Jeep 1979 CJ-5 Technical & Service Manual page 373

2B-10
MANUAL TRANSMISSION
(27) Coat bearing bore of clutch shaft with petro-
leum jelly and install 15 roller bearings in clutch shaft
bore.
CAUTION: Do not use chassis grease or a similar
"heavy" grease in the clutch shaft bore. Use petroleum
jelly only. Heavy grease will plug the lubrication holes
in the shaft and prevent proper lubrication of the roller
bearings.
(28) Coat blocking ring surface of clutch shaft with
transmission lubricant and position blocking ring on
shaft.
(29) Support main shaft assembly and insert clutch
shaft through front bearing bore in case. Seat main
shaft pilot in clutch shaft roller bearings and tap bear-
ing into position in case using rawhide mallet.
(30) Apply thin film of sealer to front bearing cap
gasket and position gasket on case. Be sure gasket notch
is aligned with oil return hole in case.
(31) Remove front bearing cap oil seal using screw-
driver and install replacement oil seal using tool J-25233
(fig.2B-15).
Fig, 2B-1S Front Bearing Gap Oil Seal Installation-
(32) Install front bearing cap and tighten attaching
bolts to 33 foot-pounds (45 N®m) torque.
NOTE: Before installing the front bearing cap, be sure
to align the cap and case index marks. Also be sure the
cap oil return slot and case oil return hole are aligned.
(33) Make wire loop about 18 to 20 inches (45.7 to 50.8
cm) long and pass wire under countershaft gear assem-
bly. Wire loop will raise and support gear assembly
when loop is pulled upward.
(34) Raise countershaft gear with wire loop (fig. 2B-
16), align bore in countershaft gear with front thrust
washer and countershaft, and start countershaft into
gear using plastic hammer (fig. 2B-16).
(35) Align roll pin hole in countershaft and roll pin
holes in case (fig. 2B-16) and complete installation of
countershaft.
Fig. 2B-16 Countershaft Installation
(36) Install countershaft access plug in rear of case
and seat plug with plastic hammer.
(37) Install countershaft roll pin in case. Use magnet
or needlenose pliers to insert and start pin in case. Use
1/2 inch (12.7 mm) diameter punch to seat pin and
install fill plug.
(38) Shift synchronizer sleeves into all gear positions
and check operation. If clutch shaft and main shaft
appear to bind in Neutral position, check for blocking
rings sticking on first or second speed gear tapers.
(39) Shift both synchronizers into gear to prevent
gears from turning.
(40) Install transfer case drive gear and gear retain-
ing nut on mainshaft. Tighten nut to 150 foot-pounds
(203 N®m) torque.
(41) Shift synchronizers to neutral position.
(42) Attach transmission to transfer case. Tighten
attaching bolts to 30 foot-pounds (41 N»m) torque.