Jeep XJ. Manual — part 380
(4) Remove bearing retainer bolts and remove rear
bearing retainer and rear bearing (Fig. 43). Use ham-
mer handle to push or tap bearing out of housing if
needed.
(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 DISASSEMBLY 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.
Fig. 41 Rear Bearing Snap Ring Removal—4WD
1 – HEAVY DUTY SNAP RING PLIERS
2 – REAR BEARING SNAP RING
3 – OUTPUT SHAFT
Fig. 42 Rear Adapter Housing Removal
1 – REAR ADAPTER HOUSING
2 – OUTPUT SHAFT
Fig. 43 Rear Adapter Housing Components
1 – BEARING RETAINER
2 – RETAINER BOLTS (3)
3 – IDLER SHAFT NOTCH
4 – COUNTERSHAFT REAR BEARING RACE
5 – REAR BEARING
21 - 56
NV3550 MANUAL TRANSMISSION
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
OUTPUT SHAFT
NOTE: The synchronizer hubs and sleeves are dif-
ferent and must not be intermixed. It is recom-
mended that each synchronizer unit be removed as
an assembly to avoid intermixing parts. It is also
recommended that each synchro hub and sleeve be
marked with a scriber or paint for correct assembly
reference.
(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
Remover Tool 1130. Position Tool 1130 between sec-
ond and third gears.
(3) Remove third gear needle bearing (Fig. 44).
(4) Remove retaining ring that secures two-piece
thrust washer on shaft (Fig. 45). Use small pry tool
to remove retaining ring.
(5) Remove two-piece thrust washer (Fig. 46). Note
position of washer locating lugs in shaft notches for
installation reference.
(6) Remove second gear and needle bearing (Fig.
47).
(7) Remove second gear synchro ring, synchro fric-
tion cone, and synchro cone (Fig. 48).
(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 shop press and Remover
Tool 1130 (Fig. 49). Position Tool 1130 between first
and reverse gears.
Fig. 44 Third Gear Needle Bearing Removal
1 – THIRD GEAR NEEDLE BEARING
Fig. 45 Thrust Washer Retaining Ring Removal
1 – PRY TOOL
2 – THRUST WASHER RETAINING RING
Fig. 46 Two-Piece Thrust Washer Removal
1 – SECOND GEAR
2 – THRUST WASHER (2–PIECE)
3 – WASHER LOCATING LUG
Fig. 47 Second Gear And Needle Bearing Removal
1 – SECOND GEAR
2 – SECOND GEAR NEEDLE BEARING
XJ
NV3550 MANUAL TRANSMISSION
21 - 57
DISASSEMBLY AND ASSEMBLY (Continued)
(11) Remove first gear needle bearing (Fig. 50).
(12) Remove output shaft bearing snap ring (Fig.
51).
(13) On 2-wheel drive models, remove output shaft
bearing.
(14) Remove fifth gear (Fig. 52).
Fig. 48 Second Gear Synchro Ring And Cones
Removal
1 – 1–2 SYNCHRO HUB AND SLEEVE
2 – INTERM RING
3 – SYNCHRO FRICTION CONE
4 – SYNCHRO CONE
5 – SYNCHRO RING
Fig. 49 Hub And Sleeve Removal—1-2 Synchro
1 – 1–2 SYNCHRO HUB AND SLEEVE
2 – SPECIAL TOOL
1130
Fig. 50 First Gear Needle Bearing Removal
1 – FIRST GEAR NEEDLE BEARING
Fig. 51 Output Shaft Bearing Snap Ring Removal
1 – OUTPUT SHAFT BEARING
2 – BEARING SNAP RING
3 – SNAP RING PLIERS
Fig. 52 Fifth Gear Removal
1 – FIFTH GEAR AND SYNCHRO RING
21 - 58
NV3550 MANUAL TRANSMISSION
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(15) Remove fifth gear needle bearing. Spread
bearing apart just enough to clear shoulder on output
shaft (Fig. 53).
(16) Remove fifth-reverse synchro hub snap ring
(Fig. 54).
(17) Remove fifth-reverse synchro hub and sleeve
with shop press (Fig. 55).
(18) Remove reverse gear and needle bearing (Fig.
56).
Fig. 53 Fifth Gear Needle Bearing Removal
1 – FIFTH GEAR NEEDLE BEARING (SPREAD BEARING TO
CLEAR SHOULDER ON SHAFT)
Fig. 54 Fifth-Reverse Synchro Hub Snap Ring
Removal
1 – FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
2 – SYNCHRO HUB SNAP RING
3 – SNAP RING PLIERS
Fig. 55 Fifth-Reverse Synchro Hub And Sleeve
Removal
1 – PRESS
2 – FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
3 – REVERSE GEAR
4 – OUTPUT SHAFT
Fig. 56 Reverse Gear And Needle Bearing Removal
1 – REVERSE GEAR AND NEEDLE BEARING
XJ
NV3550 MANUAL TRANSMISSION
21 - 59
DISASSEMBLY AND ASSEMBLY (Continued)
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