Jeep Cherokee 2000, Service Manual

Page: 935 / 1528

(16) Install the shift rail detent springs in the
intermediate plate. Note that the bottom detent
spring is shorter than the others.
(17) Install the shift rail detent plugs in the inter-
mediate plate.
(18) Install the 1–2 shift fork onto the 1–2 and 3–4
shift rails (Fig. 84).
(19) Install the snap-ring onto the 1–2 shift rail.
(20) Install the 3–4 shift fork onto the 3–4 shift
rail (Fig. 85).
(21) Install mainshaft into the intermediate plate
by guiding the output shaft through opening in inter-
mediate plate until the shift forks are aligned with
the appropriate synchronizer sleeves. The mainshaft
rear bearing will be started in the intermediate plate
but not fully driven in at this point.
(22) While an assistant supports the mainshaft,
align rear of countershaft with inner race of counter-
shaft rear bearing.
(23) Raise countershaft upward until gears mesh
with the mating gears on the mainshaft.
(24) Using a suitable rubber mallet, tap on the
input shaft and the front of the countershaft equally
to install the mainshaft rear bearing into the inter-
mediate plate and the rear of the countershaft into
the rear countershaft bearing. It may be necessary to
occasionally hold the countershaft into the intermedi-
ate plate and tap the countershaft rear bearing onto
the countershaft and into the intermediate plate.
(25) Install snap-rings onto the rear mainshaft and
countershaft bearings.
(26) Install the bolts to hold the reverse shift arm
bracket to the intermediate plate.
(27) Install new bolts to hold the shift forks to the
shift rails (Fig. 86).
(28) Position the mainshaft rear bearing retainer
over the output shaft and onto the intermediate
plate.
(29) Install new bolts to hold the bearing retainer
to the intermediate plate.
(30) Move the reverse shift arm into the reverse
gear position. The reverse gear position is with the
arm moved away from the intermediate plate (Fig.
87).
(31) Install the reverse idler gear assembly into
position on the mainshaft and reverse shift arm.
Fig. 84 Install 1–2 Shift Fork
1 – 1–2 SHIFT FORK
2 – 3–4 SHIFT RAIL
3 – 1–2 SHIFT RAIL
Fig. 85 Install 3–4 Shift Fork
1 – 3–4 SHIFT FORK
2 – 3–4 SHIFT RAIL
3 – 1–2 SHIFT RAIL
4 – 1–2 SHIFT FORK
Fig. 86 Install Shift Fork Bolts
1 – 1–2 SHIFT FORK
2 – 3–4 SHIFT FORK
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AX5 MANUAL TRANSMISSION 21 - 27
DISASSEMBLY AND ASSEMBLY (Continued)