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21 - 52
TRANSMISSION AND TRANSFER CASE
DISASSEMBLY AND ASSEMBLY (Continued)
(17) Install detent spring (Fig. 48).
(18) Install detent plug and tighten to 19 N·m (14
ft. lbs.) (Fig. 49).
Fig. 47 Install Detent Ball
Fig. 48 Install Detent Spring
Fig. 49 Install Detent Ball Plug
(19) Install shift tower and new gasket on housing
(Fig. 50). Tighten tower bolts to 18 N·m (13 ft. lbs.)
torque.
(20) Install new metal o-ring to the backup lamp
switch.
(21) Install backup lamp switch (Fig. 50). Tighten
switch to 37 N·m (27 ft. lbs.) torque.
Fig. 50 Installing Shift Tower And Backup Lamp
(22) Install new seal in adapter/extension housing.
(23) Install vehicle speed sensor, if necessary.
(24) Install clutch housing, release bearing, release
fork and retainer clip.
SHIFT MECHANISM AND GEARTRAIN
DISASSEMBLY
(1) Install suitable bolts and washers in intermedi-
ate plate (Fig. 51). Then clamp plate and gear assem-
bly in vise. Use enough washers to prevent bolts
from touching. Also be sure vise jaws are clamped on
bolt heads.
(2) Measure thrust clearance between countershaft
fifth gear and thrust ring with feeler gauge. Clear-
ance should be 0.10 to 0.40 mm (0.003 to 0.019 in.).
If clearance exceeds limits, gear and/or ring will have
to be replaced.
(3) Remove countershaft fifth gear retaining snap-
ring (Fig. 52).
(4) Remove bolt holding fifth gear shift fork to
shift rail (Fig. 53).
(5) Move fifth gear shift rail forward until the rail
is clear of the shift fork.
(6) Remove the fifth gear shift fork from the syn-
chronizer sleeve (Fig. 54).
(7) Remove the reverse shift head and rail assem-
bly from the intermediate plate (Fig. 55).
(8) Remove fifth gear blocker ring from counter-
shaft assembly with Puller L-4407 (Fig. 56).
(9) Remove fifth gear synchro ring (Fig. 57).
Switch
TJ
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