Jeep XJ. Manual — part 369
(23) Separate intermediate plate and transmission
case by tapping them loose with plastic mallet (Fig.
30).
(24) Separate the intermediate plate from the
transmission case (Fig. 31).
ASSEMBLY
(1) Remove any residual sealer from transmission
case, intermediate plate, and adapter/extension hous-
ing.
(2) Apply a 1/8 to 3/16 inch wide bead of Threeb-
ond
t Liquid Gasket TB1281, P/N 83504038, as
shown, making sure to keep sealer bead to inside of
bolt holes (Fig. 32).
(3) Align geartrain and shift rails with mating
holes in transmission case and install transmission
case to the intermediate plate (Fig. 33). Verify that
the transmission case is seated on the intermediate
plate locating pins.
Fig. 29 Remove Input Shaft Bearing Snap-ring
1 – SNAP RING PLIERS
2 – INPUT SHAFT
3 – INPUT SHAFT BEARING SNAP RING
Fig. 30 Separate Intermediate Plate and
Transmission Case
1 – INTERMEDIATE PLATE
2 – RUBBER MALLET
3 – GEAR CASE
Fig. 31 Remove Intermediate Plate from
Transmission Case
1 – GEAR CASE
2 – INTERMEDIATE PLATE
Fig. 32 Apply Sealer to Transmission Gear Case
1 – SEALER BEAD (1/8” - 3/16” WIDE)
2 – GEAR CASE
21 - 12
AX5 MANUAL TRANSMISSION
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Install new front bearing snap rings (Fig. 34).
(5) Install front bearing retainer gasket to front
bearing retainer.
(6) Install the front bearing retainer (Fig. 35) and
tighten bolts to 17 N·m (12 ft. lbs.).
(7) On 4x2 transmissions;
(a) Install speedometer drive gear locating snap-
ring (Fig. 36).
(b) Install speedometer gear lock ball in output
shaft and install speedometer gear onto output
shaft.
(c) Install speedometer gear retaining snap-ring
onto output shaft.
(8) Apply a 1/8 to 3/16 inch wide bead of Threeb-
ond
t Liquid Gasket TB1281, P/N 83504038, to seal-
ing surface of adapter/extension housing, making
sure to keep sealer bead to inside of bolt holes.
(9) Install adapter or extension housing on inter-
mediate plate (Fig. 37). Tighten housing bolts to 34
N·m (25 ft. lbs.) torque.
(10) Position shift arm in shifter tower opening of
adapter or extension housing (Fig. 38). Be sure that
the shifter arm is engaged into the shift rails.
Fig. 33 Install Transmission Gear Case to the
Intermediate Plate
1 – GEAR CASE
2 – INTERMEDIATE PLATE
Fig. 34 Install Front Bearing Snap-rings
1 – FRONT BEARING SNAP RINGS
Fig. 35 Install Front Bearing Retainer
1 – FRONT BEARING RETAINER
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AX5 MANUAL TRANSMISSION
21 - 13
DISASSEMBLY AND ASSEMBLY (Continued)
(11) Start shifter arm shaft in hole in back of
adapter or extension housing. Align shift arm and
shifter arm shaft and insert shifter arm shaft
through the shifter arm and into the forward portion
of the adapter or extension housing (Fig. 39).
(12) Rotate the shifter arm shaft until the hole in
the shift arm is aligned with the hole in the shaft.
(13) Install the shift arm retainer bolt and tighten
to 38 N·m (28 ft. lbs.) (Fig. 40).
(14) Install and tighten shifter arm shaft plug to
18 N·m (13 ft. lbs.) torque (Fig. 41).
Fig. 36 Speedometer Drive Gear Assembly
1 – SNAP RING
2 – LOCK BALL
3 – SNAP RING
4 – OUTPUT SHAFT GROOVES
5 – SPEEDOMETER GEAR
Fig. 37 Install Adapter/Extension Housing–Typical
1 – ADAPTER HOUSING
2 – INTERMEDIATE PLATE
Fig. 38 Position Shift Arm in Adapter or Extension
Housing
1 – SHIFT ARM
Fig. 39 Install Shifter Arm Shaft
1 – SHIFT ARM
2 – ADAPTER OR EXTENSION HOUSING
21 - 14
AX5 MANUAL TRANSMISSION
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(15) Install shift restrictor pins in shift tower and
tighten to 27 N·m (20 ft. lbs.) (Fig. 42).
NOTE: The restrictor pins are not interchangeable
and are color coded. Be sure to install the pin into
the same location from which it was removed.
(16) Install shift detent ball in detent opening of
case (Fig. 43).
(17) Install detent spring in case (Fig. 44).
(18) Install detent plug and tighten to 19 N·m (14
ft. lbs.) (Fig. 45).
Fig. 40 Install Shift Arm Retainer Bolt
1 – RETAINER BOLT
2 – SHIFT ARM
Fig. 41 Shifter Arm Shaft Plug Installation
1 – SHAFT PLUG
Fig. 42 Install Shifter Restrictor Pins
1 – RESTRICTOR PINS
Fig. 43 Install Detent Ball
1 – PENCIL MAGNET
2 – SHIFT DETENT BALL
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AX5 MANUAL TRANSMISSION
21 - 15
DISASSEMBLY AND ASSEMBLY (Continued)
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