Jeep Wrangler TJ. Manual — part 481
INSPECTION
NOTE: Minor corrosion, nicks, or pitting can be
smoothed with 400 grit emery and polished out with
crocus cloth.
Bearings: Inspect for worn, cracked, flat-spotted
or brinnelled.
Gears: Inspect for worn, chipped or cracked teeth.
Inspect bearing surfaces for ware or flat-spotted.
Mainshaft: Inspect for worn splines, snap ring
grooves and threads. Inspect bearing surfaces for
ware or flat-spotted.Third gear (1) (Fig. 52) and
fourth gear (2) are serviced with mainshaft
only.
Countershaft:
Inspect
for
worn,
chipped
or
cracked teeth. Inspect bearing surfaces (1) (Fig. 53)
for wear or flat-spots. Inspect 3-4 synchronizer
assembly (2).The countershaft is serviced as an
assembly.
Input Shaft: Inspect for worn, chipped or cracked
teeth (1). Inspect bearing surface (2) for wear or flat-
spots. Inspect for worn splines (3) (Fig. 54).
Fig. 52 MAINSHAFT
1 - THIRD GEAR
2 - FOURTH GEAR
Fig. 53 COUNTERSHAFT
1 - BEARING SURFACES
2 - 3-4 SYNCHRONIZER ASSEMBLY
Fig. 54 INPUT SHAFT
1 - TEETH
2 - BEARING SURFACE
3 - SPLINE
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MANUAL TRANSMISSION - NSG370
21 - 15
MANUAL TRANSMISSION - NSG370 (Continued)
Synchronizer components: Inspect for worn,
chipped or cracked teeth (1) and burned friction sur-
face (2) or flaking off friction material (3) (Fig. 55).
Synchronizers are serviced as an assembly. 3-4
synchronizer assembly (2) is serviced with
countershaft.
Shift forks: Inspect shift forks and shoes (1) (Fig.
56) for wear and distortion. Check fit of fork shoes in
synchronizer sleeve to ensure parts fit and work
smoothly, replace if necessary. If shift fork pads (2)
are worn, the shift fork must be replaced.
Housing/Tail housing: Inspect sealing and mat-
ing surfaces are free of burrs and nicks. Inspect
alignment dowels are tight and in good condition.
Input Shaft Retainer: Inspect retainer (1) release
bearing slide surface (2) (Fig. 57).
ASSEMBLY
WARNING: Use welding gloves when handling
heated components. Failure to follow these instruc-
tions will result in personal injury.
CAUTION: A bearing heater is used to assembly
some components. Use only a bearing heater/hot
plate and follow manufactures instructions. Heat
components to 100 - 177 Celsius (212° Min - 350°
Max Fahrenheit). Never use an open flame to heat
components. Never leave components on heater for
and extended amount of time. If component is dis-
colored after heating the component has been over-
heated and must not be used. Failure to follow
these instructions will result in component damage.
MAINSHAFT
NOTE: Reuse snap rings in there original locations.
Or thickest snap ring that will fit.
(1) Place mainshaft in Fixture 9648 mounted in a
vise.
Fig. 55 SYNCHRONIZER RINGS
1 - TEETH
2 - FRICTION SURFACE
3 - FRICTION MATERIAL
Fig. 56 SHIFT FORKS
1 - SHIFT FORK SHOES
2 - SHIFT FORK PADS
Fig. 57 RETAINER INPUT SHAFT
1 - RETAINER
2 - SLIDE SURFACE
21 - 16
MANUAL TRANSMISSION - NSG370
TJ
MANUAL TRANSMISSION - NSG370 (Continued)
(2) Install second gear bearing (1) (Fig. 58) on
mainshaft (2).
(3) Install second gear (1) (Fig. 59) on bearing (2).
(4) Install inner synchronizer friction ring (1) (Fig.
60) on second gear (2).
(5) Install outer synchronizer friction ring (1) (Fig.
61) on second gear (2).
Fig. 58 SECOND GEAR BEARING
1 - SECOND GEAR BEARING
2 - MAINSHAFT
Fig. 59 SECOND GEAR
1 - SECOND GEAR
2 - BEARING
Fig. 60 2ND INNER FRICTION RING
1 - SYNCHRONIZER FRICTION RING
2 - SECOND GEAR
Fig. 61 2ND OUTER FRICTION RING
1 - OUTER SYNCHRONIZER FRICTION RING
2 - SECOND GEAR
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MANUAL TRANSMISSION - NSG370
21 - 17
MANUAL TRANSMISSION - NSG370 (Continued)
(6) Install synchronizer blocker ring (1) (Fig. 62)
on second gear (2).
(7) Install 1-2 synchronizer hub (1) (Fig. 63) with
Installer 8228 (2) and a press. Align hub detent open-
ings with synchronizer rings.
(8) Install 1-2 synchronizer hub (1) (Fig. 64) snap
ring (2).
(9) Install 1-2 synchronizer sleeve (1) (Fig. 65) and
push to the bottom of the synchronizer hub (2).
Fig. 62 2ND BLOCKER RING
1 - SYNCHRONIZER BLOCKER RING
2 - SECOND GEAR
Fig. 63 1-2 SYNCHRO HUB INSTALLER
1 - 1-2 SYNCHRONIZER HUB
2 - INSTALLER
Fig. 64 1-2 SYNCHRO HUB SNAP RING
1 - SYNCHRONIZER HUB
2 - SNAP RING
Fig. 65 1-2 SYNCHRO SLEEVE
1 - 1-2 SYNCHRONIZER SLEEVE
2 - SYNCHRONIZER HUB
21 - 18
MANUAL TRANSMISSION - NSG370
TJ
MANUAL TRANSMISSION - NSG370 (Continued)
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