Jeep XJ. Manual — part 379
(3) Pull shift shaft straight out of rear housing,
shift socket, fifth-reverse fork, and 1-2 fork (Fig. 28).
(4) Remove shift socket from rear housing (Fig.
29).
(5) Remove lever and bushing (Fig. 30).
(6) Remove 3-4 fork. Rotate 3-4 fork around syn-
chro sleeve until fork clears shift arms on 1-2 and
fifth-reverse forks. Then remove 3-4 fork (Fig. 31).
(7) Remove the reverse idler shaft support bolt
(front bolt) (Fig. 32).
Fig. 26 Removing the Shift Socket Roll Pin
1 – SPECIAL TOOL
6858
2 – SHIFT SOCKET
Fig. 27 Removing Shift Shaft Lever And Bushing
Roll Pin
1 – PIN PUNCH
2 – BUSHING AND LEVER
3 – SHIFT SHAFT
Fig. 28 Shift Shaft Removal
1 – SHIFT SHAFT
2 – 3–4 FORK
3 – SHAFT DETENT NOTCHES
Fig. 29 Shift Socket And Roll Pin
1 – SHAFT BORE
2 – ROLL PIN
3 – SHIFT SOCKET
Fig. 30 Removing Shift Shaft Lever And Bushing
1 – SHAFT LEVER AND BUSHING
2 – 3–4 FORK
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NV3550 MANUAL TRANSMISSION
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(8) Loosen rear reverse idler shaft bolt (rear bolt)
(Fig. 32).
(9) Remove reverse idler shaft support segment by
sliding it straight out of housing.
(10) Support geartrain and rear housing on Assem-
bly Fixture Tool 6747 as follows:
(a) Adjust height of reverse idler pedestal rod
until the reverse idle shaft bottoms in Cup 8115.
(b) Position Adapters 6747-1A and 6747-2A on
Assembly Fixture 6747.
(c) Slide fixture tool onto input shaft, counter-
shaft and idler gear (Fig. 33).
(d) Stand geartrain and rear housing upright on
fixture (Fig. 34). Have helper hold fixture tool in
place while housing and geartrain is being rotated
into upright position.
(11) Remove rear bolt holding reverse idler shaft
in housing.
Fig. 31 Removing 3-4 Shift Fork
1 – 3–4 FORK
2 – 1–2 AND 5TH-REVERSE FORK ARMS
3 – 3–4 SYNCHRO SLEEVE
Fig. 32 Reverse Idler Shaft/Support Bolts
1 – SUPPORT BOLT
2 – SHAFT BOLT
Fig. 33 Installing Assembly Fixture On Geartrain
1 – SPECIAL TOOL 6747
2 – SPECIAL TOOL 6747–1A
3 – SPECIAL TOOL 8115
4 – REVERSE IDLER PEDESTAL
5 – SPECIAL TOOL 6747–2A
Fig. 34 Geartrain And Housing Mounted On Fixture
Tool
1 – INPUT SHAFT
2 – COUNTERSHAFT
3 – SPECIAL TOOL 6747
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NV3550 MANUAL TRANSMISSION
21 - 53
DISASSEMBLY AND ASSEMBLY (Continued)
REAR HOUSING REMOVAL—2WD
(1) On 2-wheel drive transmission, remove three
bolts that attach output shaft bearing retainer to
rear case (Fig. 35). Bolts are rear of shift tower open-
ing.
(2) Unseat output shaft bearing from bearing bore
in rear housing. Use plastic or rawhide mallet to tap
rear housing upward and off output shaft bearing as
shown (Fig. 36).
(3) Lift rear housing up and off geartrain (Fig. 37).
(4) Remove countershaft rear bearing from coun-
tershaft (Fig. 38).
(5) Examine condition of bearing bore and idler
shaft notch in rear housing. Replace housing if any of
these components are damaged.
REAR ADAPTER HOUSING REMOVAL—4WD
(1) Locate dimples in face of rear seal (Fig. 39).
Use a suitable slide hammer mounted screw to
remove seal by inserting screw into seal at dimple
locations (Fig. 40).
Fig. 35 Removing/Installing Output Shaft Bearing
Retainer Bolts—2WD
1 – OUTPUT SHAFT BEARING RETAINER BOLTS (THIRD BOLT
IS AT OPPOSITE SIDE OF CASE)
Fig. 36 Unseating Rear Housing From Output Shaft
Bearing—2WD
1 – REAR HOUSING
2 – PLASTIC OR RAWHIDE MALLET
3 – FIXTURE TOOL
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NV3550 MANUAL TRANSMISSION
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DISASSEMBLY AND ASSEMBLY (Continued)
(2) Remove rear bearing snap ring from output
shaft with heavy duty snap ring pliers (Fig. 41).
(3) Lift rear adapter housing upward and off
geartrain (Fig. 42).
Fig. 37 Rear Housing Removal—2WD
1 – REAR HOUSING
2 – SHIFT FORKS AND GEARTRAIN
Fig. 38 Remove Countershaft Rear Bearing
1 – COUNTERSHAFT REAR BEARING
2 – OUTPUT SHAFT
3 – COUNTER SHAFT
Fig. 39 Location Of Dimples In Seal Face—4WD
1 – LOCATION OF DIMPLES
2 – SEAL FACE
Fig. 40 Rear Seal Removal—4WD
1 – SLIDE HAMMER
2 – REMOVER TOOL
3 – REAR SEAL
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NV3550 MANUAL TRANSMISSION
21 - 55
DISASSEMBLY AND ASSEMBLY (Continued)
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