Jeep XJ. Manual — part 800
Fig. 76 SYNCHRO SLEEVE LOCATIONS
1 - DOUBLE GROOVE FORWARD
2 - GROOVE FORWARD
3 - FIRST GEAR SIDE MARKING TOWARD FIRST GEAR
4 - TAPER FORWARD
5 - GROOVE FORWARD
6 - 5TH-REV SYNCHRO SLEEVE
7 - 1-2 SYNCHRO SLEEVE
8 - 3-4 SYNCHRO SLEEVE
Fig. 77 IDLER GEAR AND BEARING
1 - IDLER GEAR
2 - BEARING
3 - LOCK BALL
4 - REAR OF SHAFT
Fig. 78 IDLER GEAR REAR THRUST WASHER
1 - LOCK BALL
2 - SNAP RING GROOVE
3 - THRUST WASHER
21s - 22
MANUAL NV 3550
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MANUAL NV 3550 (Continued)
2001 JEEP CHEROKEE
(7) Install lock ball in dimple at front of shaft.
Hold ball in place with petroleum jelly.
(8) Install front thrust washer on shaft and slide
washer up against gear and over lock ball (Fig. 79).
(9) Install wave washer, flat washer and remain-
ing snap ring on idler shaft (Fig. 79). Verify snap
ring is seated.
SHIFT SHAFT AND BUSHINGS/BEARINGS
Inspect shift shaft bushing and bearing for damage
and replace if necessary.
(1) Locate a bolt that will thread into the bushing
without great effort.
(2) Thread the bolt into the bushing, allowing the
bolt to make its own threads in the bushing.
(3) Attach a slide hammer or suitable puller to the
bolt and remove bushing.
(4) Use the short end of Installer 8119 to install
the new bushing.
(5) The bushing is correctly installed if the bush-
ing is flush with the transmission case.
(6) To replace the bearing locate a bolt that will
thread into the bearing without great effort.
(7) Thread the bolt into the bearing as much as
possible.
(8) Attach a slide hammer or suitable puller to the
bolt and remove the bearing.
(9) Use the short end of Installer 8119 to install
the new bearing.
(10) The bearing is correctly installed if the bear-
ing is flush with the transmission case.
DETENT PLUNGER BUSHING
Inspect detent plunger bushings for damage and
replace if necessary.
NOTE: The detent plunger bushings are installed to
a specific depth. The space between the two bush-
ings when correctly installed contain an oil feed
hole. Do not attempt to install the bushings with
anything other than the specified tool or this oil
hole may become restricted.
(1) Using the long end of Installer 8119, drive the
detent bushings through the outer case and into the
shift shaft bore.
(2) Remove the bushings from the shift shaft bore.
(3) Install a new detent plunger bushing on the
long end of Installer 8118.
(4) Start the bushing in the detent plunger bore in
the case.
(5) Drive the bushing into the bore until the tool
contacts the transmission case.
(6) Install a new detent plunger bushing on the
short end of Installer 8118.
(7) Start the bushing in the detent plunger bore in
the case.
(8) Drive the bushing into the bore until the tool
contacts the transmission case.
Fig. 79 IDLER GEAR AND SHAFT ASSEMBLY
1 - REAR OF SHAFT
2 - GEAR
3 - THRUST WASHER AND BALL
4 - WAVE WASHER
5 - FLAT WASHER
6 - FRONT OF SHAFT
7 - SNAP RING
8 - SNAP RING
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MANUAL NV 3550
21s - 23
MANUAL NV 3550 (Continued)
2001 JEEP CHEROKEE
GEARTRAIN ASSEMBLY
(1) Install Adapter 6747-1A on input shaft hub of
Fixture 6747 (Fig. 80).
(2) Install input shaft in fixture tool. Make sure
Adapter 6747-1A is positioned under shaft as shown
(Fig. 81).
(3) Install pilot bearing in input shaft (Fig. 81).
NOTE: The side of the pilot bearing with the small
diameter goes toward the input shaft.
(4) Install fourth gear synchro ring on input shaft
(Fig. 82).
(5) Adjust height of idler gear pedestal on assem-
bly fixture (Fig. 83). Start with a basic height of 18.4
cm (7-1/4 in.). Final adjustment can be made after
gear is positioned on pedestal.
Fig. 80 ASSEMBLY FIXTURE FOR GEARTRAIN
1 - SPECIAL TOOL 6747-2A
2 - SPECIAL TOOL 8115
3 - SPECIAL TOOL 6747-1A
4 - SPECIAL TOOL 6747
Fig. 81 PILOT BEARING AND INPUT SHAFT
1 - PILOT BEARING
2 - INPUT SHAFT
Fig. 82 FOURTH GEAR SYNCHRO
1 - FOURTH GEAR SYNCHRO RING
2 - INPUT SHAFT
Fig. 83 IDLER PEDESTAL BASIC HEIGHT
1 - REVERSE IDLER PEDESTAL
21s - 24
MANUAL NV 3550
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MANUAL NV 3550 (Continued)
2001 JEEP CHEROKEE
(6) Install assembled output shaft and geartrain in
input shaft (Fig. 84). Carefully rotate output shaft
until the 3-4 synchro ring seats in synchro hub and
sleeve.
(7) Install Adapter 6747-2B on front bearing hub
of countershaft. The adapter has a shoulder on one
side that goes towards the countershaft.
(8) Slide countershaft (and adapter) into fixture
slot. Verify countershaft and output shaft gears are
fully meshed with the mainshaft gears (Fig. 85).
(9) Check alignment of countershaft and output
shaft gear teeth. Note that gears may not align per-
fectly. A difference in height of 1.57 to 3.18 mm (1/16
to 1/8 in.) will probably exist. This difference will not
interfere with assembly.
(10) Position reverse idler in support cup of assem-
bly fixture (Fig. 86). Ensure idler gear is properly
meshed and aligned with shaft gear teeth and that
bolt holes are facing out and not toward geartrain.
Adjust pedestal up or down if necessary. Also be sure
that short end of idler shaft is facing up as shown.
Fig. 84 OUTPUT SHAFT AND GEARTRAIN
1 - OUTPUT SHAFT AND GEARTRAIN
2 - INPUT SHAFT
3 - FIXTURE
Fig. 85 COUNTERSHAFT ON FIXTURE
1 - OUTPUT SHAFT AND GEARTRAIN
2 - COUNTERSHAFT (SLIDE INTO PLACE ON FIXTURE TOOL)
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MANUAL NV 3550
21s - 25
MANUAL NV 3550 (Continued)
2001 JEEP CHEROKEE
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