Jeep Wrangler TJ. Manual — part 478
(9) Remove catalyst assembly (2) (Fig. 4).
(10) Remove clutch slave cylinder nuts (1) and
remove cylinder (2) (Fig. 5).
(11) Remove backup lamp switch (2) wiring con-
nector (1) (Fig. 6).
(12) Remove shift lever tower bolts (1) and remove
shift lever tower (2) (Fig. 7).
(13) Remove starter bolts and remove starter.
(14) Remove transmission bolt and remove trans-
mission.
DISASSEMBLY
(1) Remove shift tower (1) (Fig. 8) bolts (2) and
remove tower.
Fig. 5 CLUTCH SLAVE CYLINDER
1. NUTS
2. SLAVE CYLINDER
Fig. 6 BACKUP LAMP SWITCH
1. BACKUP LAMP SWITCH
2. SWITCH
Fig. 7 SHIFT LEVER
1. BOLTS
2. SHIFT TOWER
Fig. 8 SHIFT TOWER
1 - SHIFT TOWER
2 - BOLTS
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MANUAL TRANSMISSION - NSG370
21 - 3
MANUAL TRANSMISSION - NSG370 (Continued)
(2) Through shift tower opening (1) (Fig. 9) shift
two shift rails (2) forward to engage two gears.
(3) Remove countershaft plug (1) (Fig. 10) from the
front housing (2) with a seal pick.
(4) Remove countershaft bolt (1) (Fig. 11) from the
front housing (2).
(5) Remove output shaft (1) (Fig. 12) seal (2) from
rear housing (3) with a seal pick.
Fig. 9 SHIFT TOWER OPENING
1 - SHIFT TOWER OPENING
2 - SHIFT RAILS
Fig. 10 COUNTERSHAFT PLUG
1 - COUNTERSHAFT PLUG
2 - FRONT HOUSING
Fig. 11 COUNTERSHAFT BOLT
1 - COUNTERSHAFT BOLT
2 - FRONT HOUSING
Fig. 12 OUTPUT SHAFT SEAL
1 - OUTPUT SHAFT
2 - SEAL
3 - REAR HOUSING
21 - 4
MANUAL TRANSMISSION - NSG370
TJ
MANUAL TRANSMISSION - NSG370 (Continued)
(6) Remove output shaft (1) (Fig. 13) snap ring (2)
4x4 only.
(7) Stand transmission on the rear housing and
remove the housing bolts.
(8) Remove front housing (1) (Fig. 14) from the
rear housing (2).
(9) Remove shift rails (1) (Fig. 15) support plate (2)
bolts.
(10) Remove input shaft (1) (Fig. 16) roller bearing
(2).
Fig. 13 OUTPUT SHAFT SNAP RING
1 - OUTPUT SHAFT
2 - SNAP RING
Fig. 14 SPLIT HOUSING
1 - FRONT HOUSING
2 - REAR HOUSING
Fig. 15 SHIFT RAIL SUPPORT PLATE
1 - SHIFT RAILS
2 - SUPPORT PLATE
Fig. 16 INPUT SHAFT ROLLER BEARING
1 - INPUT SHAFT
2 - ROLLER BEARING
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MANUAL TRANSMISSION - NSG370
21 - 5
MANUAL TRANSMISSION - NSG370 (Continued)
(11) Remove fifth gear synchronizer blocker ring
(1) (Fig. 17) and friction ring (2).
(12) Set geartrain and shift rails with rear housing
into Build Fixture 9633.
(13) Remove mainshaft shaft (1) (Fig. 18) from
rear housing bearing with Remover 9637 (2).
(14) Remove mainshaft (1), countershaft (2) and
shift rails/forks (3) from fixture (Fig. 19).
MAINSHAFT
(1) Place mainshaft with 5-6 synchronizer facing
up in build Fixture 9648 and place in a vise.
Fig. 17 FIFTH GEAR SYNCHRO
1 - FIFTH GEAR BLOCKER RING
2 - FRICTION RING
Fig. 18 MAINSHAFT REMOVER
1 - MAINSHAFT
2 - REMOVER/INSTALLER
Fig. 19 MAIN/COUNTERSHAFT
1 - MAINSHAFT
2 - COUNTERSHAFT
3 - SHIFT RAILS AND FORKS
Fig. 20 5-6 SYNCHRO SLEEVE DETENTS
1 - SYNCHRONIZER SLEEVE
2 - DETENTS
21 - 6
MANUAL TRANSMISSION - NSG370
TJ
MANUAL TRANSMISSION - NSG370 (Continued)
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