Geartrain Components; Synchronizer Identification; Select 3–4 Synchronizer Snap-Ring - Jeep 200 Cherokee Service Manual

21 - 34 AX5 MANUAL TRANSMISSION
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 107 Geartrain Components
1 – SNAP RING
2 – FIFTH GEAR
3 – COUNTER GEAR
4 – BEARING
5 – LOCK BALL
6 – SYNCHRO HUB/SLEEVE
7 – SNAP RING
8 – SPACER
9 – COUNTER 5TH GEAR
10 – SYNCHRO RING
11 – 5TH SPLINE GEAR
12 – SNAP RING
(8) Select the thickest snap-ring that will fit into
the snap-ring groove of the output shaft (Fig. 109).
(9) Install snap-ring to hold 3–4 synchronizer onto
output shaft.
(10) Verify third gear thrust clearance with feeler
gauge (Fig. 110). Clearance should be 0.10 – 0.25 mm
(0.004 – 0.010 in.). If clearance is out of specification,
refer to Cleaning and Inspection section within this
group.
(11) Install second gear needle bearing onto output
shaft.
(12) Install second gear over bearing and onto out-
put shaft flange.
(13) Install second gear synchronizer ring onto sec-
ond gear.
(14) Position 1–2
splines of output shaft.
(15) Using Driver MD-998805, Adapter 6747-1A,
and a shop press, press the 1–2 synchronizer onto
the output shaft.
synchronizer assembly
Fig. 108 Synchronizer Identification
1 – SLEEVES
2 – HUBS
I. D. Mark
C-1
D
D-1
E
E-1
F
F-1
Fig. 109 Select 3–4 Synchronizer Snap-ring
(16) Install first gear synchronizer ring into 1–2
synchronizer.
onto
(17) Install first gear bearing inner race lock ball
in output shaft (Fig. 111).
(18) Install first gear needle bearing onto output
shaft (Fig. 112).
Snap Ring Thickness mm (in.)
1.75-1.80 (0.0689-0.0709)
1.80-1.85 (0.0709-0.0728)
1.85-1.90 (0.0728-0.0748)
1.90-1.95 (0.0748-0.0768)
1.95-2.00 (0.0768-0.0787)
2.00-2.05 (0.0788-0.0807)
2.05-2.10 (0.0807-0.0827)
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