Jeep XJ. Manual — part 367
(9) Mark front propeller shaft, axle, and transfer
case yokes for installation alignment, if equipped.
(10) Remove propeller shaft(s).
(11) Unclip wire harnesses from transmission and
transfer case, if equipped.
(12) Disconnect
transfer
case
vent
hose,
if
equipped.
(13) Disengage any wire connectors attached to
transmission or transfer case, if equipped, compo-
nents.
(14) Support transfer case, if equipped, with trans-
mission jack.
(15) Secure transfer case, if equipped, to jack with
safety chains.
(16) Disconnect transfer case shift linkage at
transfer case, if equipped.
(17) Remove nuts attaching transfer case to trans-
mission, if equipped.
(18) Remove transfer case, if equipped.
(19) Remove crankshaft position sensor (Fig. 6).
CAUTION: It is important that the crankshaft posi-
tion sensor be removed prior to transmission
removal. The sensor can easily be damaged if left
in place during removal operations.
(20) Support engine with adjustable jack stand.
Position wood block between jack and oil pan to
avoid damaging pan.
(21) Support transmission with transmission jack.
(22) Secure
transmission
to
jack
with
safety
chains.
(23) Disconnect rear cushion and bracket from
transmission.
(24) Remove rear crossmember.
(25) Disconnect transmission shift lever as follows:
(a) Lower transmission approximately 7–8 cm (3
in.) for access to shift lever.
(b) Reach up and around transmission case and
unseat shift lever dust boot from transmission shift
tower (Fig. 7). Move boot upward on shift lever for
access to retainer that secures lever in shift tower.
(c) Reach up and around transmission case and
press shift lever retainer downward with finger
pressure. Turn retainer counterclockwise to release
it.
(d) Lift lever and retainer out of shift tower (Fig.
7). Do not remove the shift lever from the floor con-
Fig. 4 Slave Cylinder—Typical
1 – CLUTCH SLAVE CYLINDER
Fig. 5 Marking Propeller Shaft And Axle Yokes
1 – REFERENCE MARKS
Fig. 6 Crankshaft Position Sensor —2.5 and 4.0L
Engine
1 – ENGINE SPEED SENSOR
2 – GROMMET
3 – MOUNTING BOLT(S)
4 – LEFT REAR OF ENGINE
5 – TRANSMISSION
21 - 4
AX5 MANUAL TRANSMISSION
XJ
REMOVAL AND INSTALLATION (Continued)
sole shifter boots. Leave the lever in place for
transmission installation.
(26) Remove clutch housing brace rod.
(27) Remove clutch housing-to-engine bolts.
(28) Pull transmission jack rearward until input
shaft clears clutch. Then slide transmission out from
under vehicle.
(29) Remove clutch release bearing, release fork,
and retainer clip.
(30) Remove clutch housing from transmission
(Fig. 8).
INSTALLATION
(1) Install clutch housing (Fig. 8) on transmission.
Tighten housing bolts to 46 N·m (34 ft. lbs.) torque.
(2) Lubricate contact surfaces of release fork pivot
ball stud and release fork with high temp grease.
(3) Install release bearing, fork, and retainer clip.
(4) Position and secure transmission on transmis-
sion jack.
(5) Lightly lubricate pilot bearing and transmis-
sion input shaft splines with Mopar
t high temp
grease.
(6) Raise transmission and align transmission
input shaft and clutch disc splines. Then slide trans-
mission into place.
(7) Install and tighten clutch housing-to-engine
bolts to the appropriate torque: Be sure the hous-
ing is properly seated on engine block before
tightening bolts.
• Tighten 3/8” diameter bolts to 37 N·m (27
ft.lbs.).
• Tighten 7/16” diameter bolts to 58 N·m (43
ft.lbs.).
• Tighten M12 bolts to 75 N·m (55 ft.lbs.).
(8) Install clutch housing brace rod.
(9) Lower transmission approximately 7–8 cm (3
in.) for access to shift tower. Be sure transmission is
in first or third gear.
(10) Reach up and around transmission and insert
shift lever in shift tower. Press lever retainer down-
ward and turn it clockwise to lock it in place. Then
install lever dust boot on shift tower.
(11) Install rear crossmember. Tighten crossmem-
ber-to-frame bolts to 41 N·m (31 ft. lbs.) torque.
(12) Install fasteners to hold rear cushion and
bracket to transmission. Then tighten transmission-
to-rear support bolts/nuts to 54 N·m (40 ft. lbs.)
torque.
(13) Remove support stands from engine and
transmission.
(14) Install and connect crankshaft position sensor.
(15) Position transfer case on transmission jack, if
equipped.
(16) Secure transfer case to jack with safety
chains, if equipped.
(17) Raise transfer case, if equipped, and align
transfer case input shaft to the transmission output
shaft.
Fig. 7 Removing/Installing Shift Lever
1 – SHIFT LEVER RETAINER
2 – DUST BOOT
3 – SHIFT TOWER
Fig. 8 Clutch Housing
1 – HOUSING-TO-TRANSMISSION BOLTS (46 N·m/34 ft. lbs.)
2 – CLUTCH HOUSING
3 – TRANSMISSION
XJ
AX5 MANUAL TRANSMISSION
21 - 5
REMOVAL AND INSTALLATION (Continued)
(18) Slide transfer case forward until case is
seated on transmission, if necessary.
(19) Install nuts to attach transfer case to trans-
mission, if equipped. Tighten transfer case-to-trans-
mission nuts to 35 N·m (26 ft. lbs.) torque.
(20) Connect transfer case shift linkage at transfer
case, if equipped.
(21) Connect transfer case vent hose, if equipped.
(22) Secure wire harnesses in clips/tie straps on
transmission and transfer case, if equipped.
(23) Engage wire connectors attached to all neces-
sary transmission or transfer case, if equipped, com-
ponents.
(24) Install rear propeller shaft slip yoke to trans-
mission or transfer case, if equipped, output shaft.
(25) Align marks on rear propeller shaft and rear
axle yokes (Fig. 9).
(26) Install and tighten propeller shaft U–joint
clamp bolts to 19 N·m (170 in. lbs.) torque.
(27) Align marks on front propeller shaft, axle,
and transfer case yokes, if equipped.
(28) Install and tighten propeller shaft U–joint
clamp bolts to 19 N·m (170 in. lbs.) torque.
(29) Install slave cylinder in clutch housing.
(30) Install skid plate, if equipped. Tighten bolts to
42 N·m (31 ft. lbs.) torque. Tighten stud nuts to 17
N·m (150 in. lbs.) torque.
(31) Fill
transmission
and
transfer
case,
if
equipped, with recommended lubricants. Refer to the
Lubricant Recommendation sections of the appropri-
ate component for correct fluid.
(32) Lower vehicle.
FRONT BEARING RETAINER SEAL
REMOVAL
(1) Remove release bearing and lever from the
transmission.
(2) Remove the bolts holding the front bearing
retainer to the transmission case.
(3) Remove the front bearing retainer from the
transmission case.
(4) Using a suitable pry tool, remove the front
bearing retainer seal.
INSTALLATION
(1) Using Tool Handle C-4171 and Seal Installer
8211, install new seal in to the front bearing retainer
(Fig. 10).
(2) Remove any residual gasket material from the
sealing surfaces of the bearing retainer and the
transmission case.
(3) Install new front bearing retainer gasket to the
front bearing retainer.
(4) Install the front bearing retainer onto the
transmission case.
(5) Install the bolts to hold the bearing retainer
onto the transmission case.
(6) Tighten the bolts to 17 N·m (12 ft. lbs.).
(7) Install release bearing and lever onto the
transmission.
Fig. 9 Align Propeller Shaft And Rear Axle Yokes
Alignment Marks
1 – REFERENCE MARKS
Fig. 10 Install Front Bearing Retainer Seal
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL 8211 (AX5) OR 8209 (AX15)
21 - 6
AX5 MANUAL TRANSMISSION
XJ
REMOVAL AND INSTALLATION (Continued)
EXTENSION HOUSING SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove propeller shaft. Refer to Group 3, Dif-
ferential and Driveline, for proper procedures.
(3) Using a suitable seal puller or screw with a
slide hammer, remove the extension housing seal
(Fig. 11).
INSTALLATION
(1) Clean seal bore of extension housing of any
residual sealer material from original seal.
(2) Using Tool Handle C-4171 and Seal Installer
8212, install new extension housing seal so that the
seal is located 0
6 0.5 mm (0 6 0.02 in.) to the face
of the extension housing (Fig. 12).
(3) Install propeller shaft. Refer to Group 3, Differ-
ential and Driveline, for proper procedures.
(4) Check and add fluid to transmission as neces-
sary. Refer to the Recommended Lubricant section for
proper fluid requirements.
(5) Lower vehicle.
ADAPTER HOUSING SEAL
REMOVAL
(1) Hoist and support vehicle.
(2) Remove transfer case.
(3) Using a suitable pry tool, or a slide hammer
mounted screw, remove the adapter housing seal
(Fig. 13).
INSTALLATION
(1) Clean seal bore of adapter housing of any
residual sealer material from original seal.
(2) Using Tool Handle C-4171 and Seal Installer
8208, install new seal so that the seal is located 0
6
0.2 mm (0
6 0.008 in.) to the seal bore face of
adapter housing (Fig. 14).
(3) Install transfer case.
(4) Check and add fluid to transmission as neces-
sary. Refer to the Recommended Lubricant section for
proper fluid requirements.
(5) Lower vehicle.
Fig. 11 Remove Extension Housing Seal
1 – SLIDE HAMMER
2 – SEAL PULLER
3 – 2WD EXTENSION HOUSING
Fig. 12 Install Extension Housing Seal
1 – SPECIAL TOOL
C-4171
2 – SPECIAL TOOL
8212
3 – EXTENSION HOUSING
Fig. 13 Remove Adapter Housing Seal
1 – ADAPTER HOUSING OIL SEAL
XJ
AX5 MANUAL TRANSMISSION
21 - 7
REMOVAL AND INSTALLATION (Continued)
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