Clutch Shaft Disassembly; Transmission Cleaning And Inspection; Transmission Assembly (T-150) - Jeep 1979 CJ-5 Technical & Service Manual

MANUAL T 1 1 1 S 1 1 S S I 0 N
2B»7
(2) Remove insert springs from second-third syn-
chronizer, remove three inserts, and separate sleeve
from synchronizer hub (fig. 2B-3).
(3) Remove snap ring and tabbed thrust washer
from shaft and remove first gear and blocking ring.
(4) Remove first-reverse hub retaining snap ring.
N O T E : Observe the position of the inserts and spring
for assembly reference.
(5) Remove sleeve and gear, insert spring, and three
inserts from hub (fig. 2B-3).
(6) Remove oil slinger and spacer from rear of main
shaft.
(7) Remove hub from output shaft using arbor
press.
CAUTION: Do not attempt to hammer the press-fit
hub from the shaft. Hammer blows will damage the hub
and shaft.
Clutch Shaft Disassembly
(1) Remove front bearing retaining snap ring and
any remaining roller bearings.
(2) Press front bearing from shaft using arbor press
and tool J-6654-01.
CAUTION: Do not attempt to drive the bearing from
the shaft using a hammer. Hammer blows will damage
the bearing and shaft.
Rear Bearing and Adapter Disassembly
(1) Clamp rear bearing adapter in vise but do not
overtighten vise.
(2) Remove rear bearing retaining snap ring using
pointed-type tool.
(3) Remove bearing adapter from vise.
(4) Press bearing out of adapter using arbor press.
(5) Remove bearing adapter lockring.
CLEANINI AND INSPECTION
Cleaning
Thoroughly wash all parts in solvent and dry using
compressed air. However, do not dry the bearings with
compressed air. Air dry the bearings or wipe them dry
using a clean shop cloth only.
Clean the needle and clutch shaft roller bearing by
wrapping the bearings in a clean cloth and submerging
them in solvent. Or, place the bearings in a shallow
parts cleaning tray and cover them with solvent. Allow
the bearings to air dry on a clean cloth.
Inspection
Inspect the transmission components. Replace any
components that exhibit the following conditions:
Case
• Cracks in bores, sides, bosses, or at bolt holes.
• Stripped threads in bolt holes.
•Nicks, burrs, rough surfaces in shaft bores or on
gasket surfaces.
Gear and Synchronizer Assemblies
• Broken, chipped, or worn gear teeth.
• Damaged splines on synchronizer hubs or sleeves.
• Broken or worn teeth or excessive wear of blocking
rings
• Bent or broken inserts.
• Damaged needle bearings or bearing bores in
countershaft gear.
• Wear or galling of countershaft, clutch shaft, or
idler gear shafts.
® Worn thrust washers.
• Nicked, broken, or worn main shaft or clutch shaft
splines.
• Bent, distorted, broken, or weak snap rings.
• Worn bushings in reverse idler gear. Replace gear if
bushings are worn. Bushings are supplied as part of
gear,only;
• Rough, galled, worn, or broken front or rear bearing.
ASSEMBLY
(1) Lubricate reverse idler gear shaft bore and
bushings with transmission lubricant.
(2) Coat transmission case reverse idler gear thrust
washer surfaces with petroleum jelly and install thrust
washers in case.
N O T E : Be sure to engage the locating tabs on the
thrust washers in the locating slots in the case.
(3) Install reverse idler gear. Align gear bore,
thrust washers, case bores, and install reverse idler gear
shaft from rear of case. Be sure to align and seat roll pin
in shaft into counterbore in rear of case (fig. 2B-8).
(4) Measure reverse idler gear end play by inserting
feeler gauge between thrust washer and gear. End play
should be 0.004 to 0.018 inch (0.10 to 0.45 mm). If end
play exceeds 0.018 inch (0.45 mm), remove idler gear and
replace thrust washers.
(5) Coat needle bearings and bearing bores in
countershaft gear with petroleum jelly. Insert Arbor
Tool J-25232 in bore of gear and install 25 needle bear-
ings and one retainer in each end of gear (fig. 2B-3).
(6) Coat countershaft gear thrust washer surfaces
with petroleum jelly and position thrust washers in
case. .
N O T E : Be sure to engage the locating tabs on the
thrust washers in the locating slots in the case.
(7) Insert countershaft into rear case bore just far
enough to hold rear thrust washer in position. This will
prevent thrust washer from being displaced when
countershaft gear is installed.