1994 JEEP CHEROKEE lock

A correct lubricant level check can only be made
when the vehicle is level; use a drive-on hoist to en-
sure this. Also allow the lubricant to settle for a
minute or so before checking. These recommenda-
tions will ensure an accurate check and avoid an un-
der-or-overfill condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants, compo-
nent damage, incorrect clutch adjustment, or by a
damaged clutch pressure plate or disc.
Substantial lubricant leaks can result in gear, shift
rail, synchro and bearing damage. If a leak goes un-
detected for an extended period, the first indications
of a problem are usually hard shifting and noise.
Incorrect or contaminated lubricants can also con-
tribute to hard shifting. The consequence of using
non-recommended lubricants is noise, excessive wear,
internal bind and hard shifting.
Improper clutch release is a frequent cause of hard
shifting. Incorrect adjustment or a worn, damaged
pressure plate or disc can cause incorrect release. If
the clutch problem is advanced, gear clash during
shifts can result.
Worn or damaged synchro rings can cause gear
clash when shifting into any forward gear. In some
new or rebuilt transmissions, new synchro rings maytend to stick slightly causing hard or noisy shifts. In
most cases, this condition will decline as the rings
wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears can generate a
mild whine that may only be audible at extreme
speeds.
Severe, obviously audible transmission noise is
generally the result of a lubricant problem. Insuffi-
cient, improper, or contaminated lubricant can pro-
mote rapid wear of gears, synchros, shift rails, forks
and bearings. The overheating caused by a lubricant
problem, can also lead to gear breakage.
TRANSMISSION REMOVAL
(1) Shift transmission into first or third gear. Then
raise vehicle on hoist.
(2) Support engine with adjustable jack stand. Be
sure to position wood block between jack and oil pan.
(3) Disconnect necessary exhaust system compo-
nents.
(4) Disconnect rear cushion and bracket from
transmission (Fig. 5). Then remove skid plate, or
rear crossmember.
(5) Disconnect transfer case shift linkage, vehicle
speed sensor wires, and vent hose.
Fig. 5 Rear Mount Components (YJ Shown)
JAX 4/5 MANUAL TRANSMISSION 21 - 3

(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

(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

(13) Remove output shaft fifth gear snap ring with
two screwdrivers (Fig. 37).
(14) Press fifth gear, rear bearing, first gear and
inner race off output shaft (Fig. 38).(15) Remove needle roller bearing.
(16) Remove synchronizer ring.
(17) Remove synchronizer lock ball with pencil
magnet (Fig. 39).
(18) Press 1-2 synchronizer and second gear off
output shaft (Fig. 40).
(19) Remove needle roller bearing from the shaft
or second gear.
Fig. 37 Removing Fifth Gear Snap Ring
Fig. 38 Removing Fifth Gear And First Gear Bearing
And Race
Fig. 39 Synchronizer Lock Ball Removal
Fig. 40 1-2 Synchronizer And Second Gear Removal
21 - 12 AX 4/5 MANUAL TRANSMISSIONJ