First-Second Synchronizer Assembly; Reverse Idler Gear; Supporting First-Second Clutch Hub - Jeep J-10 Series 1982 Technical & Service Manual

2B-38 MANUAL TRANSMISSION
(8) Place first-second synchronizer assembly on
workbench and wrap cloth around clutch sleeve. Cloth is
necessary to prevent losing shift plate lock balls during
disassembly.
(9) Remove clutch sleeve from hub.
(10) Remove cloth from sleeve and remove lock balls,
insert spring and shift plates from hub.
CLEANING AND INSPECTION
Clean and inspect the transmission case and all com
ponents thoroughly. If any transmission gear requires
replacement, also replace the gear with which it meshes.
Use new gaskets, oil seals and snap rings during
assembly.
Inspect the transmission case for cracks, worn or
scored bearing bosses. Examine the ball bearings for
cracked races, excessive wear, looseness and for tight fit
in the case bores. Inspect all gear teeth for cracks, chips,
or spots where gear hardening has worn through. Main-
shaft gears must not bind on the shaft and should not
exhibit excessive play. Inspect the synchronizer blocking
rings for cracks, excessive wear, or pitting in the tapered
area of the ring. If thrust washer condition is doubtful,
replace them.
Check all bearing rollers for flat spots, pitting, cracks
or other damage. Replace rollers as required. Inspect the
countershaft and reverse idler shafts for pitting, wear,
scores, nicks, cracks and flat spots. Small nicks or scores
can be reduced using crocus cloth or a fine-tooth file.
Replace shafts if severely worn or damaged. Inspect the
mainshaft and synchronizer hubs and sleeves for dam
aged or worn splines, cracks, worn mainshaft pilot hub
and damaged mainshaft threads. Replace parts as re
quired. Check reverse shifting arm and pivot pin for
wear or other damage, and replace if necessary.
ASSEMBLY
NOTE: Prelubricate all components with petroleum
jelly during assembly.
Reverse Idler Gear
(1) Install snap ring in one end of reverse idler gear.
(2) Install thrust washer in gear bore against snap
ring.
(3) Insert sleeve in gear bore.
(4) Install 37 roller bearings in one end of gear and
install bearing spacer (fig. 2B-69).
(5) Install remaining 37 roller bearings in opposite
end of gear and install remaining thrust washer and
snap ring.
Countershaft Gear Assembly
(1) Install bearing spacer sleeve in gear and insert
arbor tool into gear and through sleeve.
(2) Slide one bearing spacer onto arbor tool and seat
spacer against sleeve.
(3) Insert 22 roller bearings into gear bore and seat
bearings against spacer just installed.
(4) Slide second bearing spacer onto arbor tool and
seat spacer against bearings.
(5) Install 22 more roller bearings in gear bore and
seat bearings against second spacer.
(6) Install third bearing spacer on arbor tool and
seat spacer against bearings.
(7) Repeat spacer/bearing installation procedure at
opposite end of gear.
First-Second Synchronizer Assembly
NOTE: The third-fourth clutch hub is used to help as
semble the first-second synchronizer assembly.
(1) Place third-fourth clutch hub on workbench.
(2) Install insert spring in first-second clutch hub
spring groove.
(3) Position first-second clutch hub on top of third-
fourth hub so lock ball holes in first-second hub are in
uppermost position (fig. 2B-71).
FIRST-SECOND
CLUTCH HUB
THIRD-FOURTH
CLUTCH HUB
42605
Fig. 2B-71 Supporting First-Second Clutch Hub
(4) Align scribe marks on first-second hub and
sleeve and install sleeve on hub (fig. 2B-72). Allow sleeve
to bottom against workbench.
(5) Install each shifting plate, poppet spring and
lock ball assembly one at a time as follows (fig. 2B-72):
(a) Install shifting plate in hub slot.
(b) Insert poppet spring through plate.
(c) Position lock ball on poppet spring, and
compress ball and spring (fig. 2B-72).
NOTE: To ease lock ball installation use 7/32-inch
socket and l/\-inch drive extension to press lock ball
into place.