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K
TRANSMISSION- TRANSFER CASE
nuts
and washers
from
the control
levers
and
re-
move
levers. Push
the
shafts into
the case to
re-
move them and then
remove the sleeve,
poppet
ball
and
spring.
Check the
oil seals carefully
for
oil
leakage
and
replace
if
necessary. If it is
evident
that a minimum
clearance
of .001" to .007"
can-
not
be obtained between the end of
the
interlock
sleeve
and shift
levers,
even though the longest
sleeve
has been installed, remove
the original
interlock
pin from
the
shift lever
poppet
spring.
Replace
the
original interlock pin
with a transfer
case
intermediate gear needle bearing
roller,
Part
No.
809294, which
has been
ground to a
length of
.
780"
[19,8 mm.]. The installation of
this modified
roller
should
ensure
positive
engagement of the
ball at each end of
the interlock
sleeve
in
the
respective
detents of
the shifting levers as
the
transmission
is shifted
through
the
gear
pattern.
Assemble
the transmission to where
shift
action
can be
checked. If it is
apparent that the
im-
provised
pin
·
is
too long
and
is
causing a
bind
when shifting
is attempted, reduce
its length a
little
at
a
time
from the
.
780"
dimension until a
smooth shift action with a
positive
ball and
detent
engagement
is
obtained.
Install
this improvised
pin
only
when the longest
interlock sleeve
does
not
provide the
desired minimum clearance.
Reassemble in
reverse order. When
assembling the
interlock sleeve
be
sure
that
the
shift lever
poppet
spring
works freely
inside
the
interlock
and
that
the
interlock pin, or
the
modified roller substituted
for
the
pin,
is not
omitted
from inside
the
spring.
If
the notched
surfaces of
the
shifting levers are
dirty
or
rough
they
should be
thoroughly
cleaned
and smoothed. If notched
surfaces
are
scored or
damaged, the lever
or
levers
should be
replaced.
Note:
Each time an interlock sleeve or shift lever
is replaced,
check
the
clearance
between the
interlock sleeve
and
the shift
lever.
To reassemble
the transmission
proceed
as
follows:
a. Position
the
reverse idler
gear
in
the
case
and
install
the
shaft using care that the slot
at the shaft
end
is
correctly aligned to
receive the lock
plate.
b. To assemble
the countershaft
gear, it
is neces-
sary
to use Tool W-166, Fig.
187
.
Place the
mandril
through the gear set
and insert
the
long
spacer
positioning it
at
the center of
the
gear set. Place
a
set of twenty
rollers
at each end of
the spacer fol
·
lowed by
a
spacing
washer
at
each
end.
A small
amount of grease will
hold
the
spacing washer
in
position.
Place
the assembled
countershaft
gear
set
in
the bottom of the
case
with the large
gear
toward
the front.
c
.
Install
the
rear main shaft bearing on
the
main
shaft
with
the closed side of
the
bearing toward
the front
or low end of
the
shaft.
Replace
the
bear-
ing snap ring
and
main shaft snap
ring.
d.
Pass the front end of
the
main shaft through
the rear bearing opening and
assemble
the low and
reverse sliding gear on the shaft
with
the shifting
fork groove
toward
the rear.
e.
Assemble
the
second speed
gear
on the
shaft
with
the
teeth
which
engage in the clutch sleeve
toward
the front of the
case.
172
f.
Next, assemble the synchronizer unit. The as-
sembly sequence of
the synchronizer
is
shown
in
Fig. 189. First install
the two springs
in the high
and intermediate
clutch hub.
These springs
must
be
installed
with
the spring tension opposed
.
Place
the right lipped end
of a spring
in
a
slot of
the
hub
and place
the spring
in
the hub. Turn
the
hub
around and
make
exactly
the same installation
with the other
spring starting with the same
slot.
Fig.
191. Install the
three
synchronized shifting
plates in
the three
slots in
the
hub
with the
smooth
side
of the
plates
out.
Hold the plates in position
and
slip
the
second
and
direct speed clutch sleeve
over the
hub. Install
the
two blocking rings
one
one each
side of the hub.
g.
Install the
shifting
fork and
shoe.
h.
Place some heavy
grease
in
the
main shaft
pilot
and
position the thirteen needle
type
roller
bearings.
i.
Install the main drive
gear.
If the bearing has
been
removed, note
that
the closed side is
assembled
toward
the
inside of the case.
j
. Enter the main shaft bearing in
the
case
and
assemble the shaft in position.
k.
Install the front bearing retainer.
I. Turn
the transmission case over to allow
the
gears
to mesh
and
start the countershaft
through
the case at
the rear
with
the lock plate slot toward
the
rear and in alignment
with the slot
in the idler
gear
shaft.
m
.
Place
the two
rear
thrust
washers
over
the
end
of the shaft and align
the
countershaft gears
with
the shaft. Press the shaft through
the gears
placing the
front thrust
washer
in
position with the
tongue
of
the washer
in
the
slot in the
case.
n.
Install
the lock
plate.
Tap both shafts forward
to put a
bind
on
the plate to hold it in position.
o.
Install
rear
bearing snap ring
and
rear main-
shaft bearing
on
shaft.
p.
Attach rear
bearing
retainer
and gasket
to
the
transmission
case.
Tighten
cap
screws
evenly and
securely.
q.
Install
speedometer drive
gear
on shaft with
the shoulder
of
gear
toward the
front.
Check
the
oil
seal
which
is installed next and replace
with
new one if necessary.
r.
Install
the
companion
coupling
flange with
the
flat washer, lock
washer and
nut.
s. Check
the complete
transmission for operation.
t.
Install transmission case cover.
K-11
.
OPTIONAL
4-SPEED
TRANSMISSION
•
Models CJ-5.
Cj-6
A
four-speed transmission with a cane-type shift
is
optional
on
'J
eep' Models
CJ-5
and Cj-6.
This
transmission
provides four speeds forward
and
one
reverse
with
synchromesh engagement in second,
third, and fourth speed.
For quick identification, the optional 4-speed
transmission
is 11
Ys"
long whereas
the
standard
3-speed transmission is 8" long.
However
the in-
structions for
removal
and installation of the
two
transmissions
are
the
same. Use the
procedure
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