Jeep Wrangler 1997, Manual

Page: 978 / 1152

•
First gear bearing surface is 38.86 mm (1.529
in.).
•
Second gear bearing surface is 46.86 mm (1.844
in.).
•
Third gear bearing surface is 37.86 mm (1.490
in.).
Measure output shaft runout with a dial indicator
and V-blocks (Fig. 125). Runout should not exceed
0.06 mm (0.0024 in.).
Replace output shaft if measurement of any sur-
face is out of specification. 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 bearings in the first, second,
third and counter fifth gears. Install the gears on the
output shaft. Then check oil clearance between the
gears and shaft with a dial indicator (Fig. 126). Oil
clearance for all three gears is 0.16 mm (0.0063 in.)
maximum.
Check synchronizer ring wear (Fig. 127). Insert
each ring in matching gear. Measure clearance
between each ring and gear with feeler gauge. Clear-
ance should be 0.06 – 1.6 mm (0.024 – 0.063 in.).
Check shift fork–to–synchronizer hub clearance
with a feeler gauge (Fig. 128). Replace the fork if
clearance exceeds 1.0 mm (0.039 in.).
Fig. 126 Check Gear–To–Shaft Oil Clearance
Fig. 127 Check Synchronizer Ring Wear
Fig. 128 Check Fork–To–Hub Clearance
21 - 72 TRANSMISSION AND TRANSFER CASE
TJ
CLEANING AND INSPECTION (Continued)