1994 JEEP CHEROKEE lock

(15) Shift fifth gear synchronizer sleeve rearward
to lock it (Fig. 86).
(16) On AX 5, install fifth-reverse shift fork in
synchronizer sleeve. Then slide No. 4 shift rail into
fork (Fig. 87).(17) Install shift rail lock ball with pencil magnet
and screwdriver (Fig. 88).
(18) Check interlock operation as follows: Move
No. 1 shift rail rearward to first gear position. Inter-
lock operation is OK if remaining shift rails did not
move.
(19) Install new shift fork pins (Fig. 89).
Fig. 86 Locking Fifth Synchronizer
Fig. 87 Fifth-Reverse Shift Fork Installation
Fig. 88 Lock Ball Installation
Fig. 89 Installing Shift Fork Pins
JAX 4/5 MANUAL TRANSMISSION 21 - 27

(20) Install new shift rail C-rings (Fig. 90).
(21) Apply sealer to threads of lock ball plugs.
(22) Install lock balls and springs in intermediate
plate.Short spring goes in top hole of interme-
diate plate.
(23) Install lock ball and spring plugs (Fig. 91).
Tighten plugs to 19 Nzm (14 ft. lbs.) torque.ASSEMBLING GEARTRAIN AND
TRANSMISSION CASE
(1) Remove intermediate plate from vise.
(2) Install new gaskets on intermediate plate.
(3) Install transmission case on intermediate plate
(Fig. 92).
(4) Install new front bearing snap ring (Fig. 93).
Fig. 92 Installing Transmission Case
Fig. 93 Installing Front Bearing Snap Ring
Fig. 90 Installing Shift Rail C-Rings
Fig. 91 Installing Lock Ball Plugs
21 - 28 AX 4/5 MANUAL TRANSMISSIONJ

(5) Install new gasket on front bearing retainer
and install retainer on case (Fig. 94).
(6) Install adapter or extension housing on inter-
mediate plate (Fig. 95). Tighten housing bolts to 37
Nzm (27 ft. lbs.) torque.
(7) Install shift arm (Fig. 95).(8) Install shift arm lock plate with pliers (Fig. 96).
Then install and tighten lock plate set bolt to 38 Nzm
(28 ft. lbs.) torque.
(9) Install and tighten shaft plug to 18 Nzm (13 ft.
lbs.) torque (Fig. 97).
Fig. 94 Installing Front Bearing Retainer
Fig. 95 Installing Adapter Housing And Shift Arm
Fig. 96 Shift Arm Lock Plate Installation
Fig. 97 Shaft Plug Installation
JAX 4/5 MANUAL TRANSMISSION 21 - 29

(10) Install lock ball and spring in housing. Then
apply sealer to ball plug and install plug (Fig. 98).
Tighten plug to 19 Nzm (14 ft. lbs.) torque.
(11) Install reverse pins in housing (Fig. 99).
Tighten pins to 27 Nzm (20 ft. lbs.) torque.(12) Install shift tower and new gasket on housing
(Fig. 100). Tighten tower bolts to 18 Nzm (13 ft. lbs.)
torque.
(13) Install backup lamp switch (Fig. 100). Tighten
switch to 37 Nzm (27 ft. lbs.) torque.
(14) On 2-wheel drive models, install new seal in
extension housing (Fig. 101).
Fig. 98 Installing Ball Plug
Fig. 99 Install Reverse Pins
Fig. 100 Installing Shift Tower And Backup Lamp
Switch
Fig. 101 Extension Housing Seal InstallationÐ2WD
Models
21 - 30 AX 4/5 MANUAL TRANSMISSIONJ

TRANSMISSION SHIFT PATTERN
The AX 15 shift pattern is shown in Figure 3. First
and second and third and fourth gear ranges are in
line for improved shifting. Fifth and reverse gear
ranges are also in line at the extreme right of the
pattern (Fig. 3).
The AX 15 is equipped with a reverse lockout
mechanism. The shift lever must be moved through
the Neutral detent before making a shift to reverse.
TRANSMISSION LUBRICANT
Recommended lubricant for AX 15 transmissions is
Mopar 75W-90, API Grade GL-5 gear lubricant, or
equivalent.
Correct lubricant refill or top-off level is to the bot-
tom edge of the fill plug hole.
Lubricant capacity is:
²3.10 liters (3.27 qts.) in 4-wheel drive models.
²3.15 liters (3.32 qts.) in 2-wheel drive models.
TRANSMISSION SWITCH AND PLUG LOCATIONS
The fill plug is at the driver side of the gear case
(Fig. 4).
The drain plug and backup light switch are on the
passenger side of the gear case (Fig. 5).
TRANSMISSION GEAR RATIOS
The transmission gear ratios are as follows:
First gear - 3.83:1
Second gear - 2.33:1
Third gear - 1.44:1
Fourth gear - 1.00:1
Fifth gear - 0.79:1
Reverse - 4.22:1
SERVICE DIAGNOSIS
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill, or an in-
correct lubricant level check.
Leaks can occur at the mating surfaces of the gear
case, intermediate plate and adapter or extension
housing, or from the front/rear seals. A suspected
leak could also be the result of an overfill condition.
Leaks at the rear of the extension or adapter hous-
ing will be from the housing oil seals. Leaks at com-
ponent mating surfaces will probably be the result of
inadequate sealer, gaps in the sealer, incorrect bolt
tightening, or use of a non-recommended sealer.
A leak at the front of the transmission will be from
either the front bearing retainer or retainer seal. Lu-
bricant may be seen dripping from the clutch hous-
ing after extended operation. If the leak is severe, it
may also contaminate the clutch disc causing slip,
grab and chatter.
Transmissions filled from air or electrically pow-
ered lubricant containers can be underfilled. This
generally happens when the container delivery mech-
anism is improperly calibrated. Always check the lu-
bricant level after filling to avoid an under fill
condition.
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
Fig. 3 AX 15 Shift Pattern
Fig. 4 Fill Plug Location
Fig. 5 Drain Plug And Backup Light Switch Location
JAX 15 MANUAL TRANSMISSION 21 - 33

(9) Reach up and around transmission case and
unseat shift lever dust boot from transmission shift
tower (Fig. 2). Move boot upward on shift lever for
access to lever retainer.
(10) Disengage shift lever as follows:
(a) Reach up and around transmission case and
press shift lever retainer downward with your fin-
gers.
(b) Turn retainer counterclockwise to release it.
(c) Lift lever and retainer out of shift tower (Fig.
2).It is not necessary to remove shift lever
from floorpan boot. Simply leave lever in
place for later installation.
(11) Mark front and rear propeller shafts for in-
stallation alignment (Fig. 3). Then remove both
shafts.
(12) Remove crankshaft position/engine timing sen-
sor (Fig. 4).
(13) Disconnect transmission and transfer case
vent hoses.
(14) Remove slave cylinder from clutch housing.(15) Support transmission-transfer case assembly
with transmission jack. Secure assembly to jack with
safety chains.
(16) Reposition adjustable jack stand under engine.
Be sure to place wood block between jack and oil
pan.
(17) Remove clutch housing brace rod.
(18) Remove clutch housing-to-engine bolts and re-
move transmission-transfer case assembly.
(19) Remove bolts attaching transmission to trans-
fer case and separate components.
(20) Remove release bearing, fork and retainer
clip.
(21) Remove clutch housing from transmission.
TRANSMISSION INSTALLATIONÐAX 15
(1) Install clutch housing on transmission. Tighten
housing bolts to 37 Nzm (27 ft-lbs) torque.
(2) Lubricate contact surfaces of release fork, lever
and pivot ball stud. Then install bearing, fork and
clip in clutch housing.
(3) Mount transmission on transmission jack. Se-
cure transmission with safety chains.
(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 housing
is properly seated on engine before tightening
bolts.
(7) Lower transmission no more than 7.6 cm (3 in.)
for access to the shift tower.
(8) Reach up and around the transmission and in-
sert shift lever in shift tower. Press lever retainer
downward and turn it clockwise to lock it in place.
Then install lever dust boot on shift tower.
(9) Connect engine timing sensor.
Fig. 2 Removing/Installing Shift Lever
Fig. 3 Marking Propeller Shaft And Axle Yoke
Fig. 4 Timing Sensor Location
JAX 15 MANUAL TRANSMISSION 21 - 35

(6) Loosen and remove restrictor pins (Fig. 5).
(7) Remove shift arm shaft plug (Fig. 6).
(8) Remove shift arm shaft with large magnet (Fig.
7).(9) Remove shift arm (Fig. 8).
(10) Remove plug for reverse shift head lock ball.
Plug is at right side of adapter housing near backup
light switch (Fig. 9).
Fig. 5 Removing/Installing Restrictor Pins
Fig. 6 Removing/Installing Shift Lever Shaft Plug
Fig. 7 Removing/Installing Shift Lever Shaft
Fig. 8 Shift Arm Removal/Installation
Fig. 9 Removing/Installing Lock Ball Plug
JAX 15 MANUAL TRANSMISSION 21 - 37

(11) Remove lock ball spring with pencil magnet
(Fig. 10).
(12) Remove shift head lock ball with pencil mag-
net (Fig. 11).
(13) Remove backup light switch from adapter/ex-
tension housing.
(14) On 2-wheel drive models, remove distance
sensor, speedometer adapter and driven gear if not
removed previously.
(15) Remove adapter/extension housing bolts (Fig.
12).
Fig. 10 Removing/Installing Lock Ball Spring
Fig. 11 Removing/Installing Shift Head Lock Ball
Fig. 12 Adapter Housing Bolt Locations
21 - 38 AX 15 MANUAL TRANSMISSIONJ