1995 JEEP CHEROKEE torque

SHIFT MECHANISM ASSEMBLY AND
INSTALLATION
When assembling the shift mechanism, refer
to Figure 66 for component details and loca-
tion.
(1) Install reverse shift arm. Then seat shift fork
in bracket (Fig. 67).
(2) Install reverse idler gear on shaft. Then install
shaft and gear in intermediate plate (Fig. 68). Install
shaft lock plate and tighten attaching bolt to 18 Nzm
(13 ft. lbs.) torque.
(3) Install 1-2 and 3-4 shift forks in synchronizer
sleeves. Then slide No. 2 shift rail through interme-
diate plate and into forks (Fig. 69).
(4) Coat shift rail interlock pins and balls with lib-
eral quantity of petroleum jelly to hold them in place.
(5) Refer to Figure 70 for interlock ball and pin po-
sitions during following assembly steps.
Fig. 68 Installing Reverse Idler Gear And Shaft
Fig. 69 Installing No. 2 Shift Rail and Shift Forks
Fig. 67 Installing Reverse Shift Arm
JAX 4/5 MANUAL TRANSMISSION 21 - 25

(20) Install new shift rail C-rings (Fig. 83).
(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. 84).
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. 85).
(4) Install new front bearing snap ring (Fig. 86).
Fig. 83 Installing Shift Rail C-Rings
Fig. 84 Installing Lock Ball Plugs
Fig. 85 Installing Transmission Case
Fig. 86 Installing Front Bearing Snap Ring
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(5) Install new gasket on front bearing retainer
and install retainer on case (Fig. 87).
(6) Install adapter or extension housing on inter-
mediate plate (Fig. 88). Tighten housing bolts to 37
Nzm (27 ft. lbs.) torque.
(7) Install shift arm (Fig. 88).(8) Install shift arm lock plate with pliers (Fig. 89).
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. 90).
Fig. 87 Installing Front Bearing Retainer
Fig. 88 Installing Adapter Housing And Shift Arm
Fig. 89 Shift Arm Lock Plate Installation
Fig. 90 Shaft Plug Installation
JAX 4/5 MANUAL TRANSMISSION 21 - 31

(10) Install lock ball and spring in housing. Then
apply sealer to ball plug and install plug (Fig. 91).
Tighten plug to 19 Nzm (14 ft. lbs.) torque.
(11) Install reverse pins in housing (Fig. 92).
Tighten pins to 27 Nzm (20 ft. lbs.) torque.(12) Install shift tower and new gasket on housing
(Fig. 93). Tighten tower bolts to 18 Nzm (13 ft. lbs.)
torque.
(13) Install backup lamp switch (Fig. 93). Tighten
switch to 37 Nzm (27 ft. lbs.) torque.
(14) On 2-wheel drive models, install new seal in
extension housing (Fig. 94).
(15) Install vehicle speed sensor. Refer to proce-
dure in In-Vehicle Service section.
(16) Install clutch housing, release bearing, release
fork and retainer clip.
Fig. 91 Installing Ball Plug
Fig. 92 Install Reverse Pins
Fig. 93 Installing Shift Tower And Backup Lamp
Switch
Fig. 94 Extension Housing Seal InstallationÐ2WD
Models
21 - 32 AX 4/5 MANUAL TRANSMISSIONJ

(6) On XJ, remove rear crossmember. On YJ, re-
move skid plate (Fig. 1).
(7) Disconnect transmission shift linkage, speed-
ometer cable, transfer case vacuum lines and clutch
hydraulic lines.
(8) Lower transmission-transfer case assembly no
more than 7.6 cm (3 in.) for access to shift lever.
(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. 2). Then remove both
shafts.
(12) Remove crankshaft position sensor (Fig. 4).
(13) Disconnect transmission and transfer case
vent hoses.
(14) Remove slave cylinder from clutch housing.
(15) Remove wire harnesses from clips/tie straps
on transmission and transfer case.
(16) Support transmission-transfer case assembly
with transmission jack. Secure assembly to jack with
safety chains.
(17) Reposition adjustable jack stand under engine.
Be sure to place wood block between jack and oil
pan.
(18) Remove clutch housing brace rod.
(19) Remove clutch housing-to-engine bolts and re-
move transmission-transfer case assembly.
(20) Remove bolts attaching transmission to trans-
fer case and separate components.
(21) Remove release bearing, fork and retainer
clip.
(22) Remove clutch housing from transmission.
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, 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.
Fig. 2 Removing/Installing Shift Lever
Fig. 3 Marking Propeller Shaft And Axle Yoke
Fig. 4 Crankshaft Position Sensor Location
21 - 36 AX 15 MANUAL TRANSMISSIONJ

(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) Install and connect crankshaft position sensor.
(10) Align and install transfer case on transmis-
sion. Tighten transfer case attaching nuts to 35 Nzm
(26 ft. lbs.) torque.
(11) Connect transfer case vacuum and vent hoses.
(12) Install and connect transfer case shift linkage.
Check and adjust linkage if necessary.
(13) Secure wire harnesses to clips/tie straps on
transmission and transfer case.
(14) Connect backup light switch wires.
(15) Install clutch slave cylinder.
(16) Connect vehicle speed sensor wires.
(17) On XJ, install rear crossmember and attach
cushion and bracket. Tighten crossmember-to-frame
bolts to 41 Nzm (30 ft. lbs.) torque. Tighten transmis-
sion-to-rear cushion and bracket bolts/nuts to 45 Nzm
(33 ft. lbs.) torque.
(18) On YJ, install rear cushion and bracket and
skid plate. Tighten attaching bolts/nuts to indicated
torque (Fig. 1).
(19) Align and install front/rear propeller shafts.
Tighten shaft U-joint clamp bolts to 19 Nzm (170 in.
lbs.) torque.
(20) 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.
(21) Top off transmission and transfer lubricant
levels.
(22) Remove supports and lower vehicle.
TRANSMISSION DISASSEMBLY AND OVERHAUL
ADAPTER HOUSING REMOVAL
(1) Remove release bearing, release lever and re-
lease fork from clutch housing. Then remove clutch
housing from transmission.
(2) Remove backup light switch. Then remove
drain plug (Fig. 1) and drain transmission lubricant
into pan.
(3) Remove shift tower bolts and remove tower
from adapter or extension housing (Fig. 2).
(4) Remove gasket from shift tower (Fig. 3).
Fig. 1 Drain Plug And Backup Light Switch Location
Fig. 2 Shift Tower Removal/Installation
Fig. 3 Shift Tower Gasket Removal/Installation
JAX 15 MANUAL TRANSMISSION 21 - 37

(9) Coat 3-4 shift rail interlock plug with petro-
leum jelly and install plug in intermediate plate (Fig.
93).
(10) Install 3-4 shift rail in intermediate plate and
in both shift forks (Fig. 94).
(11) Verify that none of the interlock balls, plugs,
or pins were displaced during shift rail installation.
(12) Install and tighten shift fork setscrews to 20
Nzm (14 ft. lbs.) torque (Fig. 95).
(13) Install 1-2 and 3-4 shift rail C-rings (Fig. 96).
(14) Insert fifth gear shift rail through reverse
shift fork.Then slide rail into intermediate plate
just far enough to secure interlock ball. Do not
fully install shift rail at this time.
FIFTH-REVERSE GEAR AND SHIFT
COMPONENT INSTALLATION
(1) Install thrust ring lock ball in cluster gear jour-
nal (Fig. 97). Use petroleum jelly to hold ball in
place.
Fig. 93 Installing 3-4 Shift Rail Interlock Plug
Fig. 94 Installing 3-4 Shift Rail
Fig. 95 Installing Shift Fork Set Screws
Fig. 96 Installing Shift Rail C-Rings
Fig. 97 Installing Thrust Ring Lock Ball
JAX 15 MANUAL TRANSMISSION 21 - 59

(12) Align screw holes in shift fork and rail and in-
stall set screw (Fig. 108). Tighten screw to 20 Nzm
(15 ft. lbs.) torque.
(13) Install lock balls and springs in intermediate
plate (Fig. 109). Then install and tighten lock ball
plugs to 19 Nzm (14 ft. lbs.) torque.
(14) Install reverse shift arm bracket (Fig. 110).
Tighten bracket bolts to 18 Nzm (13 ft. lbs.) torque.(15) Install reverse shift arm (Fig. 110). Position
arm on reverse fork pin and engage it with pin on
shift arm bracket.
(16) Verify that shift arm shoe is engaged in re-
verse idler gear. Then secure shift arm to pin on re-
verse fork with new E-clip.
GEAR CASE AND ADAPTER INSTALLATION
(1) Dismount intermediate plate and gear assem-
blies from vise.
(2) Clean mating surfaces of intermediate plate
and transmission gear case with wax and grease re-
mover. Then wipe dry with a clean cloth.
(3) Apply 3 mm (1/8 in.) wide bead of Mopar Gas-
ket Maker, or Loctite 518 to mating surface of gear
case. Keep sealer bead inside bolt holes as shown
(Fig. 111).
Fig. 108 Shift Fork Set Screw Installation
Fig. 109 Detent Ball And Spring Installation
Fig. 110 Reverse Shift Arm And Bracket Installation
Fig. 111 Applying Sealer To Gear Case
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