Jeep XJ. Manual — part 374
(3) Remove output shaft fifth gear snap ring with
two screwdrivers (Fig. 101).
(4) Using Bearing Splitter P-334 or suitable press
plates positioned under first gear, press fifth gear,
rear bearing, first gear, and first gear bearing inner
race off output shaft (Fig. 102).
(5) Remove first gear needle roller bearing from
output shaft.
(6) Remove first gear bearing inner race lock ball
with pencil magnet (Fig. 103).
(7) Remove first gear synchronizer ring.
(8) Using Bearing Splitter P-334 or suitable press
plates positioned under second gear, press 1–2 syn-
chronizer, reverse gear, and second gear from output
shaft (Fig. 104).
(9) Remove second gear needle roller bearing from
the output shaft or second gear.
(10) Remove select fit snap-ring holding the 3–4
synchronizer onto the output shaft (Fig. 105).
(11) Using Bearing Splitter P-334 or suitable press
plates positioned under third gear, press the 3–4 syn-
chronizer and third gear from output shaft (Fig. 106).
(12) Remove third gear needle roller bearing from
output shaft or gear.
Fig. 101 Remove Fifth Gear Snap-ring
1 – SNAP RING
Fig. 102 Remove Fifth Gear, First Gear Bearing, And
Race
1 – PRESS RAM
2 – OUTPUT SHAFT
3 – FIRST-FIFTH GEAR-BEARING ASSEMBLY
Fig. 103 Remove First Gear Bearing Inner Race
Lock Ball
1 – LOCK BALL
2 – PENCIL MAGNET
21 - 32
AX5 MANUAL TRANSMISSION
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
TRANSMISSION ASSEMBLY INFORMATION
Lubricate
the
transmission
components
with
Mopar
t 75W–90, GL 3 gear lubricant during assem-
bly. Use petroleum jelly to lubricate seal lips and/or
hold parts in place during installation.
Refer to (Fig. 107) during assembly for AX5 gear
assembly identification.
(1) Lubricate transmission components with speci-
fied gear lubricant.
(2) If necessary, assemble 1–2 and 3–4 synchro-
nizer hubs, sleeves, springs and key inserts (Fig.
108).
(3) Install third gear needle bearing onto the out-
put shaft.
(4) Install third gear over bearing and onto output
shaft flange.
(5) Install third gear synchronizer ring to third
gear.
(6) Position the 3–4 synchronizer onto the output
shaft.
(7) Using Adapter 6747-1A and a shop press, press
the 3–4 synchronizer onto the output shaft.
Fig. 104 Remove Second Gear, Reverse Gear, And
1–2 Synchronizer
1 – PRESS RAM
2 – SECOND GEAR
3 – 1–2 SYNCHRONIZER HUB
Fig. 105 Remove 3–4 Synchronizer Snap Ring
1 – 3–4 SYNCHRONIZER SNAP RING
Fig. 106 Remove 3–4 Synchronizer And Third Gear
1 – 3–4 SYNCHRONIZER
2 – THIRD GEAR
XJ
AX5 MANUAL TRANSMISSION
21 - 33
DISASSEMBLY AND ASSEMBLY (Continued)
(8) Select the thickest snap-ring that will fit into
the snap-ring groove of the output shaft (Fig. 109).
(9) Install snap-ring to hold 3–4 synchronizer onto
output shaft.
(10) Verify third gear thrust clearance with feeler
gauge (Fig. 110). Clearance should be 0.10 – 0.25 mm
(0.004 – 0.010 in.). If clearance is out of specification,
refer to Cleaning and Inspection section within this
group.
(11) Install second gear needle bearing onto output
shaft.
(12) Install second gear over bearing and onto out-
put shaft flange.
(13) Install second gear synchronizer ring onto sec-
ond gear.
(14) Position
1–2
synchronizer
assembly
onto
splines of output shaft.
(15) Using Driver MD-998805, Adapter 6747-1A,
and a shop press, press the 1–2 synchronizer onto
the output shaft.
(16) Install first gear synchronizer ring into 1–2
synchronizer.
(17) Install first gear bearing inner race lock ball
in output shaft (Fig. 111).
(18) Install first gear needle bearing onto output
shaft (Fig. 112).
Fig. 107 Geartrain Components
1 – SNAP RING
2 – FIFTH GEAR
3 – COUNTER GEAR
4 – BEARING
5 – LOCK BALL
6 – SYNCHRO HUB/SLEEVE
7 – SNAP RING
8 – SPACER
9 – COUNTER 5TH GEAR
10 – SYNCHRO RING
11 – 5TH SPLINE GEAR
12 – SNAP RING
Fig. 108 Synchronizer Identification
1 – SLEEVES
2 – HUBS
I. D. Mark
Snap Ring Thickness mm (in.)
C-1
1.75-1.80 (0.0689-0.0709)
D
1.80-1.85 (0.0709-0.0728)
D-1
1.85-1.90 (0.0728-0.0748)
E
1.90-1.95 (0.0748-0.0768)
E-1
1.95-2.00 (0.0768-0.0787)
F
2.00-2.05 (0.0788-0.0807)
F-1
2.05-2.10 (0.0807-0.0827)
Fig. 109 Select 3–4 Synchronizer Snap-ring
21 - 34
AX5 MANUAL TRANSMISSION
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(19) Install first gear onto output shaft and over
bearing.
(20) Install first gear bearing inner race onto out-
put shaft and inside first gear bearing. Rotate bear-
ing race until race installs over lock ball.
(21) Position output shaft rear bearing onto output
shaft. Ensure that the snap ring groove in bearing
outer race is toward rear of output shaft.
(22) Using Driver L-4507 and suitable mallet,
drive bearing onto output shaft.
(23) Install snap-ring onto output shaft rear bear-
ing outer race.
(24) Check first–second gear thrust clearance (Fig.
113). Standard clearance is 0.10 – 0.25 mm (0.004 –
0.010 in.). If clearance is out of specification, refer to
Cleaning and Inspection section within this group.
(25) Position fifth gear onto output shaft with the
gear’s short shoulder toward the rear of shaft.
Ensure that the gear and output shaft splines are
aligned.
(26) Using Adapter 6747-1A, Driver L-4507, and a
shop press, press fifth gear onto output shaft.
(27) Select the thickest snap-ring that will fit into
the snap-ring groove of the output shaft (Fig. 114).
Fig. 110 Check Third Gear Clearance
1 – FEELER GAUGE
2 – THIRD GEAR
Fig. 111 Install First Gear Bearing Inner Race Lock
Ball
1 – FIRST GEAR LOCK BALL
Fig. 112 First Gear Components
1 – REAR BEARING
2 – INNER RACE
3 – FIRST GEAR
4 – NEEDLE BEARING
5 – FIRST GEAR LOCK BALL
Fig. 113 Check First–Second Gear Thrust Clearance
XJ
AX5 MANUAL TRANSMISSION
21 - 35
DISASSEMBLY AND ASSEMBLY (Continued)
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