Gear And Synchronizer; Check Output Shaft Runout; Check Gear–To–Race Clearance; Components - Jeep Wrangler 1997 Manual

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TRANSMISSION AND TRANSFER CASE

CLEANING AND INSPECTION (Continued)

Measure output shaft runout with a dial indicator (Fig.

120). Runout should not exceed 0.05 mm (0.002 in.).

Fig. 120 Check Output Shaft Runout

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

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. 121 Check Gear–To–Race Clearance

Fig. 122 Check Gear–To–Shaft Oil Clearance