1994 JEEP CHEROKEE transmission

(19) Remove bolts attaching output shaft rear
bearing retainer to intermediate plate (Fig. 38).
(20) Remove rear bearing retainer (Fig. 39).
(21) Remove reverse gear and shaft (Fig. 40).
SHIFT RAIL AND FORK REMOVAL
There are a total of five shift rails in the AX 15
transmission. The 1-2, 3-4, fifth gear and front re-
verse shift rails are shown in Figure 41.
Two shift rails are used for reverse gear range. The
front reverse rail is at the forward side of the inter-
mediate plate (Fig. 41). The short rear reverse rail
and reverse shift head are at the rear side of the in-
termediate plate.
It is not necessary to remove the shift rails if
they do not require service during overhaul.
Fig. 38 Removing Output Shaft Rear Bearing Retainer
BoltsFig. 39 Removing Output Shaft Rear Bearing Retainer
Fig. 40 Removing Reverse Idler Gear And Shaft
Fig. 41 Shift Rail Identification
21 - 44 AX 15 MANUAL TRANSMISSIONJ

Only the shift forks need be removed for access
to the transmission shafts and gears.
(1) Remove fifth gear shift rail (Fig. 41). Catch
lock ball in your hand as rail comes out of interme-
diate plate.
(2) Remove 1-2 and 3-4 shift rail C-rings with two
screwdrivers of equal size and length (Fig. 42).
(3) Remove shift fork set screws (Fig. 43).
(4) Remove 3-4 shift rail from shift fork and inter-
mediate plate (Fig. 44).(5) Remove 3-4 shift rail interlock plug from inter-
mediate plate with magnet (Fig. 45).
(6) Remove 1-2 shift rail from shift fork and inter-
mediate plate (Fig. 46).
Fig. 42 Removing Shift Rail C-Rings
Fig. 43 Removing Shift Fork Set Screws
Fig. 44 Removing 3-4 Shift Rail
Fig. 45 Removing 3-4 Shift Rail Interlock Plug
Fig. 46 Removing 1-2 Shift Rail
JAX 15 MANUAL TRANSMISSION 21 - 45

(7) Remove 1-2 shift rail interlock pin from shift
rail (Fig. 47).
(8) Remove 1-2 shift rail interlock plug from inter-
mediate plate (Fig. 48).
(9) Lift reverse shift fork upward and remove fifth
gear shift rail lock ball (Fig. 49).(10) Remove 3-4 shift fork (Fig. 50).
(11) Remove 1-2 shift fork (Fig. 50).
(12) Remove reverse shift rail C-ring with two
equal length and size screwdrivers (Fig. 51).
(13) Remove reverse shift rail and fork (Fig. 52).
(14) Remove interlock pin from reverse shift rail
(Fig. 53).
(15) Position shift rails, shift forks, lock balls, in-
terlock plugs and interlock pins on the workbench in
order of removal. This will help in identifying com-
ponents during inspection and assembly.
Fig. 47 Removing 1-2 Shift Rail Interlock Pin
Fig. 48 Removing 1-2 Shift Rail Interlock Plug
Fig. 49 Removing Fifth Gear Shift Rail Lock Ball
Fig. 50 Shift Fork Removal
21 - 46 AX 15 MANUAL TRANSMISSIONJ

OUTPUT SHAFT AND CLUSTER GEAR
REMOVAL
(1) Remove output shaft rear bearing snap ring
(Fig. 54).
(2) Remove cluster gear rear bearing snap ring
(Fig. 54).
(3) Tap end of output shaft with mallet to unseat
and start rear bearing out of intermediate plate (Fig.
55).(4) Remove output shaft by rocking it lightly until
rear bearing comes out of intermediate plate (Fig.
56).
(5) Remove cluster gear by pulling it straight out
of rear bearing (Fig. 57).
(6) Remove cluster gear rear bearing from inter-
mediate plate (Fig. 58).
(7) Remove input shaft from output shaft (Fig. 59).
(8) Remove output shaft pilot bearing from input
shaft (Fig. 60).
(9) Remove synchro ring from input shaft (Fig. 61).
Fig. 51 Removing Reverse Shift Rail C-Ring
Fig. 52 Removing Reverse Shift Rail And Fork
Fig. 53 Removing Reverse Shift Rail Interlock Pin
Fig. 54 Removing Bearing Snap Rings
JAX 15 MANUAL TRANSMISSION 21 - 47

(10) Remove bearing snap ring and press bearing
off input shaft (Fig. 61).
OUTPUT SHAFT DISASSEMBLY
(1) Measure thrust clearance of output shaft first,
second and third gears with feeler gauge (Fig. 62).²First gear clearance should be 0.10 - 0.40 mm
(0.003 - 0.0197 in).
²SecondÐthird gear clearance should be 0.10 - 0.30
mm (0.003 - 0.0118 in.).(2) If first gear thrust clearance is incorrect, replace
gear and thrust washer.If second or third gear clear-
ance is incorrect, either gear and bearing, or out-
Fig. 55 Unseating Output Shaft Rear Bearing
Fig. 56 Input/Output Shaft Assembly Removal
Fig. 57 Cluster Gear Removal
Fig. 58 Removing Cluster Gear Rear Bearing
Fig. 59 Input Shaft Removal
Fig. 60 Removing Input Shaft Pilot Bearing
21 - 48 AX 15 MANUAL TRANSMISSIONJ

put shaft flange is worn. Refer to output shaft
inspection in Cleaning and Inspection section.
(3) Press fifth gear and rear bearing off rear of
output shaft.
(4) Remove thrust washer, pin, and first gear and
bearing (Fig. 62).
(5) Remove first/reverse hub snap ring (Fig. 63).
(6) Remove synchro ring.
(7) Press reverse gear and first/reverse hub off
shaft as assembly.(8) Remove remaining synchro ring and second
gear and bearing (Fig. 63).
(9) Remove snap ring at front of output shaft (Fig.
63).
Fig. 62 Checking Output Shaft Gear Thrust Clearance
Fig. 63 Output Shaft And Gears
Fig. 61 Input Shaft Components
JAX 15 MANUAL TRANSMISSION 21 - 49

(10) Press 3-4 hub and sleeve off output shaft as
assembly (Fig. 63).
(11) Remove synchro ring.
(12) Remove third gear and needle bearing (Fig. 63).
TRANSMISSION CLEANING AND INSPECTION
Clean the transmission components in solvent. Dry
the cases, gears, shift mechanism and shafts with com-
pressed air.Dry the bearings with clean, dry shop
towels only. Never use compressed air on the bear-
ings. This could damage the bearing rollers.
Replace components that are obviously worn,
cracked, chipped or damaged in any way.
Inspect the transmission case. Replace the case if
cracked or porous or if any of the bearing and gear
bores are damaged.
Output Shaft Inspection
Measure thickness of the output shaft flange with
a micrometer (Fig. 64). Minimum allowable flange
thickness is 4.70 mm (0.185 in).
If shaft flange thickness is OK but previously
measured second/third gear thrust clearance
was incorrect (Fig. 62), replace the necessary
gear and needle bearing as an assembly.
Check diameter of the first, second and third gear
bearing surfaces of the output shaft (Fig. 64). Mini-
mum allowable diameters are:
²38.86 mm (1.529 in.) for first gear surface
²46.86 mm (1.844 in.) for second gear surface
²37.86 mm (1.490 in.) for third gear surface
Check output shaft runout with V-blocks and a dial
indicator (Fig. 64). Maximum allowable runout is
0.06 mm (0.0024 in.).
Replace the output shaft if any surface measured
fails to meet stated tolerance.
Cluster Gear Inspection
Inspect the cluster gear teeth. Replace the gear if
any teeth are worn or damaged or if the bearing sur-
faces are damaged.
Check diameter of the cluster gear journal with a
micrometer (Fig. 65). Minimum allowable diameter
is 27.860 mm (1.096 in.).
Check condition of the cluster gear front bearing.
Replace the bearing if worn, noisy, or damaged.
GEAR AND SYNCHRO INSPECTION
Install the synchro rings on their respective gears.
Rotate each ring on the gear and note synchro ac-
tion. Replace any synchro ring that exhibits a lack of
braking action or binds on the gear. Also replace any
ring that is worn or has chipped or broken teeth.
Measure end clearance between the synchro ring
and the gear with a feeler gauge (Fig. 66). Clearance
should be 0.06 mm - 1.6 mm (0.024 - 0.063 in.).Install the needle bearings in the first, second and
third gears. Then install the gears on the output
shaft and check shaft-to-gear clearance with a dial
indicator (Fig. 67).
Fig. 64 Checking Output Shaft Tolerances
Fig. 65 Checking Cluster Gear Journal Diameter
21 - 50 AX 15 MANUAL TRANSMISSIONJ

Maximum allowable clearance is 0.16 mm (0.0063
in.). If any gear exhibits excessive clearance, replace
the gear and needle bearing.
Check clearance between the shift forks and syn-
chro sleeves with a feeler gauge (Fig. 68). Clearance
should not exceed 1.0 mm (0.039 in.). Replace the
synchro sleeve (and matching hub) if clearance ex-
ceeds the stated limit.
Check condition of the reverse idler gear bushing
(Fig. 69). Replace the gear if the bushing is damaged or
worn.
Gear Case, Housing And Intermediate Plate
Clean the case, housing and plate with solvent and
dry with compressed air. Replace any component that
is cracked, warped or damaged in any way.
Inspect the threads in the case, housing and plate.
Minor thread damage can be repaired with steel thread
inserts if necessary. However, do not attempt to repair
if the cracks are evident around any threaded hole.
Inspect the reverse pin in the adapter/extension
housing. Replace the pin if worn or damaged. Refer
to the replacement procedure in the Transmission
Assembly section.
TRANSMISSION ASSEMBLY AND ADJUSTMENT
Lubricate the transmission components with Mopar
75W-90 gear lubricant during assembly. Use petro-
leum jelly to lubricate seal lips and/or hold parts in
place during installation.
Fig. 66 Checking Synchro Ring End Clearance
Fig. 67 Checking Gear-To-Shaft Clearance
Fig. 68 Checking Shift Fork-To-Sleeve Clearance
Fig. 69 Reverse Idler Gear Bushing
JAX 15 MANUAL TRANSMISSION 21 - 51