Jeep Cherokee 2000 Service Manual - page 1337
ASSEMBLY
(1) Install the reverse idler gear synchronizer ring
onto the reverse idler gear hub/race. Apply a film of
75W-90 GL-3 transmission oil to the contact surface
of the synchronizer ring prior to assembly.
(2) Install the reverse idler gear onto the reverse
idler gear hub/race. Apply a film of 75W-90 GL-3
transmission oil to the reverse idler gear bushing
prior to assembly. Verify that the teeth on the syn-
chronizer ring are properly engaged into the recesses
of the reverse idler gear.
(3) Install the plate washer over the reverse idler
gear hub/race and onto the reverse idler gear.
(4) Install the snap-ring to hold the reerse idler
gear onto the reverse idler hub/race.
CLEANING AND INSPECTION
AX5 MANUAL TRANSMISSION COMPONENTS
GENERAL INFORMATION
Clean the transmission components in solvent. Dry
the cases, gears, shift mechanism and shafts with
compressed air. Dry the bearings with clean, dry
shop towels only. Never use compressed air on the
bearings. This could cause severe damage to the
bearing roller and race surfaces.
If output shaft or inner race flange thickness is
within specification but any gear thrust clearance is
out of specification, replace the necessary gear and
gear needle bearing as an assembly.
GEAR CASE, ADAPTER/EXTENSION HOUSING,
INTERMEDIATE PLATE
Clean the case, housing, and intermediate plate
with solvent and dry with compressed air. Replace
the case if cracked, porous, or if any of the bearing
and gear bores are damaged.
Inspect the threads in the case, housing, and plate.
Minor thread damage can be repaired with steel
thread inserts, if necessary. Do not attempt to repair
any threads which show evidence of cracks around
the threaded hole.
OUTPUT SHAFT
Check thickness of the output shaft and inner
bearing race flanges with a micrometer or vernier
calipers (Fig. 119).
•
Minimum thickness for shaft flange is 4.80 mm
(0.189 in.)
•
Minimum thickness for first gear bearing inner
race flange is 3.99 mm (0.157 in.)
Measure diameter of the output shaft journal sur-
faces with a micrometer. Replace the shaft if either of
these surfaces are worn beyond specified limits.
•
Second
gear
surface
minimum
diameter
is
37.964 mm (1.495 in.)
•
Third gear surface minimum diameter is 34.984
mm (1.377 in.)
Measure diameter of the first gear bearing inner
race. Minimum diameter is 38.985 mm (1.535 in.).
Measure output shaft runout with a dial indicator
(Fig. 120). Runout should not exceed 0.05 mm (0.002
in.).
Replace output shaft or first gear inner bearing
race if measurement of any surface is out of specifi-
cation. Do not attempt to repair out of specification
components.
Fig. 117 Remove Reverse Idler Gear
1 – REVERSE SYNCHRONIZER RING
2 – REVERSE IDLER GEAR HUB
3 – REVERSE IDLER GEAR
Fig. 118 Remove Reverse Idler Gear Synchronizer
Ring
1 – REVERSE SYNCHRONIZER RING
2 – REVERSE IDLER GEAR HUB
XJ
AX5 MANUAL TRANSMISSION
21 - 37
DISASSEMBLY AND ASSEMBLY (Continued)