Jeep Wrangler 1997 Manual - page 976
(10) Verify third gear thrust clearance with feeler
gauge (Fig. 120). Clearance should be 0.10 – 0.30 mm
(0.003 – 0.0118 in.). If clearance is out of specifica-
tion, refer to Cleaning and Inspection section within
this group.
(11) Install second gear needle bearing onto output
shaft.
(12) Install second gear over bearing and onto out-
put shaft flange.
(13) Install second gear synchronizer ring onto sec-
ond gear.
(14) Position 1–2 synchronizer/reverse gear assem-
bly onto splines of output shaft.
(15) Using Driver MD-998805, Adapter 6761, and
a shop press, press the 1–2 synchronizer/reverse gear
onto the output shaft.
(16) Select the thickest snap-ring that will fit into
the snap-ring groove of the output shaft (Fig. 121).
(17) Install snap-ring to hold 1–2 synchronizer/re-
verse gear onto output shaft.
(18) Install first gear synchronizer ring into 1–2
synchronizer/reverse gear.
(19) Install the first gear spacer onto the input
shaft and against the 1–2 synchronizer/reverse gear
snap-ring.
(20) Install first gear needle bearing onto output
shaft (Fig. 122).
(21) Install first gear onto output shaft and over
bearing.
(22) Install the first gear thrust washer locating
pin into the output shaft.
(23) Install the first gear thrust washer onto the
output shaft. Rotate the thrust washer until the
washer locating pin aligns with the notch in the
washer.
(24) Position output shaft rear bearing onto output
shaft. Ensure that the snap ring groove in bearing
outer race is toward rear of output shaft.
(25) Using Driver L-4507 and suitable mallet,
drive bearing onto output shaft.
(26) Install snap-ring onto output shaft rear bear-
ing outer race.
(27) Check first and second gear thrust clearance
(Fig. 123). First gear clearance should be 0.10 – 0.40
mm (0.003 – 0.0197 in.). Second gear clearance
should be 0.10 – 0.30 mm (0.003 – 0.0118 in.). If
clearance is out of specification, refer to Cleaning and
Inspection section within this group.
Fig. 120 Check Third Gear Clearance
Fig. 121 Second Gear And Synchronizer Assembly
Fig. 122 First And Fifth Gear Components
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TRANSMISSION AND TRANSFER CASE
TJ
DISASSEMBLY AND ASSEMBLY (Continued)