1953 JEEP DJ oil

THREE-SPEED
TRANSMISSION

ing
snap
ring.
Care should be taken to
install
the
proper
snap
ring
at
these
locations.

fl.
Install
the mainshaft rear bearing
adapter,

spacer,
transfer
case
drive
gear,
flat
washer, and

nut.
Torque nut 130 to 170
lb-ft.
[17,9 a 23,5
kg-m.].
Refer to Fig. J-15.
o. Check the main drive bearing retainer oil seal.
If
seal is
worn
or damaged it must be replaced.
Refer to Fig. J-33. 12858

FIG.
J-34—INSTALLING
MAIN
DRIVE GEAR BEARING RETAINER

-Gasket

-Bearing
Retainer
p.
Install
main drive
gear
bearing retainer gasket,
and retainer assembly. Make certain the oil drain

hole
slot in the retainer housing and gasket are

aligned.
Install
the three
ferry
type screws and
washers. Refer to Fig. J-34.
q.
Install
the transmission
case
cover gasket,
p.
Position the transmission
gear
train
and
shift

cover housing assembly in neutral. Enter the

shifter
forks
into
the
clutch
sleeves
and
align
cover,

case
and gasket holes.
Install
capscrews and
lock­

washers
and torque 8 to 15
lb-ft.
[1,1 a 2,1
kg-m.].
Refer to Figs. J-35 and J-36.

S.
This completes the transmission reassembly. 12857

FIG.
J-35—MAINSHAFT
GEAR TRAIN
—
NEUTRAL
1— Reverse Gear

2— Low
Synchronizer Assembly

3— Low
Gear
4— Second Gear
5—
Second-Third
Synchronizer Assembly
6—
Main
Drive
Gear

FIG.
J-36—INSTALLING CANE SHIFT
COVER
ASSEMBLY
1—
Control
Housing'
Cover•''

2—
Gasket
3—
Second-Third
Shift
Fork
4— Low-Reverse
Shift
Fork 256

'Jeep*
UNIVERSAL
SERIES
SERVICE
MANUAL

J J-20
TRANSMISSION
SERVICE
DIAGNOSIS

SYMPTOMS
PROBABLE
REMEDY

Lock
in Two
Gears
Replace
Poppet
or Shift Levers

Slips
Out of High Gear Transmission Misaligned with Bellhousing

End
Play in Main Drive Gear Damaged Pilot Bearing or Front Bearing.

Slips
Out of Second
Worn
Gear Replace
Weak
Poppet
Spring Replace

Noise
in Low Gear
Gear
Teeth Worn Replace Gears
Shifting
Shoe
Bent Replace
Shoe
Lack
of Lubrication Drain and Refill

Grease
Leak into Bellhousing Gasket Broken Front Bearing Retainer Replace
Transmission Main Drive Gear Oil Seal Replace Align Transmission Case to Bellhousing
and Bellhousing to Engine
Tighten Front Retainer
Replace
J-21.
TRANSMISSION
SPECIFICATIONS

HURRICANE
F4
ENGINE
3-SPEED

Vehicle:
CJ-3B,
CJ-5,
CJ-5A,

CJ-6,
CJ-6A
DJ-5,
DJ-6
Make
Type

Speeds

Ratios: —
First
Second

Third

Fourth
Warner

T90C

Synchronous Mesh
3 Forward — 1 Reverse
3.339
to 1 1.551 to 1 1.000 to 1
Warner

T96

Synchronous Mesh
3 Forward — 1 Reverse
2.605
to 1 1.630 to 1
1.000 to 1
Reverse
Interlock
Poppet
Clearance. . .
3.798
to 1

3.536
to 1
.001" to .007"

[0,025
a 0,178 mmJ

DAUNTLESS
V-6
ENGINE
3-SPEED

Vehicle:
CJ-5,
CJ-6,
CJ-5A,
CJ-6A

DJ-5,
DJ-6
Late
CJ-5, CJ-6
Make
Warner
Warner Warner

Model
AS7
T86AA

AS9
T86AA
T14A

Type..
Synchromesh
Synchromesh Synchromesh

Speeds
3 Forward — 1 Reverse 3 Forward — 1 Reverse 3 Forward — 1 Reverse
Ratios: —
First
2.798
to 1
2.798
to 1
3.100 to 1

Second
1.687 to 1 1.687 to 1 1.612 to 1

Third
1.000 to 1
1.000 to 1 1.000 to 1
Reverse
3.798
to 1
3.798
to 1 3.100 to 1 257

'Jeep'
UNIVERSAL
SERIES
SERVICE
MANUAL

Jl
FOUR-SPEED
TRANSMISSION

Contents

SUBJECT
PAF.

GENERAL.
Jl-1

FOUR-SPEED
TRANSMISSION
REMOVAL.
Jl-2
Four-Speed Transmission
Disassembly
.
Jl-3 Four-Speed Transmission Control Housing
Disassembly
Jl-4
Four-Speed Transmission Reassembly Jl-5
SUBJECT
PAR.
Four-Speed Transmission Control Housing
Reasse mbly Jl-6

Transfer
Case Adapter Plate Oil Seal .
.
Jl-8
Four-Speed Transmission Installation Jl-7

FOUR-SPEED
TRANSMISSION
SPECIFICATIONS.
.
.
Jl-10

SERVICE
DIAGNOSIS
Jl-9 10771

FIG.
Jl-1—FOUR-SPEED
TRANSMISSION

1—
Control
Housing Gasket
2—
Control
Housing Assembly
3— Mainshaft Assembly
4—
Thrust
Washer
5—
Thrust
Washer
6— Reverse Shifting
Shoe
7— Reverse Shifting Arm
8—
C-Washer

9— Reverse Shifting Arm Pivot
10—
O-Ring

11— Reverse Idler
Gear
Assembly
12— Snap Ring
13—
Thrust
Washer
14—
Sleeve

15— Bearing Rollers
16— Spacer
17— Reverse Idler
Gear

18— Pipe Plug
19— Countershaft Gears 20— Bearing Rollers
21— Spacer 22— Spacer
23—
Thrust
Washer

2
4
—Bellhousi ng-to-Transmission Adapter Plate
25— Bearing Retainer
26— Bearing Retainer Bolt
27— Bearing Retainer Lockwasher
28— Bearing Retainer Gasket
29—
Main
Drive
Gear

30— Bearing Rollers 31— Transmission Case
32— Adapter Plate Lockwasher
33— Adapter Plate Capscrew
34— Side Opening Cover Gasket
35— Side Opening Cover Bolt
36— Side Opening Cover Lockwasher
37— Side Opening Cover 38— Countershaft
39— Shifting Arm Pivot Taper Pin
40— Bearing
41— Snap Ring
42—
Oil
Seal 43— Spacer
44— Reverse-Idler
Gear
Shaft 45—
Lock
Plate
46—
Lock
Plate Lockwasher
47—
Lock
Plate Bolt
48— Gasket
49— Adapter Plate 50— Adapter Plate Lockwasher
51— Adapter Plate Bolt
52— Cotter Key
53— Nut 54— Washer
55— Gasket 259

'Jeep*
UNIVERSAL
SERIES SERVICE
MANUAL

Jl

1—
Blocking
Rir

2—
Direct
and 1

3—
Snap
Ring

4—
Spring

5—
Shifting
Plat

6—
Direct
and 1 7—
Third
Speed
J1-3
4-Speed Transmission Disassembly

•
Refer to Fig. Jl-1.

Note;
The
models
T-98 and T-18 four-speed
transmission are similar in design with exception of
the second
speed
gear-to-mainshaft arrangement.
In
the model T-18 transmission, the second
speed

gear is a slide fit on the mainshaft, whereas in the
model T-98 transmission roller bearings and a
spacer are required in this area. Refer to Figs. Jl-3
and
Jl-4.

a.
Remove the transmission to transfer case adapter plate and gasket. Remove the oil seal from
the plate and, if damaged, discard the seal.
b. Remove the transmission control housing as­
sembly. Refer to paragraph Jl-4 for its dis­
assembly.
c. To make certain the two blocking rings, direct-

and-third
clutch hub, and direct-and-third clutch
sleeve
will
be assembled in their original relation­

ship,
mark them with a quick drying lacquer or an
electric pencil. Also mark the blocking ring, low-
and-second clutch hub, and the low-and-second
speed
gear.

d.
Slide the low-and-second
speed
gear toward the rear of the transmission case.
e.
Disengage
the reverse shifting arm and reverse shifting
shoe
from the reverse idler gear. Remove
the arm from the reverse shifting arm pivot.
f. Move the low-and-second
speed
gear
into
neutral position.
g. Remove the bearing retainer and gasket.
Remove the snap rings from the main drive gear
and
the outer race of the ball bearing.

h.
With a bearing puller, remove the main drive
gear ball bearing. 1436S
i
Hub

Gear

izer
Assembly

ironizer
Assembly
i.
Remove the oil slinger.

j.
Remove the snap ring from the outer bearing
race
of the transmission mainshaft ball bearing.
k. With a bearing puller, remove the mainshaft

ball
bearing.

Note:
It may be necessary to drive the mainshaft

rearward
by striking the end of the main drive gear with a lead hammer to get sufficient clearance
to install the bearing puller plates.

I.
Slide the direct-and-third clutch
sleeve
to the

rear
(third
speed)
position. Separate the mainshaft
assembly from the main drive gear. Be careful
not to
lose
any of the mainshaft pilot bearing
rollers.

m.
Lift
the mainshaft assembly out of the top
of the transmission case.

n.
Remove the main drive gear from the trans­
mission case.
o. Remove the mainshaft bearing rollers from the gear.
p.
Mark
relationship
between
synchronizer hubs

and
the splines on the mainshaft.
q. Begin disassembly of the main shaft assembly by removing the snap ring which holds the direct

and
third synchronizer assembly on the mainshaft,

r.
Remove the front blocking ring from the front
of the shaft.
s. Slide the direct-and-third-synchronizer assembly

and
the third-speed-gear assembly off the main-shaft.
t. Remove the snap ring at the rear of the main-
shaft. Slide the second synchronizer assembly and the blocking ring off the mainshaft.

FIG.
Jl-4—T-18
FOUR-SPEED TRANSMISSION MAINSHAFT ASSEMBLY
ng 8—Snap
Ring
15—Ball

third
Clutch
Sleeve
9—Thrust
Washer 16—Low and Second
Clutch
10—
Second
Speed
Gear
17—Retaining
Ring

11—
Mainshaft
18—Low and Second Speed
te 12—Blocking
Ring
19—Second Speed
Synchroni

rhird
Clutch
Hub 13—Shifting Plate 20—Direct and
Third
Synch

Gear
Assembly 14—Poppet
Spring
261

Jl

FOUR-SPEED TRANSMISSION

FIG.
Jl-7—SNAP
RING
AND
THRUST WASHER INSTALLATION—T-98 ONLY
1—
Thrust
Washer

2—
Snap
Ring

placing
the shaft in a vise (with
soft
metal covering the jaws) so that the threaded end of the shaft is
up.
Install
snap ring and thrust washer at the
forward
end of the
second-speed
gear position.
See Fig. Jl-7.
Install
thrust washer with the recessed side covering the snap
ring.

Note:
The second
speed
gear in the T-18 trans­ mission is a slide fit
onto
the mainshaft and
does

not contain roller bearings or a spacer.

On
model T-98 transmission, place a rubber band
around
the
second-speed
gear bearing surface on
the shaft.
Install
the thirty-four bearing rollers Fig.

Jl-3
around the shaft. See Fig. Jl-8.
Install
spacer on the shaft.
With
the tapered shoulder of the

second-speed
gear up, slide gear on the shaft far

enough
to hold the bearing rollers in place. Remove the rubber band and slide the gear down
onto
the

thrust
washer.
Install
the
rear
snap ring and the
blocking ring
onto
the tapered shoulder of the gear.
f.
Install
the
second-speed
synchronizer assembly
on the mainshaft.
Line
up the marks made at the
time of disassembly.
Install
the snap
ring.

g.
Install
the third-speed gear assembly on the
shaft with the tapered shoulder to the front.
Slide
the direct-and-third synchronizer assembly
onto
the mainshaft, lining up the marks made at
the time of disassembly.
Install
snap
ring.

h.
Install
main drive gear assembly with roller
bearings in place in front of case.
Install
mainshaft
FIG.
Jl-8—SECOND-SPEED
GEAR

ASSEMBLY—T-98 ONLY
1—
Spacer
3—Rubber
Band

2—
Bearing
Rollers
4—Thrust
Washer

assembly through top of case, making sure roller
bearings are not knocked out of place,
i.
Temporarily install main drive gear bearing

retainer
to support drive gear.
Install
snap ring on mainshaft bearing and press bearing on shaft

and
into case until snap ring is seated against case,

j-
Remove the main drive gear bearing retainer,
install
the oil slinger on the drive gear.
Install
the snap ring on the main drive gear bearing.
Then

press the bearing on the shaft and into the case.
Install
the thickest of the four available snap
rings that
will
fit into the
groove
on the main

drive
gear shaft.

k.
Slide main drive gear bearing retainer on the
shaft and hold tightly against transmission.
With

a
feeler
gauge,
measure the distance
between
the
retainer
and the case. Select gaskets that
will
be .003" to .005"
[0,076
a 0,127 mm.] thicker than
space
between
retainer and case.
Install
gaskets
and
retainer.

I.
Complete assembly of transmission.
Check

condition of
rear
oil seal and gaskets.
J1-6. Four-Speed
Transmission Control

Housing Reassembly
Reassembly of the control housing is the reverse of disassembly. Make sure lock pins are installed in
both shift forks.
Install
new expansion plugs in base of the housing. Inspect the transmission

breather
for damage and replace if necessary. 264

'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL

Jl

FIG.
Jl-9—INCORRECT
OIL
SEAL POSITION J1-7.
Installing
4-Speed
Transmission

Install
the four-speed transmission in the reverse

order
of the removal, noting the following points:

When
installing the front adapter plate (Fig. Jl-1,

insert
the bearing retainer in the adapter plate and
position the adapter plate against the flywheel
housing.
With
the adapter plate cap screws tight, make sure the bearing retainer can be removed
freely. If not, relocate the adapter plate and tighten
again to
test
proper location of adapter plate.
When
installing
rear
adapter plate, be sure cap
screw heads do not protrude beyond the adapter
plate face or interfere with transfer case fitting
tightly against
rear
adapter plate.

When
installing transfer case gear on the trans-
FIG.
Jl-10—CORRECT
OIL
SEAL POSITION

mission
rear
splined drive shaft tighten the large
gear nut securely and insert cotter pin.
Sink
cotter

pin
well into nut
slots
so it
will
clear
P.T.O.
drive.

J1-8.
Adapter Plate
Oil
Seal
It
is important that the four-speed transmission
adapter plate oil seal be correctly installed to
prevent flow of lubricant from the transfer case
to the transmission. Should the lubricant level be
low in the transfer case and high in the transmission,
check the position of the oil seal. See Fig. Jl-9 and

Jl-10.
Correctly
positioned, the lip of the oil seal is
toward
the transfer case. Always replace the oil

seal
whenever it has been removed. 265

Jl

FOUR-SPEED
TRANSMISSION
Jl-9.
TRANSMISSION
SER¥ICE
DIAGNOSIS

SYMPTOMS

Lock
In Two Gears

Slips
Out of High Gear Transmission Misaligned with Bellhousing

End
Play in Main Drive Gear Damaged Pilot Bearing or Front Bearing.
Slips Out of
Second
Worn
Gear
Weak
Poppet
Spring
PROBABLE
REMEDY

Replace
Poppet
or Shift Levers
Align Transmission Case to Bellhousing and Bellhousing to Engine
Tighten Front Retainer Replace
Replace Replace

Noise
in Low Gear
Gear
Teeth Worn. Replace Gears
Shifting
Shoe
Bent Replace
Shoe
Lack
of Lubrication Drain and Refill

Grease
Leak into Bellhousing Gasket Broken Front Bearing Retainer......... Replace Transmission Main Drive Gear Oil Seal Replace

Jl-10.
TRANSMISSION
SPECIFICATIONS

HURRICANE
F4
ENGINE
4-SPEED

Vehicle:
CJ-5,
CJ-6

Warner
T98A

Type..
• Synchronous Mesh
4 Forward — 1 Reverse
Ratios: —
First
. .
6.398
to 1

Second
3.092
to 1

Third
1.686 to 1

Fourth
1.000 to 1

7.820
to 1

DAUNTLESS
V-6
ENGINE
4-SPEED

Vehicle:
Late
CJ-5 Only

Warner

Model T-18
Type Synchromesh
4 Forward — 1 Reverse
Ratios: —
First
4.02 to 1

Second
2.41 to 1

Third
1.41 to 1

Fourth
1.00 to 1
Reverse 4.73 to 1 266

TRANSFER
CASE

FIG.
K-1—TRANSFER
CASE
—
TWO
SHIFT
LEVERS

1— Companion Flange
2—
Brake
Drum 3— Emergency Brake
4—Operating Lever
5—
Oil
Seal 6—
Lever
Stud 7—
-Rear
Cap
8— Shims

9—
Screw
10—
Lockwasher
11— Bolt
12—
-Rear
Cover
13—
Gasket

14—
Lock
Plate
15—
Transfer
Case
16— Shift Rod 17—
Poppet
Plug

18—Poppet
Spring 19—
Poppet
Ball

20— Interlock
21—Gasket 22—
Front
Cap
23—
Breather
24— Shift Lever Spring

26—Shift
Lever
25*A—Shift Lever
(used
with
4-speed

transmission) 26— Shift Lever Knob
27— Shift Lever
27A—Shift Lever
(used
with
4-speed
transmission)
28—
Pivot
Pin
29—
Lubrication
Fitting
30— Set Screw
31—
Oil
Seal 32—
Front
Yoke
33—
Gasket
34— Bolt

3
5—Lockwasher
36— Shift Rod
37—
Shift
Fork
38— Shift
Fork

39—
Filler
Pipe Plug
40—Mainshaft Gear 41— plain Washer
42—
Thrust
Washer
43—
Intermediate
Gear
44—
Snap Ring

45—
Bearing

46—
Nut 47— Washer
48— Output Clutch Shaft
49—
Output Clutch Gear
50— Snap Ring 51—
Thrust
Washer
52— Output Shaft Gear
53— Sliding Gear
54— Bushing
55— Output Shaft
56— Cone and Rollers

57—
Bearing
Cup
58—
Speedometer
Gear 59—
Needle
Bearings 60—Bearing Spacers
61—
Intermediate
Shaft
62—
Drain
Plug 63—
Gasket

64—Nut
65—
Bottom
Cover
66—
Sleeve

67—
Speedometer
Gear 68— Bushing
69—
Gasket
70— Bolt

71—Bolt
72—
Hex Nut
72— Bolt
73— Bolt
74—
Lockwasher

75— Nut
76— Output Shaft Seal 268