Jeep J-10 Series 1982 Technical & Service Manual page 564

2B-24 MANUAL TRANSMISSION
• Bent or broken inserts.
• Weak or broken insert springs.
• Damaged roller thrust or needle bearings, or bearing
bores in countershaft gear or clutch shaft.
• Worn or galled countershaft and hub, clutch shaft or
reverse idler gear shaft.
• Worn thrust washers.
•Nicked, broken or worn output or clutch shaft
splines.
• Bent, distorted, or weak snap rings.
• Worn bushing in reverse idler gear.
• Rough, galled, or broken front or rear bearing.
• Worn shift fork inserts.
• Broken, cracked, or worn shift forks.
• Bent, worn, or galled shift rail.
•Worn, bent, or broken selector arms, plates, or
interlock.
• Worn, bent, broken or stripped offset lever or worn
lever insert.
TRANSMISSION ASSEMBLY
Assembly—Transmission Cover
(1) Install nylon inserts and selector arm plates in
shift forks (fig. 2B-28).
(2) Install shift rail plug. Coat edges of plug with
sealer before installing.
(3) Coat shift rail and shift rail bores with petro
leum jelly and insert shift rail in cover. Install rail until
end of rail is flush with inside edge of cover.
(4) Position first-second shift fork in cover with
fork offset facing rear of cover and push shift rail
through fork.
NOTE: The first-second shift fork is the larger of the
two forks.
(5) Position selector arm and C-shaped interlock
plate in cover and insert shift rail through arm. Widest
part of interlock plate must face away from cover, and
selector arm roll pin hole must face downward and to
ward rear of cover.
(6) Position third-fourth shift fork in cover with
fork offset facing rear of cover. Third-fourth shift fork
selector arm plate must be positioned under first-second
shift fork selector arm plate.
(7) Insert shift rail through third-fourth shift fork
and into front shift rail bore in cover.
(8) Rotate shift rail until selector arm plate at for
ward end of rail faces away from, but is parallel to
cover.
(9) Align roll pin holes in selector arm and shift rail
and install roll pin. Be sure roll pin is installed flush
with surface of selector arm to prevent pin from con
tacting selector arm plates during shifts.
(10) Install O-ring in groove of shift rail oil seal.
(11) Install shift rail oil seal as follows:
(a) Install Oil Seal Protector Tool J-26628-2 over
threaded end of shift rail (fig. 2B-29, View A).
(b) Lubricate lip of oil seal with petroleum jelly
and slide seal over protector and onto shift rail.
(c) Seat oil seal in transmission cover using Oil
Seal Installer Tool J-26628-1 (fig. 2B-29, View B).
Assembly—Output Shaft Geartrain
NOTE: If any output shaft gear is replaced, the
countershaft gear must also be replaced to maintain
proper gear mesh and avoid noisy operation.
(1) Coat output shaft and gear bores with transmis
sion lubricant.
(2) Install and align first-second synchronizer
sleeve on output shaft hub using reference marks made
at disassembly.
(3) Install three first-second synchronizer inserts
and two insert springs in first-reverse synchronizer
sleeve. Engage tang end of each insert spring in same
synchronizer insert but position open ends of springs to
face 180 degrees from one another (fig. 2B-30). Be sure
sleeve and hub are aligned using assembly reference
marks.
(4) Install blocking ring and second gear on
mainshaft.
(5) Install tabbed thrust washer and second gear
retaining snap ring on mainshaft (fig. 2B-22 and 23).Be
sure washer tab is properly seated in mainshaft notch.
(6) Install blocking ring and first gear on output
shaft.
(7) Install first gear roll pin in output shaft (fig. 2B-
31).
(8) Install first gear thrust washer.
(9) Install rear bearing on output shaft using Tool
J-2995 and press (fig. 2B-32).
(10) Install third gear, third and fourth gear syn
chronizer hub inserts and sleeve on shaft. Hub offset
must face forward.
(11) Install thrust bearing washer on forward end of
output shaft.
Assembly—Transmission Case
CAUTION: Except for the gearshift lever attaching
bolts and fill plug, all threaded holes and bolts used in
the Model To Transmission are metric sizes. Do not
attempt to substitute a different thread-type bolt if the
original ones are lost.
(1) Coat countershaft front bearing outer cage with
Loctite 601, or equivalent, and install countershaft front
bearing flush with case using arbor press (fig. 2B-33).
(2) Coat countershaft tabbed thrust washer with
petroleum jelly and install washer so tab engages corre
sponding depression in case.