Jeep XJ. Manual — part 366
(5) Separate steering shaft from gearbox by pulling
straight apart.
(6) Raise the vehicle on a hoist.
(7) Remove the stabilizer bar clamp retaining bolts
from the frame (Fig. 14). Allow stabilizer bar to hang
free.
(8) Remove the Pittman arm from the steering
gear (Fig. 14). Refer to Group 19, Steering for the
procedure.
(9) Remove the small right front splash from the
vehicle.
(10) Remove the (3) steering gear retaining bolts
(Fig. 15).
(11) Rotate the lower radiator hose clamp, so that
the tangs are facing straight down. This will aid in
gear removal.
(12) Remove the steering gear from the vehicle.
INSTALLATION
(1) Center the steering gear travel. Rotate gear
output shaft until stop. Make a reference mark in the
same position on the gear shaft and gear housing.
Rotate gear shaft in the opposite direction until stop
while noting the number of turns. Divide that num-
ber in half and position the reference mark made
previously at that position.
(2) Install the steering gear in the vehicle.
(3) Install the (3) steering gear retaining bolts.
Torque to 95 N·m (70 ft. lbs.).
(4) Install the small right front splash on the vehi-
cle.
(5) Install the Pittman arm on the steering gear.
Refer to Group 19, Steering for the procedure. Torque
nut to 251 N·m (185 ft. lbs.).
(6) Position the stabilizer bar and install the
clamp retaining bolts. Refer to Group 2, Suspension
for a detailed procedure. Torque the bolts to 75 N·m
(40 ft. lbs.).
(7) Lower the vehicle on the hoist.
(8) Install the steering column shaft coupler on the
steering gear and install pinch bolt. Torque the bolt
to 35 N·m (26 ft. lbs.)..
(9) Install the power steering pressure and return
lines on the steering gear. Torque the lines to 28 N·m
(21 ft. lbs.).
(10) Connect the negative battery cable.
(11) Check and correct vehicle front end alignment
specifications if necessary. Refer to Group 2, Suspen-
sion for the procedure.
Fig. 14 Steering Gear
1 – LOWER RADIATOR HOSE/CLAMP
2 – STEERING GEAR
3 – PITMAN ARM
4 – STABILIZER BAR RETAINING BOLTS
5 – POWER STEERING FLUID PRESSURE LINE
6 – POWER STEERING FLUID RETURN LINE
Fig. 15 Steering Gear Retaining Bolts
1 – STEERING GEAR RETAINING BOLTS
2 – VEHICLE FRAME RAIL
19 - 8
STEERING
XJ
REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page
page
AX5 MANUAL TRANSMISSION . . . . . . . . . . . . . . . 1
NV3550 MANUAL TRANSMISSION . . . . . . . . . . . 42
AUTOMATIC TRANSMISSION—30RH . . . . . . . . . 88
AW–4 AUTOMATIC TRANSMISSION . . . . . . . . . 217
NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . . 346
NV242 TRANSFER CASE . . . . . . . . . . . . . . . . . . 375
AX5 MANUAL TRANSMISSION
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
AX5 MANUAL TRANSMISSION . . . . . . . . . . . . . . . 1
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
REMOVAL AND INSTALLATION
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT BEARING RETAINER SEAL . . . . . . . . . . . . 6
EXTENSION HOUSING SEAL . . . . . . . . . . . . . . . . 7
ADAPTER HOUSING SEAL . . . . . . . . . . . . . . . . . . 7
DISASSEMBLY AND ASSEMBLY
FRONT BEARING RETAINER . . . . . . . . . . . . . . . 8
SHIFT MECHANISM AND GEARTRAIN . . . . . . . . 17
COUNTERSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . 30
INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 31
SEMI-SYNCHRONIZED REVERSE IDLER
GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CLEANING AND INSPECTION
AX5 MANUAL TRANSMISSION COMPONENTS . . 37
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SPECIAL TOOLS
AX5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DESCRIPTION AND OPERATION
AX5 MANUAL TRANSMISSION
DESCRIPTION
The AX5 is a five speed manual transmission with
fifth gear being the overdrive range. An adapter hous-
ing is used to attach the transmission to the transfer
case on 4-wheel drive applications. A standard style
extension housing is used for the 2-wheel drive appli-
cations. The shift mechanism is integral to the trans-
mission assembly and mounted in the shift tower
portion of the adapter/extension housing (Fig. 1).
GEAR RATIOS
Gear ratios for the AX5 manual transmission are
as follows:
• First gear: 3.93:1
• Second gear: 2.33:1
• Third gear: 1.45:1
• Fourth gear: 1.00:1
• Fifth gear: 0.85:1
• Reverse gear: 4.74:1
TRANSMISSION IDENTIFICATION
The AX5 identification code is on the bottom sur-
face of the transmission case near the fill plug (Fig.
2). The first number is year of manufacture. The sec-
ond and third numbers indicate month of manufac-
ture. The next series of numbers is the transmission
serial number.
OPERATION
The manual transmission receives power through
the clutch assembly from the engine. The clutch disc
is splined to the transmission input shaft and is
turned at engine speed at all times that the clutch is
XJ
TRANSMISSION AND TRANSFER CASE
21 - 1
engaged. The input shaft is connected to the trans-
mission countershaft through the mesh of fourth
speed gear on the input shaft and the fourth counter-
shaft gear. At this point, all the transmission gears
are spinning.
The driver selects a particular gear by moving the
shift lever to the desired gear position. This move-
ment moves the internal transmission shift compo-
nents to begin the shift sequence. As the shift lever
moves the selected shift rail, the shift fork attached
to that rail begins to move. The fork is positioned in
a groove in the outer circumference of the synchro-
nizer sleeve. As the shift fork moves the synchronizer
sleeve, the synchronizer begins to speed-up or slow
down the selected gear (depending on whether we are
up-shifting or down-shifting). The synchronizer does
this by having the synchronizer hub splined to the
mainshaft, or the countershaft in some cases, and
moving the blocker ring into contact with the gear’s
friction cone. As the blocker ring and friction cone
come together, the gear speed is brought up or down
to the speed of the synchronizer. As the two speeds
match, the splines on the inside of the synchronizer
sleeve become aligned with the teeth on the blocker
ring and the friction cone and eventually will slide
over the teeth, locking the gear to the mainshaft, or
countershaft, through the synchronizer.
LUBRICANT
DESCRIPTION
Recommended lubricant for AX5 transmissions is
Mopar
t 75W–90, API Grade GL–3 gear lubricant, or
equivalent.
Correct lubricant level is from the bottom edge, to
no more than 6 mm (1/4 in.) below the bottom edge of
the fill plug hole.
The fill plug is on the passenger side of the
adapter housing (Fig. 3). The drain plug is on the
bottom of the case.
Fig. 1 AX5 Manual Transmission
Fig. 2 Transmission Identification
1 – I. D. CODE ON CASE NEAR DRAIN PLUG
21 - 2
AX5 MANUAL TRANSMISSION
XJ
DESCRIPTION AND OPERATION (Continued)
Approximate dry fill lubricant capacity is:
• 3.3 liters (3.49 quarts) for 4–wheel drive applica-
tions.
• 3.5 liters (3.70 quarts) for 2–wheel drive applica-
tions.
DIAGNOSIS AND TESTING
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill, or an incor-
rect lubricant level check.
Leaks can occur at the mating surfaces of the gear
case, intermediate plate and adaptor or extension
housing, or from the front/rear seals. A suspected
leak could also be the result of an overfill condition.
Leaks at the rear of the extension or adapter hous-
ing will be from the housing oil seals. Leaks at com-
ponent mating surfaces will probably be the result of
inadequate sealer, gaps in the sealer, incorrect bolt
tightening, or use of a non–recommended sealer.
A leak at the front of the transmission will be from
either the front bearing retainer or retainer seal.
Lubricant may be seen dripping from the clutch
housing after extended operation. If the leak is
severe, it may also contaminate the clutch disc caus-
ing the disc to slip, grab, and/or chatter.
A correct lubricant level check can only be made
when the vehicle is level. Also allow the lubricant to
settle for a minute or so before checking. These rec-
ommendations will ensure an accurate check and
avoid an underfill or overfill condition. Always check
the lubricant level after any addition of fluid to avoid
an incorrect lubricant level condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper, or contaminated lubricants. The con-
sequence of using non–recommended lubricants is
noise, excessive wear, internal bind, and hard shift-
ing. Substantial lubricant leaks can result in gear,
shift rail, synchro, and bearing damage. If a leak
goes undetected for an extended period, the first indi-
cations of component damage are usually hard shift-
ing and noise.
Component damage, incorrect clutch adjustment,
or a damaged clutch pressure plate or disc are addi-
tional probable causes of increased shift effort. Incor-
rect adjustment or a worn/damaged pressure plate or
disc can cause incorrect release. If the clutch problem
is advanced, gear clash during shifts can result.
Worn or damaged synchro rings can cause gear clash
when shifting into any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to
stick slightly causing hard or noisy shifts. In most
cases, this condition will decline as the rings wear–
in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears generate a mild
whine that is audible, but generally only at extreme
speeds.
Severe, highly audible transmission noise is gener-
ally the initial indicator of a lubricant problem.
Insufficient, improper, or contaminated lubricant will
promote rapid wear of gears, synchros, shift rails,
forks and bearings. The overheating caused by a
lubricant problem, can also lead to gear breakage.
REMOVAL AND INSTALLATION
TRANSMISSION
REMOVAL
(1) Shift transmission into first or third gear.
(2) Raise and support vehicle on suitable safety
stands.
(3) Support engine with adjustable jack stand.
Position wood block between jack and oil pan to
avoid damaging pan.
(4) Remove crossmember/skid plate.
(5) Disconnect necessary exhaust system compo-
nents.
(6) Remove skid plate, if equipped.
(7) Remove slave cylinder (Fig. 4) from clutch
housing.
(8) Mark rear propeller shaft and rear axle yokes
for installation alignment (Fig. 5).
Fig. 3 Fill Plug Location
1 – FILL PLUG LOCATION
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AX5 MANUAL TRANSMISSION
21 - 3
DESCRIPTION AND OPERATION (Continued)
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