1995 JEEP CHEROKEE Service Repair Manual

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Page 1385 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (5) Pull No. 4 shift rail outward and remove lock balls and pin (Fig. 11). (6) Remove No. 4 shift rail, fifth gear and No. 3 shift fork (Fig. 12). (7) Pull No. 5 shift rail and shift head out of plate

Page 1386 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (10) Remove shift rail No. 2 and shift forks 1 and 2 (Fig. 16). (11) Remove reverse idler gear and shaft (Fig. 17).(12) Remove reverse shift arm and fork (Fig. 18). MAINSHAFT DISASSEMBLY (1) On AX 5,

Page 1387 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (2) Engage two synchro sleeves to lock mainshaft gears (Fig. 20). (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 counte

Page 1388 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (6) Remove reverse shift arm bracket (Fig. 24). (7) Remove rear bearing retainer bolts with appro- priate size torx bit and remove retainer (Fig. 25).(8) Remove rear bearing snap ring (Fig. 26). (9) T

Page 1389 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (12) Measure thrust clearance of output shaft gears (Fig. 28). Clearance should be 0.10 - 0.25 mm (0.004 - 0.010 in.). (13) Remove output shaft fifth gear snap ring with two screwdrivers (Fig. 29).(14

Page 1390 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (18) Press 1-2 synchronizer and second gear off output shaft (Fig. 32). (19) Remove needle roller bearing from the shaft or second gear. (20) Remove 3-4 synchronizer snap ring (Fig. 33). (21) Press 3-

Page 1391 of 2198

JEEP CHEROKEE 1995 Service Repair Manual Fig. 35 Checking Shaft And Bearing Race Flange Thickness Fig. 36 Checking Shaft And Race Diameters Fig. 37 Checking Output Shaft Runout Fig. 38 Checking Gear-To-Race Clearance 21 - 14 AX 4/5 MANUAL TR

Page 1392 of 2198

JEEP CHEROKEE 1995 Service Repair Manual Install the needle bearings and the second, third and counter fifth gears on the output shaft. Then check oil clearance between the gears and shaft with a dial indicator (Fig. 39). Oil clearance for a
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