3-Speed Transmission Disassembly (Model T-150); Transmission Installation - Jeep 1979 CJ-5 Technical & Service Manual

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MANUAL TRANSMISSION
TRANSMISSION INSTALLATION
(1) Install lubricating wick in pilot bushing.
(2) If removed, install wave washer on throwout
lever, position throwout bearing in lever, and center
bearing over clutch cover release levers.
CAUTION; Protect the transmission clutch shaft
splines and maintain throwout bearing alignment when
installing the transmission.
(3) Slide transmission-transfer case assembly into
position. Maneuver assembly as necessary to align
clutch shaft and driven plate splines.
(4) Install bolts attaching transmission to clutch
housing or transmission adapter.
(5) Attach rear crossmember to frame side sills.
(6) On eight-cylinder models, connect exhaust pipes
to manifolds.
(7) Connect speedometer cable, backup lamp switch
wires, and TCS switch, if equipped.
(8) Install front propeller shaft. Be sure to align
index marks made during removal.
(9) Connect rear propeller shaft to transfer case. Be
sure to align index marks made during removal.
(10) Lower vehicle.
(11) On models with T-18A transmission, install
transfer case shift lever.
(12) On models with T-18A or CJ models with T-150
transmission, install shift lever locating pins in housing
and install shift lever, spring, spring seat, gasket, if
equipped, and shift lever cap in housing. Tighten lever
cap securely.
(13) On Cherokee and Truck models with T-15A
transmission, place transmission gears in Neutral and
install shift control housing. Be sure shift forks are fully
seated in synchronizer sleeves.
(14) On Cherokee and Truck models with T-15A
transmission, align shift control housing, housing gas-
ket and transmission case bolt holes and install housing
attaching bolts and lockwashers. Tighten bolts to 12
foot-pounds (16 N»m) torque.
(15) Install transmission access cover and floor cov-
ering on floorpan.
(16) Install boot, trim rings and shift knob on shift
lever.
(17) Check transmission for proper shifting.
(18) Check and correct lubricant level if necessary.
P i p Page
Assembly 2B-7 Shift Control Housing 2B-11
Cleaning and Inspection 2B-7 Specifications 2B-12
Disassembly 2B-4
DISASSEMBLY- . - . \
:
(1) Remove bolts * attaching transfer case to
transmission.
(2) Separate transfer case and transmission.
(3) Remove shift control housing.
(4) Move second-third synchronizer sleeve forward
and first-reverse sleeve rearward to lock mainshaft.
(5) Remove transfer case drive gear locknut, flat
washer, and drive gear (fig. 2B-3).
(6) Move both synchronizer sleeves back to Neutral
position.
(7) Remove fill plug.
(8) Remove countershaft roll pin using 3/16 (4.7
mm) diameter pin punch. Roll pin is accessible through
fill plug hole (fig. 2B-4).
(9) Remove countershaft and access plug using Ar-
bor Tool J-25232 (fig. 2B-5). Remove countershaft from
rear of case. Allow countershaft gear to remain at bot-
tom of case after countershaft removal.
(10) Punch alignment marks in front bearing cap
and transmission case for assembly reference.
(11) Remove front bearing cap and gasket.
(12) Remove large lockring from front bearing.
(13) Remove clutch shaft and front bearing as as-
sembly using tool J-6654-01 (fig. 2B-6).
(14) Remove second-third synchronizer blocking ring
from clutch shaft or synchronizer hub.
(15) Remove rear bearing and adapter using brass
drift and hammer (fig. 2B-7).
(16) Remove main shaft and geartrain assembly. Tilt
spline end of shaft downward and lift forward end of
shaft upward and out of case.
(17) Remove countershaft gear and arbor tool as
assembly.
(18) Remove countershaft gear thrust washers,
countershaft roll pin, and any main shaft pilot roller
bearings which may have fallen into case during clutch
shaft removal.
(19) Remove reverse idler gear shaft. Insert brass
drift through clutch shaft bore in front of case and tap
shaft until end of shaft with roll pin clears counterbore
in rear of case (fig. 2B-8) and remove shaft.
(20) Remove reverse idler gear and thrust washers.