Jeep XJ. Manual — part 802
(7) Align shift socket with shaft and slide shaft
through socket and into shift shaft bearing in rear
housing (Fig. 103).
(8) Rotate shift shaft so detent notches in shaft are
facing the TOP of the transmission housing.
CAUTION: Positioning of the shift shaft detent
notch is important. Both of the shaft roll pins can
be installed even when the shaft is 180° off. If this
occurs, the transmission will have to be disassem-
bled again to correct shaft alignment.
(9) Select correct new roll pin for shift shaft lever
(Fig. 104). Shaft lever roll pin is approximately 22
mm (7/8 in.) long. Shift socket roll pin is approxi-
mately 33 mm (1-1/4 in.) long.
Fig. 100 LEVER AND BUSHING
1 - SHAFT LEVER
2 - LEVER BUSHING
3 - BUSHING LOCK PIN SLOT
Fig. 101 LEVER AND BUSHING ASSENBLY
1 - SHIFT SHAFT
2 - SHAFT LEVER AND BUSHING
3 - 3-4 FORK
Fig. 102 SHAFT IN LEVER OPENING
1 - SHIFT SHAFT
Fig. 103 SHIFT SOCKET
1 - SHIFT SOCKET
2 - SHIFT SHAFT
Fig. 104 ROLL PIN IDENTIFICATION
1 - SHAFT LEVER ROLL PIN
2 - SHIFT SOCKET ROLL PIN
21s - 30
MANUAL NV 3550
XJ
MANUAL NV 3550 (Continued)
2001 JEEP CHEROKEE
(10) Align roll pin holes in shift shaft, lever and
bushing. Then start roll pin into shaft lever by hand
(Fig. 105).
(11) Seat shaft lever roll pin with pin punch (Fig.
106).
CAUTION: The shaft lever roll pin must be flush
with the surface of the lever. The lever bushing will
bind on the roll pin if the pin is not seated flush.
(12) Verify that lock pin slot in lever bushing is
positioned as shown (Fig. 106).
(13) Align roll pin holes in shift socket and shift
shaft. Then start roll pin into shift shaft by hand
(Fig. 107).
(14) Seat roll pin in shift socket with pin punch.
Roll pin must be flush with socket (Fig. 108).
(15) Verify that notches in shift fork arms are
aligned. Realign arms if necessary.
Fig. 105 ROLL PIN IN SHIFT SHAFT
1 - SHAFT LEVER ROLL PIN (” LONG)
2 - LEVER AND BUSHING
Fig. 106 SHIFT SHAFT LEVER ROLL
1 - BUSHING LOCK PIN SLOT
2 - SEAT ROLL PIN FLUSH WITH LEVER
Fig. 107 ROLL PIN IN SHIFT SOCKET
1 - ROLL PIN
2 - SHIFT SOCKET
3 - SHIFT SHAFT
Fig. 108 SEATING SHIFT SOCKET ROLL PIN
1 - PIN PUNCH
2 - SHIFT SOCKET
3 - SEAT ROLL PIN FLUSH
4 - SHIFT SOCKET
XJ
MANUAL NV 3550
21s - 31
MANUAL NV 3550 (Continued)
2001 JEEP CHEROKEE
FRONT HOUSING AND INPUT SHAFT BEARING
RETAINER
(1) Install reverse blocker, retainter and retainer
bolt in front housing.
(2) If previously removed, input shaft bearing in
front housing (Fig. 109). Install snap ring and use
plastic mallet to seat bearing. Bearing goes in from
front side of housing only.
(3) Apply liberal quantity of petroleum jelly to
countershaft front bearing. Then insert bearing in
front housing race (Fig. 109). Large diameter side of
bearing cage goes toward countershaft (Fig. 110).
Small diameter side goes toward bearing race in
housing.
(4) Reach into countershaft front bearing with fin-
ger, and push each bearing roller outward against
race. Then apply extra petroleum jelly to hold rollers
in place. This avoids having rollers becoming dis-
placed during housing installation.
(5) Apply small amount of petroleum jelly to shift
shaft bushing in front housing.
(6) Apply 1/8 in. wide bead of Mopar Gasket
Maker or equivalent, to mating surfaces of front and
rear housings (Fig. 111).
(7) Have helper hold rear housing and geartrain in
upright position. Then install front housing on rear
housing and geartrain.
(8) Work front housing downward onto geartrain
until seated on rear housing.
CAUTION: If the front housing will not seat on the
rear housing, either the shift components are not in
Neutral, or one or more components are mis-
aligned. Do not force the front housing into place.
This will only result in damaged components.
(9) Tap rear housing alignment dowels back into
place with hammer and pin punch. Both dowels
should be flush fit in each housing. Have helper hold
transmission upright while dowels are tapped back
into place.
(10) Place transmission in horizontal position.
Fig. 109 INPUT SHAFT AND COUNTERSHAFT
FRONT BEARING
1 - INPUT SHAFT BEARING
2 - COUNTERSHAFT FRONT BEARING
3 - SHIFT SHAFT BUSHING
Fig. 110 COUNTERSHAFT FRONT BEARING
1 - BEARING RACE
2 - PETROLEUM JELLY
3 - COUNTERSHAFT FRONT BEARING
Fig. 111 SEAL FRONT/REAR HOUSINGS
1 - HOUSING FLANGE SURFACE
2 - MOPAR GASKET MAKER (OR LOCTITE 518)
21s - 32
MANUAL NV 3550
XJ
MANUAL NV 3550 (Continued)
2001 JEEP CHEROKEE
(11) Apply Mopar Gasket Maker or equivalent to
housing attaching bolts. Apply sealer material sealer
to underside of bolt heads and to bolt shanks and
threads (Fig. 112).
(12) Install and start housing attaching bolts by
hand (Fig. 112). Then tighten bolts to 34 N·m (25 ft.
lbs.).
(13) Install shift shaft bushing lock bolt (Fig. 113).
Apply Mopar Gasket Maker or equivalent, to bolt
threads, shank and underside of bolt head before
installation.
CAUTION: If the lock bolt cannot be fully installed,
do not try to force it into place. Either the shift
shaft is not in Neutral or the shaft bushing (or
lever) is misaligned.
(14) Lubricate
then
install
shift
shaft
detent
plunger in housing bore (Fig. 114). Lubricate plunger
with
petroleum
jelly
or
gear
lubricant.
Verify
plunger is fully seated in detent notch in shift
shaft.
(15) Install detent spring inside plunger (Fig. 114).
(16) Install plug on detent spring and compress
spring. Then drive detent plug into transmission case
until plug seats.
(17) Install backup light switch (Fig. 115).
(18) Install input shaft snap ring (Fig. 116).
(19) Install new oil seal in front bearing retainer
with Installer 6448 (Fig. 117).
(20) Apply bead of Mopar silicone sealer or equiv-
alent to flange surface of front bearing retainer (Fig.
118).
Fig. 112 HOUSING BOLTS
1 - HOUSING ATTACHING BOLTS
Fig. 113 SHIFT SHAFT BUSHING LOCK BOLT
1 - SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET
Fig. 114 SHIFT SHAFT DETENT PLUNGER
1 - FRONT HOUSING
2 - PLUG
3 - SPRING
4 - PLUNGER
Fig. 115 BACKUP LIGHT SWITCH
1 - BACKUP LIGHT SWITCH
XJ
MANUAL NV 3550
21s - 33
MANUAL NV 3550 (Continued)
2001 JEEP CHEROKEE
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