Jeep Wrangler 1997 Manual - page 977
(28) Position fifth gear onto output shaft with the
gear’s long shoulder toward the rear of shaft. Ensure
that the gear and output shaft splines are aligned.
(29) Using Adapter 6761, Driver L-4507, and a
shop press, press fifth gear onto output shaft.
(30) Select the thickest snap-ring that will fit into
the snap-ring groove of the output shaft (Fig. 124).
(31) Install snap-ring to hold fifth gear onto output
shaft.
(32) Install output shaft pilot bearing into the
input shaft.
(33) Install the input shaft to the output shafts.
CLEANING AND INSPECTION
AX15 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 flange thickness is within specifica-
tion but any gear thrust clearance is out of specifica-
tion, 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 flange with a
micrometer or vernier calipers (Fig. 125). Minimum
allowable flange thickness is 4.70 mm (0.185 in.).
Check diameter of the first, second, and third gear
bearing surfaces on the output shaft. Minimum
diameters are as follows:
Fig. 123 Check First–Second Gear Thrust Clearance
Fig. 124 Select/Install Fifth Gear Snap Ring
Fig. 125 Check Output Shaft Tolerances
TJ
TRANSMISSION AND TRANSFER CASE
21 - 71
DISASSEMBLY AND ASSEMBLY (Continued)