1994 JEEP CHEROKEE lock

(4) Remove cluster gear front bearing snap ring
(Fig. 19).
(5) Loosen gear case by tapping it away from inter-
mediate plate with rubber mallet (Fig. 20).
(6) Remove gear case from geartrain and interme-
diate plate (Fig. 21).(7) On 2-wheel drive models, remove speedometer
gear snap ring and remove speedometer gear and
spacer from output shaft.
FIFTH GEAR AND SYNCHRO ASSEMBLY
REMOVAL
(1) Remove three lock ball plugs from intermediate
plate (Fig. 22).
(2) Remove three lock ball springs and lock balls
from intermediate plate with pencil magnet (Fig. 23).
Fig. 19 Removing Cluster Gear Front Bearing Snap Ring
Fig. 20 Loosening Gear Case
Fig. 21 Gear Case Removal
Fig. 22 Lock Ball Plug Locations
Fig. 23 Removing/Installing Lock Ball And Spring
21 - 40 AX 15 MANUAL TRANSMISSIONJ

(13) Loosen fifth spline gear with standard two-jaw
puller (Fig. 32). Position puller jawsbehind fifth
counter gearas shown.
(14) Remove fifth spline gear (Fig. 33).
(15) Remove fifth gear synchro ring (Fig. 34).(16) Remove fifth gear synchro and sleeve assem-
bly (Fig. 35).
(17) Remove counter fifth gear thrust ring (Fig. 36).
(18) Remove thrust ring lock ball with pencil mag-
net (Fig. 37).
Fig. 37 Removing Thrust Ring Lock Ball
Fig. 32 Loosening Fifth Spline Gear
Fig. 33 Removing Fifth Spline Gear
Fig. 34 Removing Fifth Gear Synchro Ring
Fig. 35 Removing Counter Fifth Gear And Synchro
Assembly
Fig. 36 Removing Fifth Gear Thrust Ring
JAX 15 MANUAL TRANSMISSION 21 - 43

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) 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

SHIFT RAIL AND FORK INSTALLATION
The shift rail interlock pins, balls and plugs must
be installed in the correct sequence for proper shift-
ing. Refer to the installation diagram (Fig. 85) dur-
ing assembly.
Coat the intermediate plate shift rail bores and
the interlock balls, pins and plugs with a heavy
coating of petroleum jelly before assembly. The
jelly will hold the interlock components in place
making installation easier. Use a pencil magnet
to hold and insert the interlocks. Then use a
small screwdriver to push the interlock compo-
nents into place.
(1) Coat reverse rail interlock pin with petroleum
jelly and install pin in rail (Fig. 86).
Fig. 85 Shift Rail Ball-Plug-Pin Position
Fig. 86 Installing Reverse Shift Rail Interlock Pin
21 - 56 AX 15 MANUAL TRANSMISSIONJ

(2) Install reverse shift rail in intermediate plate
(Fig. 87).
(3) Install reverse shift rail C-ring (Fig. 51).
(4) Position 1-2 and 3-4 shift forks in synchro
sleeves (Fig. 88).
(5) Coat reverse rail lock ball with petroleum jelly.
Then tilt reverse shift fork upward and insert ball in
intermediate plate (Fig. 89).(6) Coat 1-2 shift rail interlock plug with petro-
leum jelly and install it in intermediate plate bore
(Fig. 90).
(7) Coat 1-2 shift rail interlock pin with petroleum
jelly and insert it in shift rail (Fig. 91).
Fig. 87 Installing Reverse Shift Rail And Fork
Fig. 88 Shift Fork Installation
Fig. 89 Installing Reverse Shift Rail Lock Ball
Fig. 90 Installing 1-2 Shift Rail Interlock Plug
Fig. 91 Installing 1-2 Shift Rail Interlock Pin
JAX 15 MANUAL TRANSMISSION 21 - 57