Low Lubricant Level; Hard Shifting; Transmission Noise; Transmission Removal - Jeep 200 Cherokee Service Manual

XJ
DESCRIPTION AND OPERATION (Continued)
Approximate dry fill lubricant capacity is:
• 3.3 liters (3.49 quarts) for 4–wheel drive applica-
tions.
• 3.5 liters (3.70 quarts) for 2–wheel drive applica-
tions.
Fig. 3 Fill Plug Location
1 – FILL PLUG LOCATION

DIAGNOSIS AND TESTING

LOW LUBRICANT LEVEL

A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill, or an incor-
rect lubricant level check.
Leaks can occur at the mating surfaces of the gear
case, intermediate plate and adaptor or extension
housing, or from the front/rear seals. A suspected
leak could also be the result of an overfill condition.
Leaks at the rear of the extension or adapter hous-
ing will be from the housing oil seals. Leaks at com-
ponent mating surfaces will probably be the result of
inadequate sealer, gaps in the sealer, incorrect bolt
tightening, or use of a non–recommended sealer.
A leak at the front of the transmission will be from
either the front bearing retainer or retainer seal.
Lubricant may be seen dripping from the clutch
housing after extended operation. If the leak is
severe, it may also contaminate the clutch disc caus-
ing the disc to slip, grab, and/or chatter.
A correct lubricant level check can only be made
when the vehicle is level. Also allow the lubricant to
settle for a minute or so before checking. These rec-
ommendations will ensure an accurate check and
avoid an underfill or overfill condition. Always check
the lubricant level after any addition of fluid to avoid
an incorrect lubricant level condition.
AX5 MANUAL TRANSMISSION

HARD SHIFTING

Hard shifting is usually caused by a low lubricant
level, improper, or contaminated lubricants. The con-
sequence of using non–recommended lubricants is
noise, excessive wear, internal bind, and hard shift-
ing. Substantial lubricant leaks can result in gear,
shift rail, synchro, and bearing damage. If a leak
goes undetected for an extended period, the first indi-
cations of component damage are usually hard shift-
ing and noise.
Component damage, incorrect clutch adjustment,
or a damaged clutch pressure plate or disc are addi-
tional probable causes of increased shift effort. Incor-
rect adjustment or a worn/damaged pressure plate or
disc can cause incorrect release. If the clutch problem
is advanced, gear clash during shifts can result.
Worn or damaged synchro rings can cause gear clash
when shifting into any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to
stick slightly causing hard or noisy shifts. In most
cases, this condition will decline as the rings wear–
in.

TRANSMISSION NOISE

Most manual transmissions make some noise dur-
ing normal operation. Rotating gears generate a mild
whine that is audible, but generally only at extreme
speeds.
Severe, highly audible transmission noise is gener-
ally the initial indicator of a lubricant problem.
Insufficient, improper, or contaminated lubricant will
promote rapid wear of gears, synchros, shift rails,
forks and bearings. The overheating caused by a
lubricant problem, can also lead to gear breakage.

REMOVAL AND INSTALLATION

TRANSMISSION
REMOVAL
(1) Shift transmission into first or third gear.
(2) Raise and support vehicle on suitable safety
stands.
(3) Support engine with adjustable jack stand.
Position wood block between jack and oil pan to
avoid damaging pan.
(4) Remove crossmember/skid plate.
(5) Disconnect necessary exhaust system compo-
nents.
(6) Remove skid plate, if equipped.
(7) Remove slave cylinder (Fig. 4) from clutch
housing.
(8) Mark rear propeller shaft and rear axle yokes
for installation alignment (Fig. 5).
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