Jeep XJ. Manual — part 375
(28) Install snap-ring to hold fifth gear onto output
shaft.
SEMI-SYNCHRONIZED REVERSE IDLER GEAR
DISASSEMBLY
(1) Remove snap-ring holding the reverse idler
gear onto the reverse idler gear hub/race (Fig. 115).
(2) Remove the plate washer from the reverse idler
gear hub/race (Fig. 116).
(3) Remove the reverse idler gear from the reverse
idler gear hub/race (Fig. 117).
(4) Remove the reverse idler gear synchronizer
ring from the reverse idler gear hub/race (Fig. 118).
I. D. Mark
Snap Ring Thickness mm (in.)
A
2.67-2.72 (0.1051-0.1071)
B
2.73-2.78 (0.1075-0.1094)
C
2.79-2.84 (0.1098-0.1118)
D
2.85-2.90 (0.1122-0.1142)
E
2.91-2.96 (0.1146-0.1165)
F
2.97-3.02 (0.1169-0.1189)
G
3.03-3.08 (0.1193-0.1213)
H
3.09-3.14 (0.1217-0.1236)
J
3.15-3.20 (0.1240-0.1260)
K
3.21-3.26 (0.1264-0.1283)
L
3.27-3.32 (0.1287-0.1307)
Fig. 114 Select/Install Fifth Gear Snap Ring
Fig. 115 Remove Reverse Idler Gear Snap-ring
1 – REVERSE IDLER GEAR
2 – SNAP-RING
3 – REVERSE IDLER GEAR HUB
4 – PLATE WASHER
Fig. 116 Remove Reverse Idler Gear Plate Washer
1 – REVERSE IDLER GEAR
2 – PLATE WASHER
21 - 36
AX5 MANUAL TRANSMISSION
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
(1) Install the reverse idler gear synchronizer ring
onto the reverse idler gear hub/race. Apply a film of
75W-90 GL-3 transmission oil to the contact surface
of the synchronizer ring prior to assembly.
(2) Install the reverse idler gear onto the reverse
idler gear hub/race. Apply a film of 75W-90 GL-3
transmission oil to the reverse idler gear bushing
prior to assembly. Verify that the teeth on the syn-
chronizer ring are properly engaged into the recesses
of the reverse idler gear.
(3) Install the plate washer over the reverse idler
gear hub/race and onto the reverse idler gear.
(4) Install the snap-ring to hold the reerse idler
gear onto the reverse idler hub/race.
CLEANING AND INSPECTION
AX5 MANUAL TRANSMISSION COMPONENTS
GENERAL INFORMATION
Clean the transmission components in solvent. Dry
the cases, gears, shift mechanism and shafts with
compressed air. Dry the bearings with clean, dry
shop towels only. Never use compressed air on the
bearings. This could cause severe damage to the
bearing roller and race surfaces.
If output shaft or inner race flange thickness is
within specification but any gear thrust clearance is
out of specification, replace the necessary gear and
gear needle bearing as an assembly.
GEAR CASE, ADAPTER/EXTENSION HOUSING,
INTERMEDIATE PLATE
Clean the case, housing, and intermediate plate
with solvent and dry with compressed air. Replace
the case if cracked, porous, or if any of the bearing
and gear bores are damaged.
Inspect the threads in the case, housing, and plate.
Minor thread damage can be repaired with steel
thread inserts, if necessary. Do not attempt to repair
any threads which show evidence of cracks around
the threaded hole.
OUTPUT SHAFT
Check thickness of the output shaft and inner
bearing race flanges with a micrometer or vernier
calipers (Fig. 119).
• Minimum thickness for shaft flange is 4.80 mm
(0.189 in.)
• Minimum thickness for first gear bearing inner
race flange is 3.99 mm (0.157 in.)
Measure diameter of the output shaft journal sur-
faces with a micrometer. Replace the shaft if either of
these surfaces are worn beyond specified limits.
• Second gear surface minimum diameter is
37.964 mm (1.495 in.)
• Third gear surface minimum diameter is 34.984
mm (1.377 in.)
Measure diameter of the first gear bearing inner
race. Minimum diameter is 38.985 mm (1.535 in.).
Measure output shaft runout with a dial indicator
(Fig. 120). Runout should not exceed 0.05 mm (0.002
in.).
Replace output shaft or first gear inner bearing
race if measurement of any surface is out of specifi-
cation. Do not attempt to repair out of specification
components.
Fig. 117 Remove Reverse Idler Gear
1 – REVERSE SYNCHRONIZER RING
2 – REVERSE IDLER GEAR HUB
3 – REVERSE IDLER GEAR
Fig. 118 Remove Reverse Idler Gear Synchronizer
Ring
1 – REVERSE SYNCHRONIZER RING
2 – REVERSE IDLER GEAR HUB
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AX5 MANUAL TRANSMISSION
21 - 37
DISASSEMBLY AND ASSEMBLY (Continued)
COUNTERSHAFT
Inspect the countershaft gear teeth. Replace the
countershaft if any teeth are worn or damaged.
Inspect the bearing surfaces and replace shaft if any
surface shows damage or wear.
Check condition of the countershaft front bearing.
Replace the bearing if worn, noisy, or damaged.
GEAR AND SYNCHRONIZER
Install the needle bearing and inner race in the
first gear. Then check oil clearance between the gear
and inner race (Fig. 121). Clearance should be 0.009
– 0.032 mm (0.0004 – 0.0013 in.).
Install the needle bearings and the second, third
and counter fifth gears on the output shaft. Then
check oil clearance between the gears and shaft with
a dial indicator (Fig. 122). Oil clearance for all three
gears is 0.009 – 0.0013 mm (0.0004 – 0.0013 in.).
Check synchronizer ring wear (Fig. 123). Insert
each ring in matching gear. Measure clearance
between each ring and gear with feeler gauge.
Replace ring if clearance exceeds 2.0 mm (0.078 in.).
Check shift fork–to–synchronizer hub clearance
with a feeler gauge (Fig. 124). Replace the fork if
clearance exceeds 1.0 mm (0.039 in.).
(1) Inspect all mainshaft gear teeth. Replace any
gear which shows any worn or damaged teeth.
Fig. 119 Check Shaft And Bearing Race Flange
Thickness
1 – OUTPUT SHAFT FLANGE
2 – INNER RACE FLANGE
Fig. 120 Check Output Shaft Runout
1 – OUTPUT SHAFT JOURNAL
Fig. 121 Check Gear–To–Race Clearance
1 – GEAR
2 – INNER RACE
21 - 38
AX5 MANUAL TRANSMISSION
XJ
CLEANING AND INSPECTION (Continued)
SPECIFICATIONS
TORQUE
DESCRIPTION
TORQUE
Plugs, Access . . . . . . . . . . . . . . . 19 N·m (14 ft.lbs.)
Bolts, Adapter Housing . . . . . . . 34 N·m (25 ft.lbs.)
Switch, Back-up Light . . . . . . . 44 N·m (32.5 ft.lbs.)
Plugs, Drain and Fill . . . . . . . . 44 N·m (32.5 ft.lbs.)
Bolts, Front Bearing Retainer . . 17 N·m (12 ft.lbs.)
Plugs, Interlock and Detent . . . . 19 N·m (14 ft.lbs.)
Screws, Propeller Shaft Clamp . . . . . . . 16–23 N·m
(140–200 in.lbs.)
Bolts, Rear Mount to Transmission . . . . 33–60 N·m
(24–44 ft.lbs.)
Nut, Rear Mount Clevis . . 54–75 N·m (40–55 ft.lbs.)
Nuts, Rear Mount to Crossmember . . . . 41–68 N·m
(30–50 ft.lbs.)
Pins, Restrictor . . . . . . . . . . . . 27.4 N·m (20 ft.lbs.)
Bolts, Reverse Shift Arm Bracket . . . . . . . . 18 N·m
(13 ft.lbs.)
Screw, Shift Arm Set . . . . . . . . . 38 N·m (28 ft.lbs.)
Screws, Shift Fork Set . . . . . . . . 20 N·m (15 ft.lbs.)
Nut, Shift Knob . . . . . . . . 20–34 N·m (15–25 ft.lbs.)
Screws, Shifter Floor Cover . . . . . . . . . . . . 2–3 N·m
(17–30 in.lbs.)
Bolts, Shift Tower . . . . . . . . . . . . 18 N·m (13 ft.lbs.)
Nuts, Transfer Case Mounting . . . . . . . 30–41 N·m
(22–30 ft.lbs.)
Fig. 122 Check Gear–To–Shaft Oil Clearance
1 – GEAR BEING CHECKED
2 – OUTPUT SHAFT
Fig. 123 Check Synchronizer Ring Wear
1 – FEELER GAUGE
2 – SYNCHRONIZER RING
Fig. 124 Check Fork–To–Hub Clearance
1 – SHIFT FORK
2 – FEELER GAUGE
3 – SYNCHRONIZER SLEEVE
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AX5 MANUAL TRANSMISSION
21 - 39
CLEANING AND INSPECTION (Continued)
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