1995 JEEP XJ engine

(2) Remove fitting from pump housing (Fig. 10).
Prevent flow control valve and spring from
sliding out of housing bore.
(3) Remove and discard O-ring seal.
INSTALLATION
(1) If necessary, clean and install flow control valve
and spring in pump housing bore.Be sure the hex
nut end of the valve is facing in toward pump.
(2) Install O-ring seal onto fitting (Fig. 10).
(3) Install flow control valve in pump housing and
tighten to 75 Nzm (55 ft. lbs.) torque.
(4) Install pressure hose to valve.
POWER STEERING PUMPÐINITIAL OPERATION
CAUTION: The fluid level should be checked with
engine off to prevent injury from moving compo-
nents. Use only Mopar Power Steering Fluid. Do not
use automatic transmission fluid. Do not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicate FULL COLD when the
fluid is at normal temperature 21ÉC to 27ÉC (70ÉF to
80ÉF).
(1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(2) Start the engine and let run for a few seconds.
Then turn the engine off.
(3) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine.
(4) Raise the front wheels off the ground.
(5) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
stops.
(6) Add power steering fluid if necessary.
(7) Lower the vehicle and turn the steering wheel
slowly from lock to lock.
(8) Stop the engine. Check the fluid level and refill
as required.
(9) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
Fig. 10 Flow Control Valve Fitting
JSTEERING 19 - 15

PITMAN SHAFT SEALSÐIN CAR REPLACEMENT
REMOVAL
(1) Remove pitman arm from gear. Refer to Pitman
Arm Removal in Steering Linkage.
(2) Clean exposed end of pitman shaft and hous-
ing. Use a wire brush to clean the shaft splines.
(3) Remove retaining ring with snap ring pliers
(Fig. 2).
CAUTION: Use care not to score the housing bore
when prying out seals and washers.
(4) Remove backup washer and double lip seal
with screwdriver.
²Start the engine and turn the steering wheel fully
to the LEFT to force out the seals and washers.
²Stop the engine
(5) Remove backup washer and single lip seal with
screwdriver.
(6) Inspect the housing for burrs and remove if
necessary. Inspect the pitman shaft seal surface for
roughness and pitting. If pitted replace shaft.
INSTALLATION
(1) Install single lip seal with Installer or a suit-
able size deep socket (Fig. 3).
(2) Coat the double lip seal and washer with
grease.
(3) Install the backup washer.
(4) Install the double lip seal.
(5) Install the backup washer.
(6) Install the retainer ring with snap ring pliers.
(7) Center the steering gear.
(8) Install the pitman arm. Refer to Pitman Arm
Installation in Steering Linkage.(9) Add power steering fluid. Refer to Power Steer-
ing Initial Operation.
INTERMEDIATEÐCOUPLING SHAFT
REMOVAL
(1) Place the front wheels in the straight ahead po-
sition.
(2) Remove the shaft pinch bolt at the steering
gear and column (Fig. 4, 5). Unbolt steering gear
from frame rail to remove shaft. Refer to Steering
Gear Replacement in this section.
INSTALLATION
(1) Align the intermediate (coupler) shaft to the
steering gear and column.
(2) Position the steering gear on the frame. Refer
to Steering Gear Replacement in this section.
(3) Install and tighten the pinch bolts to 34 Nzm
(25 ft. lbs.) torque.
STEERING GEAR REPLACEMENT
REMOVAL
(1) Place the front wheels in the straight ahead po-
sition with the steering wheel centered.
(2) Disconnect and cap the fluid hoses from steer-
ing gear. Refer to Pressure and Return Hose Replace-
ment in this Group.
(3) Remove the column coupler shaft from the gear.
Refer to the removal procedures in this section.
(4) Remove pitman arm from gear. Refer to Pitman
Arm Removal in the Steering Linkage section.
Fig. 2 Pitman Shaft Seals
Fig. 3 Pitman Shaft Seal Installation
JSTEERING 19 - 23

STEERING RHD
GENERAL SERVICE PROCEDURE INFORMATION
Right hand drive service procedures and torque
specifications involving steering; linkage, gear and
column are the same as left hand drive vehicles ex-
cept where shown. Refer to appropriate service pro-
cedures regarding each component in the system.
The steering linkage consists of a pitman arm, drag
link, and tie rod. Adjustment sleeves are used on the
tie rod and drag link for toe and steering wheel
alignment (Fig. 1).
RECIRCULATING-BALL POWER STEERING GEARS
The steering gears can be adjusted and internally
serviced. The components CANNOT be interchanged
with those of a left hand drive vehicle.
The steering gear has a 17.5:1 ratio.
POWER STEERING PUMP
PRESSURE AND RETURN LINE
REPLACEMENT
Cap hose open ends and pump/steering gear fit-
tings to prevent entry of foreign material.
WARNING: POWER STEERING FLUID (AND PUMP
COMPONENTS) AND THE EXHAUST SYSTEM CAN
BE EXTREMELY HOT IF THE ENGINE HAS BEEN
RECENTLY OPERATING. DO NOT START THE EN-
GINE WITH ANY LOOSE OR DISCONNECTED
HOSES. DO NOT ALLOW THE LINES TO TOUCH A
HOT EXHAUST MANIFOLD.REMOVAL
(1) Place a drain pan under the pump and gear.
(2) Disconnect the pressure and return line from
the steering gear (Fig. 2, 3).
(3) Disconnect the pressure and return line from
the pump (Fig. 4). Drain the fluid from pump and
reservoir.
Fig. 1 RHD Steering Linkage
Fig. 2 Fluid Lines On Steering Gear
19 - 74 STEERINGJ

(4) Tighten fittings at pump and gear to 28 Nzm
(21 ft. lbs.) torque.
(5) After installation, add power steering fluid, in-
spect and test for fluid leaks.
PUMP REPLACEMENT
REMOVAL
(1) Remove and cap pressure and return lines from
pump. Refer to Pressure and Return Line Replace-
ment in this section.(2) Remove belt tension, turn tensioner clock-wise
and slip belt off pulley (Fig. 6).
(3) Remove the screws retaining front bracket and
pump to the rear bracket (Fig. 7, 8).
(4) Remove screws that attach the front bracket to
the rear bracket (Fig. 9).
(5) Remove pump from bracket.
To remove the rear bracket from engine, the air
conditioning compressor and bracket must be re-
moved first. Refer to Group 24, Heating and Air Con-
ditioning for removal procedures.
(6) Remove fan from pulley and hub on rear
bracket.
(7) Remove 4 screws attaching the rear bracket to
block (Fig. 10, 11).
(8) Remove bracket from engine.
Fig. 6 Belt Tensioner
Fig. 7 Pump Mounting Screw Removal/Installation
Fig. 8 Power Steering Pump Mounting
Fig. 9 Front Bracket
19 - 76 STEERINGJ

INSTALLATION
(1) Install the rear bracket to engine. Install
screws finger tight.
(2) Tighten front screws to 48 Nzm (35 ft. lbs.)
torque. Tighten side screw to 48 Nzm (35 ft. lbs.)
torque. It is important to torque the front screws
FIRST and the side screw LAST. This will prevent
the bracket from twisting or distorting.
(3) Install fan to pulley and hub. Tighten the nuts
to 27 Nzm (20 ft. lbs.) torque.
(4) Install air conditioning bracket and compressor
to engine. Refer to Group 24, Heating and Air Condi-
tioning for installation procedures.(5) Loose assemble screws through front bracket,
pump and into rear bracket.
(6) Install screws that attach the front bracket to
the rear bracket (Fig. 8). Tighten the screws to 27
Nzm (20 ft. lbs.) torque (Fig. 7).
(7) Install belt, turn tensioner clockwise and slip
belt onto pulley (Fig. 6).
(8) Install pressure and return lines to pump. Re-
fer to Pressure and Return Line Replacement in this
section.
(9) After installation, add power steering fluid, in-
spect and test for fluid leaks. Refer to Power Steering
PumpÐInitial Operation.
Fig. 11 Rear Bracket (Side View)Fig. 10 Rear Bracket (Front View)
JSTEERING 19 - 77

TRANSMISSION AND TRANSFER CASE
CONTENTS
page page
30RH/32RH AUTOMATIC TRANSMISSION.... 67
AW 4 AUTOMATIC TRANSMISSION........ 165
AX 15 MANUAL TRANSMISSION........... 33
AX 4/5 MANUAL TRANSMISSION............ 1NP231 TRANSFER CASE................. 283
NP242 TRANSFER CASE................. 306
TRANSMISSION/TRANSFER CASE
SPECIFICATIONS..................... 333
AX 4/5 MANUAL TRANSMISSION
INDEX
page page
Cleaning and Inspection.................... 13
Gear Ratios.............................. 2
General Information........................ 1
Recommended Lubricant.................... 2
Service Diagnosis.......................... 2
Shift Pattern.............................. 2Transmission Assembly and Adjustment......... 16
Transmission Disassembly and Overhaul......... 5
Transmission Identification................... 2
Transmission Installation..................... 5
Transmission Removal...................... 3
GENERAL INFORMATION
The AX 4 is a four speed manual transmission. The
AX 5 is a five speed manual transmission. Fifth gear
in the AX 5 is an overdrive range. The shift mecha-
nism in both models is integral and mounted in theshift tower portion of the adapter housing (Fig. 1).
The AX 4/5 is used for 2.5L engine applications.
Fig. 1 AX 4/5 Manual Transmission
JTRANSMISSION AND TRANSFER CASE 21 - 1

happens when the container delivery mechanism is im-
properly calibrated. Always check the lubricant level af-
ter filling to avoid an under fill condition.
A correct lubricant level check can only be made
when the vehicle is level; use a drive-on hoist to en-
sure this. Also allow the lubricant to settle for a
minute or so before checking. These recommenda-
tions will ensure an accurate check and avoid an un-
der-or-overfill condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants, compo-
nent damage, incorrect clutch adjustment, or by a
damaged clutch pressure plate or disc.
Substantial lubricant leaks can result in gear, shift
rail, synchro and bearing damage. If a leak goes un-
detected for an extended period, the first indications
of a problem are usually hard shifting and noise.
Incorrect or contaminated lubricants can also con-
tribute to hard shifting. The consequence of using
non-recommended lubricants is noise, excessive wear,
internal bind and hard shifting.
Improper clutch release is a frequent cause of hard
shifting. Incorrect adjustment or a worn, damaged
pressure plate or disc can cause incorrect release. If
the clutch problem is advanced, gear clash during
shifts can result.
Worn or damaged synchro rings can cause gear clash
when shifting into any forward gear. In some new or re-
built transmissions, new synchro rings may tend to
stick slightly causing hard or noisy shifts. In most
cases, this condition will decline as the rings wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears generate a mild
whine that is audible but only at extreme speeds.
Severe, highly audible transmission noise is gener-
ally the result of a lubricant problem. Insufficient,
improper, or contaminated lubricant will promote
rapid wear of gears, synchros, shift rails, forks and
bearings. The overheating caused by a lubricant
problem, can also lead to gear breakage.
TRANSMISSION REMOVAL
(1) Shift transmission into first or third gear. Then
raise vehicle on hoist.
(2) Support engine with adjustable jack stand. Po-
sition wood block between jack and oil pan to avoid
damaging pan.
(3) Disconnect necessary exhaust system components.
(4) Remove skid plate.
(5) Disconnect rear cushion and bracket from
transmission (Fig. 5).
(6) Remove rear crossmember.
Fig. 5 Rear Mount Components (YJ Shown)
JAX 4/5 MANUAL TRANSMISSION 21 - 3

(7) Disconnect transfer case shift linkage at trans-
fer case.
(8) Disconnect vehicle speed sensor wires and
transfer case vent hose.
(9) Remove slave cylinder from clutch housing.
(10) Disconnect transmission shift lever as follows:
(a) Lower transmission-transfer case assembly
approximately 7-8 cm (3 in.) for access to shift le-
ver.
(b) Reach up and around transmission case and
unseat shift lever dust boot from transmission shift
tower (Fig. 6). Move boot upward on shift lever for
access to retainer that secures lever in shift tower.
(c) Reach up and around transmission case and
press shift lever retainer downward with your fin-
gers. Turn retainer counterclockwise to release it.
(d) Lift lever and retainer out of shift tower (Fig.
6).Do not remove the shift lever from the
floorpan boots. Leave the lever in place for
later transmission installation.
(11) Mark front and rear propeller shafts for in-
stallation alignment (Fig. 7). Then remove both
shafts.
(12) Remove crankshaft position position sensor
(Figs. 8, 9).
CAUTION: It is important that the crankshaft posi-
tion sensor be removed prior to transmission re-
moval. The sensor can easily be damaged if left in
place during removal operations.
(13) Unclip wire harnesses from transmission and
transfer case.
(14) Remove slave cylinder from clutch housing.
(15) Support transmission with transmission jack.
(16) Remove nuts attaching transfer case to trans-
mission and remove transfer case.
(17) Secure transmission to jack with safety
chains.
(18) Remove clutch housing brace rod.(19) Remove clutch housing-to-engine bolts.
(20) Pull transmission jack rearward until input
shaft clears clutch. Then slide transmission out from
under vehicle.
Fig. 6 Removing/Installing Shift Lever
Fig. 7 Marking Propeller Shaft And Axle Yokes
Fig. 8 Crankshaft Position Sensor (2.5L)
Fig. 9 Crankshaft Position Sensor (4.0L)
21 - 4 AX 4/5 MANUAL TRANSMISSIONJ