Jeep XJ. Manual — part 797
(4) Remove bearing retainer bolts and remove rear
bearing retainer and rear bearing (Fig. 33). If needed
push or tap bearing out of the housing with a ham-
mer.
(5) Examine condition of bearing bore, counter-
shaft rear bearing race and idler shaft notch in rear
housing. Replace housing if race, bore or notch are
worn or damaged.
GEARTRAIN FROM FIXTURE
(1) Remove
reverse
idler
gear
assembly
from
assembly fixture cup.
(2) Remove 1-2 and fifth-reverse forks from syn-
chro sleeves.
(3) Slide countershaft out of fixture tool.
(4) Remove output shaft bearing retainer from
rear surface of fifth gear (retainer will drop onto gear
after bolts are removed).
(5) Lift and remove output shaft and gears off
input shaft.
(6) Lift and remove input shaft, pilot bearing and
fourth gear synchro ring from assembly fixture tool.
OUTPUT SHAFT
NOTE: The synchronizer hubs and sleeves are dif-
ferent and must not be intermixed. Remove each
synchronizer unit as an assembly to avoid intermix-
ing parts. Reference mark or tag each synchro hub
and sleeve for correct assembly.
Fig. 31 REAR BEARING SNAP RING - 4WD
1 - HEAVY DUTY SNAP RING PLIERS
2 - REAR BEARING SNAP RING
3 - OUTPUT SHAFT
Fig. 32 REAR ADAPTER HOUSING
1 - REAR ADAPTER HOUSING
2 - OUTPUT SHAFT
Fig. 33 REAR ADAPTER HOUSING COMPONENTS
1 - BEARING RETAINER
2 - RETAINER BOLTS (3)
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT REAR BEARING RACE
5 - REAR BEARING
21s - 10
MANUAL NV 3550
XJ
MANUAL NV 3550 (Continued)
2001 JEEP CHEROKEE
(1) Remove snap ring that secures 3-4 synchro hub
on output shaft.
(2) Remove 3-4 synchro assembly, third gear syn-
chro ring and third gear with shop press and Bearing
Splitter 1130. Position splitter between second and
third gears.
(3) Remove third gear needle bearing (Fig. 34).
(4) Remove retaining ring that secures two-piece
thrust washer on shaft (Fig. 35). Use a small pry tool
to remove retaining ring.
(5) Remove two-piece thrust washer (Fig. 36). Note
position of washer locating lugs in shaft notches for
installation reference.
(6) Remove second gear and needle bearing (Fig.
37).
Fig. 34 THIRD GEAR NEEDLE BEARING
1 - THIRD GEAR NEEDLE BEARING
Fig. 35 THRUST WASHER
1 - PRY TOOL
2 - THRUST WASHER RETAINING RING
Fig. 36 TWO-PIECE THRUST WASHER
1 - SECOND GEAR
2 - THRUST WASHER (2–PIECE)
3 - WASHER LOCATING LUG
Fig. 37 SECOND GEAR AND NEEDLE BEARING
1 - SECOND GEAR
2 - SECOND GEAR NEEDLE BEARING
XJ
MANUAL NV 3550
21s - 11
MANUAL NV 3550 (Continued)
2001 JEEP CHEROKEE
(7) Remove second gear synchro ring, synchro fric-
tion cone and synchro cone (Fig. 38).
(8) Remove interm ring.
(9) Remove 1-2 synchro hub snap ring.
(10) Remove 1-2 synchro hub and sleeve and first
gear from output shaft with press and Bearing Split-
ter 1130 (Fig. 39). Position splitter between first and
reverse gears.
(11) Remove first gear needle bearing (Fig. 40).
(12) Remove output shaft bearing snap ring (Fig.
41).
(13) On 2-wheel drive models, remove output shaft
bearing.
(14) Remove fifth gear (Fig. 42).
Fig. 38 SECOND GEAR SYNCHRO RING AND
CONES
1 - 1–2 SYNCHRO HUB AND SLEEVE
2 - INTERM RING
3 - SYNCHRO FRICTION CONE
4 - SYNCHRO CONE
5 - SYNCHRO RING
Fig. 39 HUB SLEEVE AND 1-2 SYNCHRO
1 - 1-2 SYNCHRO HUB AND SLEEVE
2 - BEARING SPITTER
Fig. 40 FIRST GEAR NEEDLE BEARING
1 - FIRST GEAR NEEDLE BEARING
Fig. 41 OUTPUT SHAFT BEARING SNAP RING
1 - OUTPUT SHAFT BEARING
2 - BEARING SNAP RING
3 - SNAP RING PLIERS
Fig. 42 FIFTH GEAR
1 - FIFTH GEAR AND SYNCHRO RING
21s - 12
MANUAL NV 3550
XJ
MANUAL NV 3550 (Continued)
2001 JEEP CHEROKEE
(15) Remove fifth gear needle bearing. Spread
bearing apart just enough to clear shoulder on output
shaft (Fig. 43).
(16) Remove fifth-reverse synchro hub snap ring
(Fig. 44).
(17) Remove fifth-reverse synchro hub and sleeve
with a press (Fig. 45).
(18) Remove reverse gear and needle bearing (Fig.
46).
REVERSE IDLER
(1) Remove idler gear snap rings (Fig. 47).
(2) Remove thrust washer, wave washer, thrust
plate and idler gear from shaft.
(3) Remove idler gear needle bearing from shaft.
Fig. 43 FIFTH GEAR NEEDLE BEARING
1 - FIFTH GEAR NEEDLE BEARING
Fig. 44 FIFTH-REVERSE SYNCHRO HUB SNAP
RING
1 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
2 - SYNCHRO HUB SNAP RING
3 - SNAP RING PLIERS
Fig. 45 FIFTH-REVERSE SYNCHRO HUB AND
SLEEVE
1 - PRESS
2 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
3 - REVERSE GEAR
4 - OUTPUT SHAFT
Fig. 46 REVERSE GEAR AND NEEDLE BEARING
1 - REVERSE GEAR AND NEEDLE BEARING
XJ
MANUAL NV 3550
21s - 13
MANUAL NV 3550 (Continued)
2001 JEEP CHEROKEE
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