Jeep XJ. Manual — part 371
(14) Remove snap-ring holding output shaft rear
bearing into the intermediate plate (Fig. 60).
(15) Remove countershaft rear bearing snap-ring.
(16) With aid of an assistant, support the main-
shaft and countershaft. Tap on the rear of the main-
shaft and countershaft with a suitable plastic mallet.
This will release the countershaft from the counter-
shaft rear bearing and the mainshaft rear bearing
from the intermediate plate. The countershaft will
release from the countershaft bearing first and can
be removed by moving the countershaft rearward and
downward (Fig. 61).
(17) Remove the mainshaft by moving the main-
shaft forward until the mainshaft rear bearing is
clear of the intermediate plate and then rotating the
mainshaft downward out of the shift forks (Fig. 62).
(18) Remove the 3–4 shift fork from the 3–4 shift
rail (Fig. 63).
(19) Remove the snap-ring from near the end of
the 1–2 shift rail to allow the removal of the 1–2
shift fork.
Fig. 59 Remove Reverse Shift Arm Bracket Bolts
1 – REVERSE SHIFT ARM BOLTS
Fig. 60 Remove Output Shaft Rear Bearing
Snap-ring
1 – OUTPUT SHAFT REAR BEARING SNAP-RING
2 – COUNTERSHAFT REAR BEARING SNAP-RING
Fig. 61 Remove Countershaft and Countershaft
Rear Bearing
1 – INPUT SHAFT
2 – INTERMEDIATE PLATE
3 – OUTPUT SHAFT
4 – COUNTERSHAFT
5 – COUNTERSHAFT REAR BEARING
Fig. 62 Remove Mainshaft
1 – SHIFT FORKS
2 – MAINSHAFT
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AX5 MANUAL TRANSMISSION
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(20) Remove the 1–2 shift fork from the 1–2 and
the 3–4 shift rails (Fig. 64).
(21) Remove threaded plugs from intermediate
plate. Then remove lock ball and spring from plug
holes with pencil magnet (Fig. 65). Note that the bot-
tom spring is shorter in length than the other two
springs.
(22) Remove the intermediate plate from the vise,
rotate the plate 180°, and reinstall the plate in the
vise using the same bolt and washer mounting set-
up.
CAUTION: The interlock balls and pins are different
sizes and shapes. Be sure to correctly identify
which position an item is removed from to ensure
that it is reinstalled in the same location.
Fig. 63 Remove 3–4 Shift Fork
1 – 3–4 SHIFT FORK
2 – 3–4 SHIFT RAIL
3 – 1–2 SHIFT RAIL
4 – 1–2 SHIFT FORK
Fig. 64 Remove 1–2 Shift Fork
1 – 1–2 SHIFT FORK
2 – 3–4 SHIFT RAIL
3 – 1–2 SHIFT RAIL
Fig. 65 Remove Lock Ball And Spring
1 – THREADED PLUGS
2 – LOCK BALL
3 – SPRING
4 – PENCIL MAGNET
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AX5 MANUAL TRANSMISSION
21 - 21
DISASSEMBLY AND ASSEMBLY (Continued)
(23) Remove fifth gear shift rail (Fig. 66).
(24) Remove fifth gear check ball (Fig. 67) and
interlock pin.
(25) Remove reverse shift head and rail assembly
(Fig. 68).
(26) Remove snap-ring holding reverse shift rail
into intermediate plate.
(27) Remove reverse shift rail and reverse shift
fork and arm assembly from intermediate plate (Fig.
69).
Fig. 66 Remove Fifth Gear Shift Rail
1 – INTERMEDIATE PLATE
2 – FIFTH GEAR SHIFT RAIL
Fig. 67 Remove Fifth Gear Check Ball
1 – FIFTH GEAR CHECK BALL
Fig. 68 Remove Reverse Shift Head And Rail
Assembly
1 – REVERSE SHIFT HEAD AND RAIL ASSEMBLY
Fig. 69 Remove Reverse Shift Rail
1 – REVERSE SHIFT RAIL AND REVERSE FORK ASSEMBLY
21 - 22
AX5 MANUAL TRANSMISSION
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DISASSEMBLY AND ASSEMBLY (Continued)
(28) Remove interlock pin from reverse shift rail
(Fig. 70).
(29) Remove reverse elongated check ball (Fig. 71).
(30) Remove snap-ring on 3–4 shift rail.
(31) Remove 1–2 shift rail from intermediate plate.
(32) Remove interlock pin from 1–2 shift rail (Fig.
72).
(33) Remove 1–2 shift rail elongated check ball
from intermediate plate (Fig. 73).
(34) Remove 3–4 shift rail from intermediate plate.
Fig. 70 Remove Interlock Pin From Reverse Shift
Rail
1 – REVERSE SHIFT RAIL
2 – INTERLOCK PIN
Fig. 71 Remove Reverse Check Ball
1 – REVERSE CHECK BALL
Fig. 72 Remove 1–2 Shift Rail Interlock Pin
1 – INTERLOCK PIN
2 – 1–2 SHIFT RAIL
Fig. 73 Remove 1–2 Check Ball
1 – 1–2 CHECK BALL
2 – 3–4 SHIFT RAIL
XJ
AX5 MANUAL TRANSMISSION
21 - 23
DISASSEMBLY AND ASSEMBLY (Continued)
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