1995 JEEP YJ transmission

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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(15) Shift fifth gear synchronizer sleeve rearward
to lock it (Fig. 79).
(16) On AX 5, install fifth-reverse shift fork in syn-
chronizer sleeve. Then slide No. 4 shift rail into fork
(Fig. 80).(17) Install shift rail lock ball with pencil magnet
and screwdriver (Fig. 81).
(18) Check interlock operation as follows: Move No.
1 shift rail rearward to first gear position. Interlock
operation is OK if remaining shift rails did not move.
(19) Install new shift fork pins (Fig. 82).
Fig. 79 Locking Fifth Synchronizer
Fig. 80 Fifth-Reverse Shift Fork Installation
Fig. 81 Lock Ball Installation
Fig. 82 Installing Shift Fork Pins
JAX 4/5 MANUAL TRANSMISSION 21 - 29

(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
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