1995 JEEP CHEROKEE Service Repair Manual

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Page 1425 of 2198

JEEP CHEROKEE 1995 Service Repair Manual Fig. 51 Reverse Shift Rail C-Ring Removal
Fig. 52 Reverse Shift Rail And Fork Removal
Fig. 53 Reverse Shift Rail Interlock Pin Removal
Fig. 54 Removing Bearing Snap Rings
21 - 48 AX 15 MANUAL TRANSMIS

Page 1426 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (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

Page 1427 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (9) Remove synchro ring from input shaft (Fig. 61).
(10) Remove bearing snap ring and press bearing
off input shaft (Fig. 61).
OUTPUT SHAFT DISASSEMBLY
(1) Measure thrust clearance of output shaft fir

Page 1428 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (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 bea

(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).
(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.
Then dry the cases, gears, shift mechanism and
shafts with compressed air.Dry the bearings with
clean, dry shop towels only. Never use com-
pressed air on the bearings. This could damage
the bearing rollers.
Replace components that are obviously worn,
cracked, chipped or damaged.
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.
Fig. 64 Checking Output Shaft Tolerances
Fig. 65 Checking Cluster Gear Journal Diameter
JAX 15 MANUAL TRANSMISSION 21 - 51

Page 1429 of 2198

JEEP CHEROKEE 1995 Service Repair Manual GEAR AND SYNCHRO INSPECTION
Install the synchro rings on their respective gears.
Rotate each ring on the gear and note synchro action.
Replace any synchro ring that exhibits a lack of
braking action o

GEAR AND SYNCHRO INSPECTION
Install the synchro rings on their respective gears.
Rotate each ring on the gear and note synchro action.
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 to 1.6 mm (0.024 to 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).
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 scored 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/extensionhousing. Replace the pin if worn or damaged. Refer
to the replacement procedure in the Transmission As-
sembly section.
TRANSMISSION ASSEMBLY AND ADJUSTMENT
Lubricate the transmission components with gear
lubricant during assembly. Use petroleum jelly to lu-
bricate seal lips and/or hold parts in place during in-
stallation.
Fig. 66 Checking Synchro Ring End Clearance
Fig. 67 Checking Gear-To-Shaft Clearance
Fig. 68 Checking Shift Fork-To-Sleeve Clearance
21 - 52 AX 15 MANUAL TRANSMISSIONJ

Page 1430 of 2198

JEEP CHEROKEE 1995 Service Repair Manual FRONT BEARING/BEARING SEAL/REVERSE
SHAFT PIN INSTALLATION
(1) Press front bearing on input shaft. Then secure
bearing with thickest snap ring that will fit in shaft
groove (Fig. 70).
(2) Press front b

Page 1431 of 2198

JEEP CHEROKEE 1995 Service Repair Manual OUTPUT SHAFT ASSEMBLY
(1) Lubricate output shaft journals, gears and nee-
dle bearings with recommended gear lubricant.
(2) Install third gear and needle bearing on shaft
(Fig. 63)
(3) Install synchro

Page 1432 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (14) Install selective snap ring (Fig. 78). Use thick-
est snap ring that will fit in output shaft groove.
(15) Install synchro ring on first gear (Fig. 79).
(16) Install first gear spacer on shaft an

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