Third-Fourth Synchronizer Assembly; Clutch Shaft Assembly; Mainshaft And Geartrain Assembly; Second Gear And Thrust Washer Installation - Jeep J-10 Series 1982 Technical & Service Manual

42606
Fig. 2B-72 Assembling First-Second Synchronizer
(d) Maintain pressure on ball and spring and
slide shifting plate downward in hub slot until ball is
held in position by clutch sleeve.
(6) Install remaining shift plates, poppet springs
and lock balls as described in previous step.
(7) Complete synchronizer assembly by pressing
down on hub and pulling up on sleeve.
Third-Fourth Synchronizer Assembly
(1) Align and assemble third-fourth clutch hub and
sleeve using reference marks made at disassembly.
(2) Insert shifting plates in hub slots.
(3) Install insert springs so one end of each spring is
hooked into same shifting plate (fig. 2B-73).
Clutch Shaft Assembly
(1) Lubricate mainshaft bearing rollers and clutch
shaft bore with generous quantity of petroleum jelly.
(2) Install 22 bearing rollers in clutch shaft bore.
Use additional petroleum jelly to help retain rollers in
bore if necessary.
(3) Coat blocking ring with petroleum jelly and in
stall ring on clutch shaft.
Mainshaft and Geartrain Assembly
(1) Install second gear from front of mainshaft (fig.
2B-74).
(2) Install second gear thrust washer so step bore in
washer faces front end of mainshaft.
(3) Install second gear snap ring. Be sure thrust
washer step bore fits over snap ring.
(4) Install second gear rear snap ring, blocking ring,
first-second synchronizer assembly and snap ring from
rear of mainshaft.
MANUAL TRANSMISSION ZB-39
SHIFT
PLATE
Fig. 2B-73 Third-Fourth Synchronizer Shifting Plate
and Retaining Ring Installation
60308
42608
Rg. 2B-74 Second Gear and Thrust Washer Installation
NOTE: The first-second synchronizer clutch sleeve
shift fork groove must face the rear of the mainshaft
(fig. 2B-75).
(5) Install third gear on mainshaft and install
blocking ring on gear.
(6) Install third-fourth synchronizer assembly on
mainshaft (fig. 2B-69).
NOTE: The third-fourth synchronizer must be in
stalled with the chamfered side of the hub facing the
front of the mainshaft (fig. 2B-76).
(7) Install third-fourth synchronizer retaining ring
(fig. 2B-69).
(8) Install mainshaft bearing roller spacer on shaft
pilot hub (fig. 2B-69).