Jeep Wrangler 1997, Manual

Page: 940 / 1152

Measure output shaft runout with a dial indicator (Fig.
120). Runout should not exceed 0.05 mm (0.002 in.).
Replace output shaft or first gear inner bearing
race if measurement of any surface is out of specifi-
cation. Do not attempt to repair out of specification
components.
COUNTERSHAFT
Inspect the countershaft gear teeth. Replace the
countershaft if any teeth are worn or damaged.
Inspect the bearing surfaces and replace shaft if any
surface shows damage or wear.
Check condition of the countershaft front bearing.
Replace the bearing if worn, noisy, or damaged.
GEAR AND SYNCHRONIZER
Install the needle bearing and inner race in the
first gear. Then check oil clearance between the gear
and inner race (Fig. 121). Clearance should be 0.009
– 0.032 mm (0.0004 – 0.0013 in.).
Install the needle bearings and the second, third
and counter fifth gears on the output shaft. Then
check oil clearance between the gears and shaft with
a dial indicator (Fig. 122). Oil clearance for all three
gears is 0.009 – 0.0013 mm (0.0004 – 0.0013 in.).
Check synchronizer ring wear (Fig. 123). Insert
each ring in matching gear. Measure clearance
between each ring and gear with feeler gauge.
Replace ring if clearance exceeds 2.0 mm (0.078 in.).
Check shift fork–to–synchronizer hub clearance
with a feeler gauge (Fig. 124). Replace the fork if
clearance exceeds 1.0 mm (0.039 in.).
(1) Inspect all mainshaft gear teeth. Replace any
gear which shows any worn or damaged teeth.
Fig. 120 Check Output Shaft Runout
Fig. 121 Check Gear–To–Race Clearance
Fig. 122 Check Gear–To–Shaft Oil Clearance
21 - 34 TRANSMISSION AND TRANSFER CASE
TJ
CLEANING AND INSPECTION (Continued)