Jeep XJ. Manual — part 370
(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. 46).
(22) Install bolts to hold shift tower to transmis-
sion 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. 47). 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. 44 Install Detent Spring
1 – PENCIL MAGNET
2 – DETENT BALL SPRING
Fig. 45 Install Detent Ball Plug
1 – TORX BIT
2 – DETENT BALL PLUG
Fig. 46 Install Shift Tower
1 – SHIFT TOWER
2 – ADAPTER/EXTENSION HOUSING
Fig. 47 Install Backup Lamp Switch
1 – SHIFT TOWER
2 – BACKUP LAMP SWITCH
21 - 16
AX5 MANUAL TRANSMISSION
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
SHIFT MECHANISM AND GEARTRAIN
DISASSEMBLY
(1) Install suitable bolts and washers in intermedi-
ate plate (Fig. 48). 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.
(2) Remove countershaft fifth gear retaining snap-
ring (Fig. 49).
(3) Remove bolt holding fifth gear shift fork to
shift rail (Fig. 50).
Fig. 48 Positioning Intermediate Plate In Vise
1 – INTERMEDIATE PLATE
2 – BOLTS
Fig. 49 Remove Fifth Gear Snap-ring
1 – FIFTH GEAR SNAP RING (SELECT FIT)
Fig. 50 Remove Shift Fork Retainer Bolt
1 – SHIFT FORK RETAINER BOLT
2 – FIFTH GEAR SHIFT RAIL
3 – FIFTH GEAR SHIFT FORK
XJ
AX5 MANUAL TRANSMISSION
21 - 17
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Remove fifth gear blocker ring from counter-
shaft assembly with Puller L-4407 (Fig. 51).
(5) Remove fifth gear synchro ring (Fig. 52).
(6) Remove the countershaft fifth gear assembly
from countershaft (Fig. 53).
(7) Remove fifth gear thrust ring from counter-
shaft (Fig. 54).
(8) Remove fifth gear thrust ring lock ball from
countershaft (Fig. 55).
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.
Fig. 51 Remove Fifth Gear Blocker Ring
1 – FIFTH GEAR BLOCKER RING
Fig. 52 Remove Fifth Gear Synchro Ring
1 – FIFTH GEAR SYNCHRO RING
Fig. 53 Remove Fifth Gear and Synchro Assembly
1 – FIFTH GEAR SYNCHRO SLEEVE ASSEMBLY
2 – COUNTER FIFTH GEAR
Fig. 54 Remove Fifth Gear Thrust Ring
1 – LOCK BALL NOTCH
2 – FIFTH GEAR THRUST RING
21 - 18
AX5 MANUAL TRANSMISSION
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(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. 56).
NOTE: Be sure to retrieve the pin and compression
spring from the reverse idler shaft.
(11) Remove bolts holding output shaft rear bear-
ing retainer to the intermediate plate and remove
retainer (Fig. 57).
(12) Remove bolts holding 1–2 and 3–4 shift forks
to the shift rails (Fig. 58) and discard bolts.
(13) Remove
bolts
holding
reverse
shift
arm
bracket to intermediate plate (Fig. 59).
Fig. 55 Remove Fifth Gear Thrust Ring Lock Ball
1 – PENCIL MAGNET
2 – CLUSTER GEAR
3 – LOCK BALL RECESS
4 – THRUST RING LOCK BALL
Fig. 56 Remove Reverse Idler Shaft
1 – REVERSE IDLER SHAFT
Fig. 57 Remove Output Shaft Rear Bearing Retainer
1 – OUTPUT SHAFT REAR BEARING RETAINER
Fig. 58 Remove Shift Fork To Shift Rail Bolts
1 – 1–2 SHIFT FORK
2 – 3–4 SHIFT FORK
XJ
AX5 MANUAL TRANSMISSION
21 - 19
DISASSEMBLY AND ASSEMBLY (Continued)
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