Intermediate Case and Fifth Gear Installation
Intermediate Case and Fifth Gear InstallationInstall the alignment dowels (56) in the intermediate case.
Remount the transmission in the repair stand so the shift rail ends are facing upward.
Carefully move the fifth-reverse shift rail into fifth gear position.
CAUTION: Do not move the fifth-reverse shift rail beyond fifth gear position. The fifth-reverse detent ball will disengage if the rail is moved too far. It the ball disengages, the transmission will have to be completely disassembled in order to reinstall it.
Apply Jeep silicone sealer to the mounting surfaces of the front case and intermediate case.
Align and install the intermediate case (83) on the front case.
Install and tighten the intermediate case attaching bolts to 18 Nm (13 ft-lbs) torque.
Install the intermediate shaft (43) and fifthreverse synchronizer hub (44). Be sure the shaft is fully seated on the cluster gear.
Assemble the fifth gear shift fork (62) and synchronizer (45).
Start the the fifth-reverse fork (62) on the shift rail (63). Then slide the fork and synchronizer downward onto the intermediate shaft and synchronizer hub. Align the synchronizer and hub according to the reference marks made during disassembly.
Secure the shift fork (62) to the shift rail (63) with a roll pin (61). Use tool B.V.l. FM. O6to hold the fork in position while installing the roll pin.
Install the fifth intermediate gear (46) and needle bearing (47) on the intermediate shaft (43). Do not install the thrust washer, preload shim or bearing race at this time.
Install the fifth gear snap ring (4) on the mainshaft (20).
Press the roller bearing (2) onto the fifth gear (3).
Coat the bore of the fifth gear and the bearing rollers with transmission lubricant.
Install the assembled fifth gear (3) and roller bearing (2) on the mainshaft (20) with tool B.V.l. FM. 19.
Install the fifth gear lock ring (1) on the mainshaft (20). Be sure the lock ring is fully seated in the shaft groove.