1995 JEEP XJ Service And Repair Manual

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Page 1569 of 2158

JEEP XJ 1995 Service And Repair Manual (2) Remove threaded plugs from intermediate plate. Then remove lock ball and spring from plug holes with pencil magnet (Fig. 8). (3) Remove shift fork pins with punch and hammer (Fig. 9). (4) Remove s

Page 1570 of 2158

JEEP XJ 1995 Service And 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 1571 of 2158

JEEP XJ 1995 Service And 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 1572 of 2158

JEEP XJ 1995 Service And 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 1573 of 2158

JEEP XJ 1995 Service And 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 1574 of 2158

JEEP XJ 1995 Service And 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 1575 of 2158

JEEP XJ 1995 Service And 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 1576 of 2158

JEEP XJ 1995 Service And 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
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