Jeep XJ. Manual — part 384
(7) Install Adapter 6747-2A on front bearing hub of
countershaft, if not previously done. The adapter has
a shoulder on one side. The shoulder goes toward the
countershaft.
(8) Slide countershaft (and adapter) into fixture
slot. Verify that countershaft and output shaft gears
are fully meshed with the mainshaft gears before
proceeding (Fig. 95).
(9) Check alignment of countershaft and output
shaft gear teeth. Note that gears may not align per-
fectly. A difference in height of 1.57 to 3.18 mm (1/16
to 1/8 in.) will probably exist. This difference will not
interfere with assembly. However, if the difference is
greater than this, the countershaft adapter tool is
probably upside down. Remove countershaft, reverse
adapter tool, reinstall countershaft and check align-
ment again.
Fig. 94 Output Shaft And Geartrain Installed In Input
Shaft
1 – OUTPUT SHAFT AND GEARTRAIN
2 – INPUT SHAFT
3 – SPECIAL TOOL
6747
Fig. 95 Countershaft Installed On Fixture Tool
1 – OUTPUT SHAFT AND GEARTRAIN
2 – COUNTERSHAFT (SLIDE INTO PLACE ON FIXTURE TOOL)
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DISASSEMBLY AND ASSEMBLY (Continued)
(10) Position reverse idler in support cup of assem-
bly fixture (Fig. 96). Be sure idler gear is properly
meshed and aligned with shaft gear teeth and that
bolt holes are facing out and not toward geartrain.
Adjust pedestal up or down if necessary. Also be sure
that short end of idler shaft is facing up as shown.
(11) On 2-wheel drive transmission, thread one
Pilot Stud 8120 in center or passenger side hole of
output shaft bearing retainer. Then position retainer
on fifth gear as shown (Fig. 97).
(12) Assemble 1-2 and fifth reverse-shift forks (Fig.
98). Arm of fifth-reverse fork goes through slot in 1-2
fork.
Fig. 96 Reverse Idler Assembly Positioned On
Assembly Fixture Pedestal
1 – OUTPUT SHAFT AND GEARTRAIN
2 – COUNTERSHAFT
3 – REVERSE IDLER ASSEMBLY
4 – TOOL PEDESTAL
Fig. 97 Positioning Output Shaft Bearing Retainer
For Rear Housing Installation
1 – SPECIAL TOOL
8120
2 – OUTPUT SHAFT BEARING RETAINER
Fig. 98 Assembling 1-2 And Fifth-Reverse Shift
Forks
1 – INSERT ARM THROUGH 1–2 FORK
2 – 1–2 FORK
3 – FIFTH-REVERSE FORK
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21 - 73
DISASSEMBLY AND ASSEMBLY (Continued)
(13) Install
assembled
shift
forks
in
synchro
sleeves (Fig. 99). Be sure forks are properly seated in
sleeves.
REAR HOUSING—2WD
(1) Drive adapter housing alignment dowels back
into housing until dowels are flush with mounting
surface (Fig. 100).
(2) Apply liberal quantity of petroleum jelly to
countershaft rear bearing and bearing race.
(3) Install countershaft rear bearing in bearing
race (Fig. 101).
CAUTION: The
countershaft
bearings
can
be
installed backwards if care is not exercised. Be
sure the large diameter side of the roller retainer
faces the countershaft and the small diameter side
faces the race and housing (Fig. 102).
(4) Apply extra petroleum jelly to hold counter-
shaft rear bearing in place when housing is installed.
(5) Apply light coat of petroleum jelly to shift shaft
bushing/bearing in rear housing (Fig. 102).
(6) Reach into countershaft rear 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. This will result in
misalignment
between
bearing
and
countershaft
bearing hub.
Fig. 99 Shift Forks Installed In Synchro Sleeves
1 – SYNCHRO SLEEVES
2 – FORK ARMS
3 – SHIFT FORKS
Fig. 100 Preparing Rear Housing Dowels For
Installation
1 – HOUSING ALIGNMENT DOWELS
2 – REAR HOUSING
3 – DOWEL FLUSH WITH SURFACE
Fig. 101 Lubricating Countershaft Rear Bearing
1 – COUNTERSHAFT REAR BEARING
2 – REAR BEARING RACE
3 – REAR HOUSING
4 – PETROLEUM JELLY (APPLY TO BEARING AND RACE)
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DISASSEMBLY AND ASSEMBLY (Continued)
(7) Install rear housing onto geartrain (Fig. 103).
Be sure bearing retainer pilot stud is in correct bolt
hole in housing. Also be sure countershaft and output
shaft bearings are aligned in housing and on counter-
shaft. It may be necessary to lift upward on counter-
shaft slightly to ensure that the countershaft rear
bearing engages to the countershaft before the rear
output shaft bearing engages the housing.
(8) Seat rear housing on output shaft rear bearing
and countershaft. Use plastic or rawhide mallet to
tap housing into place.
(9) Install the three bolts that secure rear bearing
retainer to rear housing as follows:
(a) Apply Mopar
t Gasket Maker, or equivalent,
to bolt threads, bolt shanks and under bolt heads
(Fig. 104).
(b) Start first two bolts in retainer (Fig. 105). It
may be necessary to move retainer rearward (with
pilot stud) in order to start bolts in retainer.
(c) Remove Pilot Stud 8120 and install last
retainer bolt (Fig. 105).
(d) Tighten all three retainer bolts to 30-35 N·m
(22-26 ft. lbs.) torque.
Fig. 102 Countershaft Rear Bearing Seated In
Seated in Race
1 – SHIFT SHAFT BUSHING/BEARING
2 – COUNTERSHAFT REAR BEARING (SEATED IN RACE)
Fig. 103 Rear Housing Installation—2WD
1 – REAR HOUSING
2 – SHIFT FORKS AND GEARTRAIN
Fig. 104 Applying Sealer To Retainer And Housing
Bolts
1 – MOPAR GASKET MAKER (OR LOCTITE 518)
2 – RETAINER AND HOUSING BOLTS
3 – APPLY SEALER TO UNDERSIDE OF BOLT HEAD, SHANK
AND THREADS
Fig. 105 Removing Pilot Stud Tool And Installing
Retainer Bolts—2WD
1 – BEARING RETAINER BOLT
2 – SPECIAL TOOL 8120
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NV3550 MANUAL TRANSMISSION
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DISASSEMBLY AND ASSEMBLY (Continued)
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