1995 JEEP YJ manual transmission

Fig. 56 Selecting/Installing Fifth Gear Snap Ring
Fig. 57 Installing Input Shaft Bearing Rollers
Fig. 58 Installing Output Shaft In Intermediate Plate
JAX 4/5 MANUAL TRANSMISSION 21 - 21

(21) Install counter gear in intermediate plate (Fig.
59).
(22) Install rear bearing snap ring and install
bearing retainer (Fig. 60). Tighten retainer screws to
18 Nzm (13 ft. lbs.) torque.(23) Install reverse shift arm (Fig. 61). Tighten at-
taching bolt to 18 Nzm (13 ft. lbs.) torque.
(24) Install lock ball, spacer and needle bearing
(Fig. 62) on counter shaft.
(25) On AX 5, assemble counter fifth gear and syn-
chro components (Figs. 42 and 62).
Fig. 59 Counter Gear Installation
Fig. 60 Installing Bearing Retainer And Snap Ring
Fig. 61 Installing Reverse Shift Fork
Fig. 62 Counter Fifth Gear And Synchronizer
Assembly (AX 5)
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(26) On AX 5, install assembled gear and synchro-
nizer on counter shaft (Fig. 63).
(27) Install remaining synchronizer ring and spline
fifth gear (Fig. 64). Use length of pipe to tap gear
into place.
(28) Shift 1-2 and 3-4 synchronizer sleeves into
gear to lock output shaft and counter gear (Fig. 20).
(29) On AX 4, install oil slinger and lock nut on
counter gear (Fig. 42).
(30) On AX 5, install fifth gear snap ring (Fig. 65).
(31) Disengage 1-2 and 3-4 synchronizer sleeves.
(32) On AX 5, check counter fifth gear thrust clear-
ance (Fig. 66). Standard clearance is 0.10 - 0.30 mm
(0.004 - 0.010 in.). Adjust clearance with different
thickness snap ring if necessary.
Fig. 65 Checking Fifth Gear Thrust Clearance (AX 5)
Fig. 63 Fifth Gear And Synchronizer Installation (AX 5)
Fig. 64 Installing Fifth Gear (AX 5)
JAX 4/5 MANUAL TRANSMISSION 21 - 23

Fig. 66 Shift Components
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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

Fig. 70 Interlock Ball And Pin Position
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(6) Insert first interlock pin in intermediate plate
(Fig. 71). Use pencil magnet and screwdriver to in-
stall pin.
(7) Install smaller diameter interlock pin in No. 1
rail (Fig. 72).(8) Slide No. 1 rail through 1-2 shift fork (Fig. 73).
(9) Install largest interlock pin between Nos. 1 and
3 shift rails (Fig. 74).
Fig. 71 Installing First Interlock Pin
Fig. 72 Installing Interlock Pin In No. 1 Shift Rail
Fig. 73 Installing No. 1 Shift Rail
Fig. 74 Installing 1-3 Shift Rail Interlock Pin
JAX 4/5 MANUAL TRANSMISSION 21 - 27

(10) Install interlock pin in No. 3 shift rail (Fig.
75).
(11) Slide No. 3 rail into reverse shift head (Fig.
76).(12) Assemble reverse shift head and No. 5 shift
rail.
(13) Install No. 5 shift rail in intermediate plate
and engage shift head on No. 3 shift rail (Fig. 77).
(14) Install reverse shift head lock ball with screw-
driver and pencil magnet (Fig. 78).
Fig. 75 Installing No. 3 Shift Rail Interlock Pin
Fig. 76 Installing No. 3 Shift Rail
Fig. 77 Installing Reverse Shift Head
Fig. 78 Installing Reverse Shift Head Lock Ball
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