Synchronizer And Third Gear; Geartrain Components; Assembly - Jeep Wrangler 2001 Service Manual

21s - 30 MANUAL-AX5
OUTPUT SHAFT (Continued)
(11) With Bearing Splitter P-334 or press plates
positioned under third gear, press the 3-4 synchro-
nizer and third gear from output shaft (Fig. 92).
Fig. 92 3-4 Synchronizer And Third Gear
1 - 3-4 SYNCHRONIZER
2 - THIRD GEAR
(12) Remove third gear needle roller bearing from
output shaft or gear.

ASSEMBLY

NOTE: Lubricate the transmission components with
Mopar 75W-90 GL 3 gear lubricant during assembly.
Use petroleum jelly to lubricate seal lips and/or
hold parts in place during installation.
Refer to (Fig. 93) during assembly for AX5 gear
assembly identification.
(1) Lubricate transmission components with speci-
fied gear lubricant.
(2) If necessary, assemble 1-2 and 3-4 synchronizer
hubs, sleeves, springs and key inserts (Fig. 94).
(3) Install third gear needle bearing onto the out-
put shaft.
(4) Install third gear over bearing and onto output
shaft flange.
(5) Install third gear synchronizer ring to third
gear.
(6) Position the 3-4 synchronizer onto the output
shaft.
(7) Using Adapter 6747-1A and a shop press, press
the 3-4 synchronizer onto the output shaft.
(8) Select the thickest snap-ring that will fit into
the snap-ring groove of the output shaft (Fig. 95).
2001 JEEP WRANGLER
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
(9) Install snap-ring to hold 3-4 synchronizer onto
output shaft.
(10) Verify third gear thrust clearance with feeler
gauge (Fig. 96). Clearance should be 0.10 - 0.25 mm
(0.004 - 0.010 in.). If clearance is out of specification,
refer to Cleaning and Inspection.
(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
splines of output shaft.
(15) With Driver MD-998805, Adapter 6747-1A and
a shop press, press the 1-2 synchronizer onto the out-
put shaft.
(16) Install first gear synchronizer ring into 1-2
synchronizer.
(17) Install first gear bearing inner race lock ball
in output shaft (Fig. 97).
Fig. 93 Geartrain Components
1-2 synchronizer
TJ
assembly onto