1994 JEEP CHEROKEE Service Repair Manual

(8) Install 1-2 shift rail in intermediate plate and
1-2 fork (Fig. 92).
(9) Coat 3-4 shift rail interlock plug with petro-
leum jelly and install plug in intermediate plate (Fig.
93).
(10) Install 3-4 shift rail in intermediate plate and
in both shift forks (Fig. 94).
(11) Verify that none of interlock balls, plugs, or
pins were displaced during shift rail installation.
(12) Install and tighten shift fork setscrews to 20
Nzm (14 ft. lbs.) torque (Fig. 95).
(13) Install 1-2 and 3-4 shift rail C-rings (Fig. 96).
(14) Insert fifth gear shift rail through reverse
shift fork.Then slide rail into intermediate plate
just far enough to secure interlock ball. Do not
fully install shift rail at this time.
Fig. 94 Installing 3-4 Shift Rail
Fig. 95 Installing Shift Fork Set Screws
Fig. 96 Installing Shift Rail C-Rings
Fig. 92 Installing 1-2 Shift Rail
Fig. 93 Installing 3-4 Shift Rail Interlock Plug
21 - 58 AX 15 MANUAL TRANSMISSIONJ

FIFTH-REVERSE GEAR AND SHIFT
COMPONENT INSTALLATION
(1) Install thrust ring lock ball in cluster gear
journal (Fig. 97). Use petroleum jelly to hold ball in
place.
(2) Install fifth gear thrust ring (Fig. 98). Be sure
thrust ring notch fits over lock ball.
(3) Assemble counter fifth gear, synchro sleeve, in-
serts and insert springs (Fig. 99).
(4) Lubricate two-piece bearing with petroleum
jelly and install it in counter fifth gear (Fig. 100).
(5) Install counter fifth gear and synchro assembly
on cluster gear journal (Fig. 101).
Fig. 97 Installing Thrust Ring Lock Ball
Fig. 98 Installing Fifth Gear Thrust Ring
Fig. 99 Assembling Fifth Gear And Synchro
Assembly
Fig. 100 Installing Counter Fifth Gear Bearing
Fig. 101 Installing Counter Fifth Gear And Sleeve
JAX 15 MANUAL TRANSMISSION 21 - 59

(6) Install synchro ring in synchro sleeve (Fig. 102).
(7) Install fifth spline gear on cluster journal (Fig.
103). Tap spline gear into place with plastic mallet if
necessary.
(8) Install fifth gear selective snap ring (Fig. 104).
Use thickest snap ring that will fit in shaft groove.
(9) Install reverse shift head and rail (Fig. 105).
Then install lock ball in shift head.
(10) Position fifth gear shift fork in synchro sleeve
(Fig. 106).
(11) Install fifth gear shift rail (Fig. 107). Slide rail
through fork, shift head, intermediate plate and re-
verse shift fork. Be sure interlock ball is not dis-
placed during installation.
(12) Align screw holes in shift fork and rail and in-
stall set screw (Fig. 108). Tighten screw to 20 Nzm
(15 ft. lbs.) torque.
(13) Install lock balls and springs in intermediate
plate (Fig. 109). Then install and tighten lock ball
plugs to 19 Nzm (14 ft. lbs.) torque.
(14) Install reverse shift arm bracket (Fig. 110).
Tighten bracket bolts to 18 Nzm (13 ft. lbs.) torque.(15) Install reverse shift arm (Fig. 110). Position
arm on reverse fork pin and engage it with pin on
shift arm bracket.
(16) Verify that shift arm shoe is engaged in re-
verse idler gear. Then secure shift arm to pin on re-
verse fork with new E-clip.
GEAR CASE AND ADAPTER INSTALLATION
(1) Dismount intermediate and gear assemblies
from vise.
Fig. 104 Installing Fifth Gear Snap Ring
Fig. 105 Installing Reverse Shift Head And Rail
Fig. 102 Installing Fifth Gear Synchro Ring
Fig. 103 Installing Fifth Spline Gear
21 - 60 AX 15 MANUAL TRANSMISSIONJ

(2) Clean mating surfaces of intermediate plate
and transmission gear case with wax and grease re-
mover. Then wipe dry with a clean cloth.
Fig. 106 Installing Fifth Gear Shift Fork
Fig. 107 Installing Fifth Gear Shift Rail
Fig. 108 Shift Fork Set Screw Installation
Fig. 109 Detent Ball And Spring Installation
Fig. 110 Reverse Shift Arm And Bracket Installation
JAX 15 MANUAL TRANSMISSION 21 - 61

(3) Apply 3 mm (1/8 in.) wide bead of Mopar Gas-
ket Maker to mating surface of gear case. Keep
sealer bead inside bolt holes as shown (Fig. 111).
(4) Install gear case (Fig. 112). Align shift rails and
bearings in case and tap case into position.
(5) Verify that gear case is seated on intermediate
plate dowel pins.
(6) Install front bearing snap rings (Fig. 113).
(7) Clean gear case and front bearing retainer seal-
ing surfaces with wax and grease remover. Then
wipe dry with a clean cloth.
(8) Install new seal in front bearing retainer. Then
lubricate seal lip with petroleum jelly.Installation
depth for seal is 10.5 - 11.5 mm (0.413 - 0.453 in.).
(9) Applya3mm(1/8 in.) wide bead of Mopar
Gasket Maker to front bearing retainer sealing sur-
face.
(10) Align and install front bearing retainer (Fig.
114). Be sure retainer is properly seated on case and
bearings.
(11) Install and tighten front bearing retainer bolts
to 17 Nzm (12 ft. lbs.) torque.(12) On 2-wheel drive models, install speedometer
gear, lock ball and retaining rings (Fig. 115). Be sure
lock ball is engaged in gear.
(13) Inspect condition o reverse pin in adapter/ex-
tension housing (Fig. 116). If pin is worn or damaged,
replace it as follows:
(a) Remove roll pin access plug (Fig. 117).
(b) Tap roll pin out of housing with pin punch
(Fig. 118). Then remove old reverse pin.
(c) Install new reverse pin and secure it with roll
pin. Then install and tighten access plug to 19 Nzm
(14 ft. lbs.) torque.
(14) Clean sealing surfaces of adapter or extension
housing and intermediate plate with wax and grease
remover. Then wipe dry with a clean cloth.
Fig. 111 Applying Sealer To Gear Case
Fig. 112 Installing Gear Case
Fig. 113 Installing Front Bearing Snap Rings
Fig. 114 Installing Front Bearing Retainer
21 - 62 AX 15 MANUAL TRANSMISSIONJ

(15) Apply 3 mm (1/8 in.) wide bead of Mopar Gas-
ket Maker to sealing surface of adapter or extension
housing. Keep sealer bead inside bolt holes as shown
in Figure 111.(16) Align and install adapter or extension housing
on intermediate plate (Fig. 119). Be sure housing is
seated on intermediate plate dowel pins.
(17) Coat threads of housing attaching bolts with
silicone sealer. Then install and tighten bolts to 37
Nzm (27 ft. lbs.) torque.
(18) Install detent ball (Fig. 120).
(19) Install detent spring (Fig. 121).
(20) Install detent access plug (Fig. 122). Tighten
plug to 19 Nzm (14 ft. lbs.) torque.
(21) Lubricate shift arm shaft and install it in
adapter housing (Fig. 123).
(22) Position shift arm in adapter housing (Fig.
124). Be sure arm is engaged in shift rails.
(23) Align shift arm with shaft and push shaft into
arm.
(24) Rotate shift arm shaft until set screw holes in
shaft and arm are aligned.
(25) Install and tighten shift arm set screw to 38
Nzm (28 ft. lbs.) torque (Fig. 125).
(26) Install and tighten restrictor pins to 19 Nzm
(14 ft. lbs.) torque (Fig. 125).
Fig. 115 Speedometer Gear Installation (2WD
Models)
Fig. 116 Reverse Pin Position
Fig. 117 Access Plug Removal/Installation
Fig. 118 Roll Pin Removal/Installation
Fig. 119 Adapter/Extension Housing Installation
JAX 15 MANUAL TRANSMISSION 21 - 63

Fig. 120 Installing Detent Ball
Fig. 121 Installing Detent Spring
Fig. 122 Installing Detent Access Plug
Fig. 123 Installing Shift Arm Shaft
Fig. 124 Shift Arm Installation
Fig. 125 Set Screw And Restrictor Pin Installation
21 - 64 AX 15 MANUAL TRANSMISSIONJ

(27) Install and tighten shift arm shaft access plug
to 19 Nzm (14 ft. lbs.) torque (Fig. 126).
(28) Position new shift tower gasket on adapter
housing (Fig 127).
(29) Install shift tower (Fig. 128). Tighten tower
attaching bolts to 18 Nzm (13 ft. lbs.) torque.
(30) Install new gasket on backup light switch and
install switch. Tighten switch to 37 Nzm (27 ft. lbs.)
torque.
(31) Install new washer on drain plug. Then install
and tighten plug to 37 Nzm (27 ft. lbs.) torque.
(32) If transmission will be filled with gear lubri-
cant before installation, place transmission in a levelposition. Then fill with Mopar 75W-90, grade GL-5
gear lubricant. Correct fill level is to bottom edge of
fill plug hole.
(33) Install new washer on fill plug. Then install
and tighten plug to 37 Nzm (27 ft. lbs.) torque.
(34) Install clutch housing and release bearing
components.
(35) On 2-wheel drive models, install new seal in
extension housing with suitable size installer tool
(Fig. 129). Lubricate seal lips with petroleum jelly
before installation.
(36) On 2-wheel drive models, install speedometer
driven gear (if removed), and vehicle speed sensor.
Fig. 126 Access Plug Installation
Fig. 127 Shift Tower Gasket Installation
Fig. 128 Shift Tower Installation
Fig. 129 Installing Extension Housing SealÐ2WD
Models
JAX 15 MANUAL TRANSMISSION 21 - 65