1994 JEEP CHEROKEE transmission

(6) Remove slave cylinder from clutch housing.
(7) Disconnect transmission shift lever as follows:
(a) Lower transmission-transfer case assembly ap-
proximately 7-8 cm (3 in.) for access to shift lever.
(b) Reach up and around transmission case and
unseat shift lever dust boot from transmission shift
tower (Fig. 6). Move boot upward on shift lever for
access to retainer that secures lever in shift tower.
(c) Reach up and around transmission case and
press shift lever retainer downward with your fin-
gers. Turn retainer counterclockwise to release it.
(d) Lift lever and retainer out of shift tower (Fig.
6).Do not remove the shift lever from the
floorpan boots. Leave the lever in place for
later transmission installation.
(8) Mark front and rear propeller shafts for instal-
lation alignment (Fig. 7). Then remove shafts.
(9) Remove crankshaft position position sensor (Fig.
8).
(10) Disconnect vehicle speed sensor wires.
(11) Disconnect transmission and transfer case
vent hoses.(12) Disconnect clutch master cylinder hydraulic
line from concentric bearing inlet line (Fig. 8).
(13) Support transmission-transfer case assembly
with a transmission jack. Secure assembly to jack
with safety chains.
(14) Remove clutch housing brace rod on 4-cylinder
models.
(15) Remove clutch housing-to-engine bolts and re-
move transmission-transfer case assembly.
(16) Remove bolts attaching transmission to trans-
fer case and separate components.
(17) Remove release bearing, fork and retainer clip.
(18) Remove clutch housing.
TRANSMISSION INSTALLATION
(1) Install clutch housing on transmission. Tighten
housing bolts to 37 Nzm (27 ft. lbs.) torque.
(2) Lubricate contact surfaces of release fork pivot
ball stud and release fork with high temp grease.
Then install release bearing, fork and retainer clip.
(3) Mount transmission on transmission jack.
(4) Lightly lubricate pilot bearing and transmis-
sion input shaft splines with Mopar high tempera-
ture grease.
(5) Align transmission input shaft and clutch disc
splines and install transmission.
(6) Install and tighten clutch housing-to-engine
bolts to 38 Nzm (28 ft. lbs.) torque.Be sure the
housing is properly seated on engine block be-
fore tightening bolts.
(7) Lower transmission approximately 7-8 cm (3
in.) for access to shift tower. Be sure transmission is
in first or third gear.
(8) Reach up and around transmission and insert
shift lever in shift tower. Press lever retainer down-
ward and turn it clockwise to lock it in place. Then
install lever dust boot on shift tower.
(9) Install slave cylinder in clutch housing.
(10) Connect engine timing sensor wires.
(11) Remove jack from under transmission and
mount transfer case on jack.Fig. 6 Removing/Installing Shift Lever
Fig. 7 Marking Propeller Shaft And Axle Yokes
Fig. 8 Hydraulic Line And Timing Sensor Location
21 - 4 AX 4/5 MANUAL TRANSMISSIONJ

(12) Align transfer case and transmission shafts
and install transfer case. Tighten transfer case-to-
transmission nuts/bolts to 35 Nzm (26 ft. lbs.) torque.
(13) Remove jack stand from under engine and re-
position jack under transmission. Then remove trans-
mission jack.
(14) Connect transfer case vent hose and shift link-
age. Check and adjust linkage if necessary.
(15) Connect transmission and transfer case vent
hoses.
(16) Connect backup light switch wires.
(17) Connect vehicle speed sensor wires.
(18) Install and connect crankshaft position sensor
if equipped.
(19) Install rear crossmember, or skid plate (Fig. 5).
On XJ, tighten crossmember-to-frame bolts to 41 Nzm
(31 ft. lbs.) torque. Then tighten transmission-to-rear
support bolts/nuts to 45 Nzm (33 ft. lbs.) torque. On YJ,
tighten bolts/nuts to indicated torque (Fig. 5).
(20) Align and install front/rear propeller shafts.
Tighten shaft U-joint clamp bolts to 19 Nzm (170 in.
lbs.) torque.
(21) On XJ, install skid plate, if removed. Tighten
bolts to 42 Nzm (31 ft. lbs.) torque. Tighten stud nuts
to 17 Nzm (150 in. lbs.) torque.
(22) Top off transmission and transfer case lubri-
cant levels.
(23) Lower vehicle.
TRANSMISSION DISASSEMBLY AND OVERHAUL
ADAPTER HOUSING AND FRONT BEARING
RETAINER REMOVAL
(1) Drain transmission lubricant.
(2) Remove concentric bearing.
(3) Remove clutch housing bolts and remove housing.
(4) On 2-wheel drive models, remove vehicle speed
sensor, speedometer adapter and speedometer driven
gear. Then remove extension housing seal (Fig. 9).(5) Remove detent spring and ball. Remove detent
plug (Fig. 10) and remove detent spring and ball
with pencil magnet.
(6) Remove shift arm set bolt (Fig. 11) and remove
bolt and lockplate.
Fig. 10 Detent Ball Plug Location
Fig. 11 Set Bolt Removal
Fig. 9 Removing 2-Wheel Drive Extension Housing Seal
JAX 4/5 MANUAL TRANSMISSION 21 - 5

(7) Remove shift lever shaft plug (Fig. 12). Then
pull shaft out with large magnet.
(8) Remove adapter housing bolts.
(9) Remove adapter housing by tapping it loose
with plastic mallet.
(10) Remove front bearing snap rings (Fig. 13).
(11) Remove front bearing retainer and intermedi-
ate plate by tapping them loose with plastic mallet
(Fig. 14).
SHIFT MECHANISM DISASSEMBLY
(1) Install two clutch housing bolts and spare
washers in intermediate plate (Fig. 15). Then clamp
plate and gear assembly in vise.Use enough wash-
ers to prevent bolts from touching. Also be sure
vise jaws are clamped on bolt heads (Fig. 15).
Fig. 15 Positioning Intermediate Plate In Vise
Fig. 12 Removing Shift Lever Shaft Plug
Fig. 13 Removing Bearing Retainer Snap Ring
Fig. 14 Removing Bearing Retainer And
Intermediate Plate
21 - 6 AX 4/5 MANUAL TRANSMISSIONJ

(2) Remove threaded plugs from intermediate
plate. Then remove lock ball and spring from plug
holes with pencil magnet (Fig. 16).
(3) Remove shift fork pins with punch and hammer
(Fig. 17).(4) Remove shift rail C-rings (Fig. 18).
(5) Pull No. 4 shift rail outward and remove lock
balls and pin (Fig. 19).
Fig. 16 Removing Lock Ball And Spring
Fig. 17 Removing Shift Fork Pin
Fig. 18 Shift Rail C-Ring Removal
Fig. 19 Removing No. 4 Shift Rail, Lock Balls And
Pin
JAX 4/5 MANUAL TRANSMISSION 21 - 7

(6) Remove No. 4 shift rail, fifth gear and No. 3
shift fork (Fig. 20).
(7) Pull No. 5 shift rail and shift head out of plate
(Fig. 21).
(8) Remove shift rail No.3.Catch interlock pins
as rail is removed (Fig. 22).
(9) Remove No. 1 shift rail and interlock pin (Fig.
23).
(10) Remove shift rail No. 2 and shift forks 1 and 2
(Fig. 24).
Fig. 20 Removing No. 4 Shift Rail And Fifth Gear
Shift Fork
Fig. 21 Removing No. 5 Shift Rail And Shift Head
Fig. 22 Removing No. 3 Shift Rail And Interlock Pin
Fig, 23 Removing No. 1 Shift Rail And Interlock Pin
Fig. 24 Removing Shift Forks And No. 2 Shift Rail
21 - 8 AX 4/5 MANUAL TRANSMISSIONJ

(11) Remove reverse idler gear and shaft (Fig. 25).
(12) Remove reverse shift arm and fork (Fig. 26).MAINSHAFT DISASSEMBLY
(1) On AX 5, measure fifth counter gear thrust
clearance with feeler gauge (Fig. 27). Clearance
should be 0.10 - 0.30 mm (0.004 - 0.012 in.).
(2) Engage two synchro sleeves to lock mainshaft
gears (Fig. 28).
Fig. 25 Removing Reverse Idler Gear And Shaft
Fig. 26 Reverse Shift Arm Removal
Fig. 27 Measuring Counter Fifth Gear Thrust
Clearance
Fig. 28 Locking Mainshaft Gears
JAX 4/5 MANUAL TRANSMISSION 21 - 9

(3) On AX 4, remove counter gear nut and oil
slinger. On AX 5, remove select fit snap ring that se-
cures fifth spline gear and counter fifth gear on shaft
(Fig. 29).
(4) Remove fifth spline gear, synchronizer and
counter fifth gear with two-jaw puller (Fig. 30).(5) Remove spacer and remove lock ball with pen-
cil magnet (Fig. 31).
(6) Remove reverse shift arm bracket (Fig. 32).
Fig. 29 Removing Fifth Gear Snap Ring
Fig. 30 Removing Fifth Gear Assembly
Fig. 31 Spacer And Lock Ball Removal
Fig. 32 Removing Reverse Shift Arm Bracket
21 - 10 AX 4/5 MANUAL TRANSMISSIONJ

(7) Remove rear bearing retainer bolts with appro-
priate size torx bit and remove retainer (Fig. 33).
(8) Remove rear bearing snap ring (Fig. 34).(9) Tap intermediate plate with plastic mallet and
pull output shaft-counter gear assemblies out of plate
(Fig. 35).
(10) Remove rear bearing from intermediate plate.
(11) Remove input shaft and shaft roller bearings
from output shaft.
(12) Measure thrust clearance of output shaft
gears (Fig. 36). Clearance should be 0.10 - 0.25 mm
(0.004 - 0.010 in.).
Fig. 33 Removing Rear Bearing Retainer
Fig. 34 Removing Rear Bearing Snap Ring
Fig. 35 Removing Counter Gear And Output Shaft
Fig. 36 Checking Output Shaft Gear Thrust
Clearance
JAX 4/5 MANUAL TRANSMISSION 21 - 11