Jeep Wrangler 1999 Electronic Service Manual page 806

TJ
CLEANING AND INSPECTION (Continued)
Inspect the threads in the case, housing, and plate.
Minor thread damage can be repaired with steel
thread inserts, if necessary. Do not attempt to repair
any threads which show evidence of cracks around
the threaded hole.
OUTPUT SHAFT
Check thickness of the output shaft flange with a
micrometer or vernier calipers (Fig. 125). Minimum
allowable flange thickness is 4.70 mm (0.185 in.).
Fig. 125 Check Output Shaft Tolerances
Check diameter of the first, second, and third gear
bearing surfaces on the output shaft. Minimum
diameters are as follows:
• 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
TRANSMISSION AND TRANSFER CASE
Fig. 126 Check Gear–To–Shaft Oil Clearance
between each ring and gear with feeler gauge. Clear-
ance should be 0.06 – 1.6 mm (0.024 – 0.063 in.).
Fig. 127 Check Synchronizer Ring Wear
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.).
Check the condition of the reverse idler gear bush-
ing (Fig. 129). Replace the gear if the bushing is
damaged or worn.
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