Transmission Assembly (T-18A) - Jeep 1979 CJ-5 Technical & Service Manual

MANUAL TRANSMISSION 2B-23
ASSEMBLY
NOTE; Prefabricate all components with petroleum
jelly during assembly.
Reverse Idler Gear
(1) Install snap ring in one end of reverse idler gear.
(2) Install thrust washer in gear bore against snap
ring.
(3) Insert sleeve in gear bore.
(4) Install 37 roller bearings in one end of gear and
install bearing spacer (fig. 2B-35).
(5) Install remaining 37 roller bearings in opposite
end of gear and install remaining thrust washer and
snap ring.
Countershaft Gear Assembly
(1) Install bearing spacer sleeve in gear and insert
arbor tool into gear and through sleeve.
(2) Slide one bearing spacer onto arbor tool and seat
spacer against sleeve.
(3) Insert 22 roller bearings into gear bore and seat
bearings against spacer just installed.
(4) Slide second bearing spacer onto arbor tool and
seat spacer against bearings.
(5) Install 22 more roller bearings in gear bore and
seat bearings against second spacer.
(6) Install third bearing spacer on arbor tool and
seat spacer against bearings.
(7) Repeat spacer/bearing installation procedure at
opposite end of gear.
First-Second Synchronizer Assembly
N O T E : The third-fourth clutch hub is used to help as-
semble the first-second synchronizer assembly.
(1) Place third-fourth clutch hub on work bench.
(2) Install insert spring in first-second clutch hub
spring groove.
4 2 6 0 5
Fig. 21-37 Supporting First-Second Clutch Hub
(3) Position first-second clutch hub on top of third-
fourth hub so lock ball holes in first-second hub are in
uppermost position (fig. 2B-37).
(4) Align scribe marks on first-second hub and
sleeve and install sleeve on hub (fig. 2B-38). Allow sleeve
to bottom against work bench.
(5) Install each shifting plate, poppet spring, and
lock ball assembly one at a time as follows (fig. 2B-38):
(a) Install shifting plate in hub slot.
(b) Insert poppet spring through plate.
(c) Position lock ball on poppet spring, and
compress ball and spring (fig. 2B-38).
(d) Maintain pressure on ball and spring and
slide shifting plate downward in hub slot until ball is
held in position by clutch sleeve.
(6) Install remaining shift plates, poppet springs
and lock balls as described in previous step.
(7) Complete synchronizer assembly by pressing
down on hub and pulling up on sleeve.
4 2 6 0 6
Fig. ZB-38 Assembling First-Second Synchronizer
Third-Fourth Synchronizer Assembly
(1) Align and assemble third-fourth clutch hub and
sleeve using reference marks made at disassembly.
(2) Insert shifting plates in hub slots.
(3) Install insert springs so one end of each spring is
hooked into same shifting plate (fig. 2B-39).
Clutch Shaft Assembly
(1) Lubricate mainshaft bearing rollers and clutch
shaft bore with generous quantity of petroleum jelly.
(2) Install 22 bearing rollers in clutch shaft bore.
Use additional petroleum jelly to help retain rollers in
bore if necessary.
(3) Coat blocking ring with petroleum jelly and in-
stall ring on clutch shaft.