COMPRESSION SPRING
Fig. 89 Install Reverse Idler Shaft
1 – REVERSE IDLER SHAFT
Fig. 90 Align Idler Shaft Pin
1 – REVERSE IDLER GEAR ASSEMBLY
2 – ALIGNMENT NOTCH
21 - 28
AX5 MANUAL TRANSMISSION
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(37) Position the reverse idler gear shaft lock plate
onto the intermediate plate.
(38) Install a new bolt to hold the idler gear shaft
lock plate to the intermediate plate.
(39) Install the fifth gear thrust ring lock ball to
the countershaft (Fig. 92).
(40) Install the fifth gear thrust ring onto the
countershaft and over the lock ball (Fig. 93).
(41) Install fifth gear shift fork to the countershaft
fifth gear assembly.
(42) Install the countershaft fifth gear bearings
into the countershaft fifth gear assembly.
(43) Position the countershaft fifth gear assembly
on the countershaft. Ensure that the fifth gear fork is
installed onto the fifth gear shift rail.
(44) Install the fifth gear synchro ring.
(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. 94).
(48) Measure countershaft fifth gear thrust clear-
ance.
(49) Select a snap-ring so that the thrust clearance
is 0.10–0.30 mm (0.004–0.010 in.).
(50) Install snap-ring to hold fifth gear blocker
ring onto countershaft.
Fig. 91 Depress Pin In Reverse Idler Gear Shaft
1 – DEPRESS PIN
Fig. 92 Install Fifth Gear Thrust Ring Lock Ball
1 – PENCIL MAGNET
2 – CLUSTER GEAR
3 – LOCK BALL RECESS
4 – THRUST RING LOCK BALL
Fig. 93 Install Fifth Gear Thrust Ring
1 – LOCK BALL NOTCH
2 – FIFTH GEAR THRUST RING
Fig. 94 Install Fifth Gear Retainer Bolt
1 – SHIFT FORK RETAINER BOLT
2 – FIFTH GEAR SHIFT RAIL
3 – FIFTH GEAR SHIFT FORK
XJ
AX5 MANUAL TRANSMISSION
21 - 29
DISASSEMBLY AND ASSEMBLY (Continued)
(51) Remove intermediate plate from vise and
remove bolts and washers from intermediate.
COUNTERSHAFT
DISASSEMBLY
(1) Remove select fit snap-ring holding the coun-
tershaft 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.
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 neu-
tral 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.
(4) Remove the fourth gear synchronizer ring from
the input shaft (Fig. 97).
(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.
I. D.
MARK
SNAP RING THICKNESS MM (IN.)
1
2
3
4
5
6
2.05 - 2.10
2.10 - 2.15
2.15 - 2.20
2.20 - 2.25
2.25 - 2.30
2.30 - 2.35
(0.0807 - 0.0827)
(0.0827 - 0.0846)
(0.0846 - 0.0866)
(0.0866 - 0.0886)
(0.0886 - 0.0906)
(0.0906 - 0.0925)
Fig. 95 Countershaft Front Bearing Snap-ring
Fig. 96 Separate Input and Output Shafts
1 – INPUT SHAFT ASSEMBLY
2 – OUTPUT SHAFT AND GEAR ASSEMBLY
Fig. 97 Input Shaft Components
1 – BEARING
2 – SYNCHRO RING
3 – INPUT SHAFT
4 – BEARING SNAP RING
21 - 30
AX5 MANUAL TRANSMISSION
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(5) Install output shaft pilot bearing rollers in
input shaft bore (Fig. 99). Ensure to use sufficient
petroleum jelly to hold rollers in position.
(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 out-
put 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.).
I. D. Mark
Snap Ring Thickness mm (in.)
0
1
2
3
4
5
2.05-2.10 (0.0807-0.0827)
2.10-2.15 (0.0827-0.0846)
2.15-2.20 (0.0846-0.0866)
2.20-2.25 (0.0866-0.0886)
2.25-2.30 (0.0886-0.0906)
2.30-2.35 (0.0906-0.0925)
Fig. 98 Select Input Shaft Bearing Snap-ring
Fig. 99 Install Output Shaft Pilot Bearing Rollers
1 – INPUT SHAFT
2 – BEARING ROLLERS
Fig. 100 Check Output Shaft Gear Thrust Clearance
XJ
AX5 MANUAL TRANSMISSION
21 - 31
DISASSEMBLY AND ASSEMBLY (Continued)
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