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TJ
DISASSEMBLY AND ASSEMBLY (Continued)
(11) Install reverse shift head and rail assembly
into the intermediate plate.
(12) Install the fifth gear interlock ball and check
ball (Fig. 83).
Fig. 83 Install Fifth Gear Check Ball
(13) Install fifth gear shift rail (Fig. 84).
Fig. 84 Install Fifth Gear Shift Rail
(14) Remove the intermediate plate from the vise,
rotate the plate 180°, and reinstall the plate in the vise
using the same bolt and washer mounting set-up.
(15) Install the shift rail detent balls in the inter-
mediate plate.
(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. 85).
(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. 86).
(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
TRANSMISSION AND TRANSFER CASE
Fig. 85 Install 1–2 Shift Fork
Fig. 86 Install 3–4 Shift Fork
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.
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Troubleshooting
