Jeep 200 Cherokee, Service Manual

Page: 1512 / 2119

(14) Separate front housing from rear housing
(Fig. 23). Use plastic mallet to tap front housing off
alignment dowels.
(15) Remove and inspect input shaft bearing.
Inspect countershaft front bearing race (Fig. 24).
(16) Note position of input shaft, shift shaft and
forks, and geartrain components in housing (Fig. 25).
SHIFT SHAFT, SHIFT FORKS AND REVERSE IDLER SEGMENT
(1) Unseat the roll pin that secures the shift
socket tot he shift shaft with Special Tool 6858 as fol-
lows:
(a) Position Tool 6858 on the shift shaft. Center
the tool over the roll pin and verify that the tool
legs are firmly seated on the shift socket (Fig. 26).
(b) Tilt the socket toward the side of the case.
This positions the roll pin at a slight angle to avoid
trapping the pin between the gear teeth.
(c) Tighten the tool punch to press the roll pin
downward and out of the shift socket (Fig. 26). The
roll pin does not have to be completely removed
from the shift socket. The roll pin must only be
clear of the shift shaft. Be careful not to push the
pin into the geartrain.
(2) Using a hammer and suitable punch, drive out
roll pin that secures shift bushing and lever to shift
shaft (Fig. 27).
NOTE: Be sure to use the proper size punch to
avoid bending the shift shaft.
Fig. 23 Front Housing Removal
1 – FRONT HOUSING
2 – REAR HOUSING
3 – DOWELS (2)
4 – PLASTIC MALLET
Fig. 24 Input Shaft Bearing and Countershaft Front
Bearing Race Location
1 – INPUT SHAFT BEARING
2 – FRONT HOUSING
3 – COUNTERSHAFT FRONT BEARING
Fig. 25 Geartrain And Shift Component
Identification
1 – SHIFT SHAFT
2 – BUSHING
3 – REAR HOUSING
4 – REVERSE IDLER AND SUPPORT
5 – OUTPUT SHAFT AND GEARS
6 – COUNTERSHAFT
7 – 1–2 FORK
8 – INPUT SHAFT
9 – 3–4 FORK
XJ
NV3550 MANUAL TRANSMISSION 21 - 51
DISASSEMBLY AND ASSEMBLY (Continued)