Component Service
MANUAL TRANSMISSION
T4/5 Application
Model
Eagle
35/38 87
CJ-7 Scrambler Cherokee Wagoneer
NOVEMBER 1983
88
77/78 75 U.S.A./CANADA EDITION
8981 320 380 All information and specifications in this manual are based on the latest data available at the time of publication. American Motors Corporation reserves the right to discontinue designs or change specifications without notice or incurring obligation. Copyright \u00a9 1983 American Motors Corporation. All Rights Reserved, and AMC are registered trademarks of American Motors Corporation. Jeep is a registered trademark of Jeep Corporation. Litho in U.S.A.
GENERAL INFORMATION . . . . . . . . . . . . . . . General
1
Special Tools Torque Specifications.
2 4
1
T4 MANUAL TRANSMISSION OVERHAUL .. 5 T4 Manual Transmission
(Exploded) Transmission Disassembly Cleaning and Inspection. Transmission Assembly
5 7 16 .17
T5 MANUAL TRANSMISSION OVERHAUL ., 27 Special Tools .27 Torque Specifications. 27 T5 Manual Transmission
(Exploded) Transmission Disassembly Cleaning and Inspection. Transmission Assembly
28 30 40 41
The number used for Canadian manufactured vehicles is the body sequence number preceded by a C (for Canada) and followed by The T4 four-speed and T5 five-speed trans 83 or 84 to identify the year of manufacture. The missions are used with AMC/Jeep vehicles that sequence number begins and ends with an are equipped with either a four-cylinder or sixasterisk (*) to prevent alteration by extension. cylinder engine. GENERAL
These transmissions provide synchromesh Gearshift Patterns engagement in all forward gear positions. Reverse gear is not synchronized. All forward gears are helical cut and are in constant mesh. The gearshift pattern for the four forward gears of four-speed transmissions is an H configuration. An additional position for reverse Both transmissions are designed and manu gear is included as well as a separate position factured with metric dimensions. Therefore, for the fifth gear with five-speed transmissions. when repairing these transmissions, use only An interlock mechanism prevents accidental the specified metric dimensioned fasteners. engagement of reverse gear when shifting from any of the forward gears. The transmission case, cover and adapter housing for both transmissions are cast To shift to reverse gear for both T4 and T5 aluminum. An internal, single-rail shift mech transmissions, press the gearshift lever to the anism is located in the cover. extreme right and rearward. To shift from reverse gear, move the gearshift lever back to the neutral detent position. Transmission identification Both transmissions have an identification tag attached at the rear of the transmission case that provides the AMC/Jeep and vendor part numbers. This information is essential when ordering replacement parts. If the tag is removed during service operations, ensure that it is securely attached to the transmission case at the original location after completion of the service operations.
Special Identification Vehicles manufactured for sale in the states of Georgia and Tennessee have certain compo nents identified by a nonrepeating number. For both transmissions, the number is stamped on a boss located on the left side of the transmission case.
1
90640
Lubrication
SPECIFICATIONS The specified lubricant for both T4 and T5 Lubrication transmissions is AMC/Jeep/Renault Manual Level to b ot to m o f fi ll h o le Transmission Fluid (P/N 8983 000 000 ). Do not Recommended Lubricant — AMC/Jeep/Renauit use any other type of fluid when adding to or Manual Transmission Fluid {P/N 8983 000 000 ) refilling a transmission. Lubricant Capacity — T4 U.S. Measure imperial Measure
Capacities
3.5 pints 2.9 pints
Metric Measure
1.7 liters
.Lubricant Capacity — T5 U.S. Measure Imperial Measure
T4: 1.7 liters (3.5 U.S. pints) T5:1.9 liters (4.0 U.S. pints)
4.0 pints 3.7 pints
Metric Measure
1.9 liters
C A U T I O N : Do not use any gear lubricants containing lead, sulphur, or chlorine com pounds. These chemicals are not compatible with the lubrication requirements for AMC/Jeep manual transmissions.
86226
SPECIAL TOOLS
Recommended
Description
Required
J-26625
Front Bearing Cap Seal Installation Tool
•
J-29895
Rear Countershaft Bearing Installation Tool
•
J-25215
Puller Assembly
J-33032
Protector Sleeve
J-29721
Bearing Removal Set
•
J-29721-9
Adapter (P/O J-29721)
•
J-22912-01
Bearing Removal Tool
•
J-26628-1
Oil Seal Installation Tool
•
J-26628-2
Oil Seal Protector
•
J-6133-01
Bearing Installation Tool
J-29184
Seal Installation Tool
J-8001
Dial Indicator
Tool Ref
• •
• • •
2
TORQUE SPECIFICATIONS Component
Service Set-To Torque
Service Recheck Torque
Adapter Housing Bolt
27 N-m (20 ft-lbs)
20-34 N-m (15-25 ft-lbs)
Backup Lamp Switch
20 N-m (15 ft-lbs)
16-24 N-m (12-18 ft-lbs)
Filler Plug
31 N-m (23 ft-lbs)
20-41 N-m (15-30 ft-lbs)
Front Bearing Cap Bolt
18 N-m (13 ft-lbs)
15-20 N-m (11-15 ft-lbs)
Shift Control Housing Bolt
18 N-m (13 ft-lbs)
15-20 N-m (11-15 ft-lbs)
Reverse Gear Shift Lever Pivot Pin Bolt
58 N-m (43 ft-lbs)
47-68 N-m (35-50 ft-lbs)
Transmission Cover Bolt
12 N-m ( 7 ft-lbs)
8-15 N-m ( 6-11 ft-lbs)
T4 MANUAL TRANSMISSION (EXPLODED)
81197A
5
T4 MANUAL TRANSMISSION (EXPLODED) LEGEND 1. TRANSMISSION COVER 2. SHIFT RAIL 3. FIRST-SECOND GEAR SHIFT FORK 4. SELECTOR PLATE 5. SELECTOR ARM INTERLOCK PLATE AND PIN 6. THIRD-FOURTH GEAR SHIFT FORK 7. PLUG •8. THRUST WASHER, REAR BEARING AND CUP 9. FIRST GEAR 10. FIRST GEAR BLOCKING RING 11. OUTPUT SHAFT 12. REVERSE SLIDING GEAR AND INSERT SPRINGS 13. FIRST GEAR PIN 14. SYNCHRONIZER INSERT 15. SECOND GEAR BLOCKING RING 16. SECOND GEAR 17. THRUST WASHER 18. SNAP RING 19. THIRD GEAR 20. THIRD GEAR BLOCKING RING 21. THIRD-FOURTH GEAR SYNCHRONIZER SPRING, HUB, INSERT AND SLEEVE 22. FOURTH GEAR BLOCKING RING 23. NEEDLE THRUST BEARING AND RACE 24. CLUTCH SHAFT NEEDLE ROLLER BEARING 25. COUNTERSHAFT NEEDLE THRUST BEARING AND RACE 26. COUNTERSHAFT REAR BEARING 27. COUNTERSHAFT REAR SPACER 28. COUNTERSHAFT GEAR 29. COUNTERSHAFT FRONT THRUST WASHER 30. COUNTERSHAFT FRONT BEARING 31. OFFSET LEVER 32. DAMPER SLEEVE 33. ROLL PIN 34. DETENT SPRING 35. DETENT BALL 36. ADAPTER HOUSING 37. IDENTIFICATION TAG 38. ADAPTER HOUSING SEAL 39. VENT 40. REVERSE IDLER GEAR SHAFT 41. ROLL PIN 42. REVERSE IDLER GEAR 43. BUSHING 44. REVERSE GEAR LEVER FORK 45. REVERSE GEAR LEVER PIVOT PIN BOLT 46. BACKUP LAMP SWITCH 47. DRAIN PLUG 48. TRANSMISSION CASE 49. CLUTCH SHAFT 50. FRONT BEARING 51. FRONT BEARING RACE 52. SHIM 53. OIL SEAL 54. FRONT BEARING CAP
81197B
6
engaged in the housing detent plate that prevents moving the lever far enough rearward for removal.
TRANSMISSION DISASSEMBLY
C A U T I O N : Except for the gearshift Sever attaching bolts and the filler plug, all the bolts and threaded holes used in the T4 transmission case have metric dimensioned lengths and threads. If replacement bolts are required during overhaul, use only bolts that have the same thread size and length as the original bolts. Remove the drain bolt from the transmission case and drain the lubricant. Use a pin punch and hammer to remove the roll pin (1) attaching the offset lever (2) to the shift rail (3).
8622B
Remove the detent ball (5) and spring (6) from the offset lever (2) and remove the roll pin (1) from the adapter housing or offset lever.
86227
Remove the adapter housing-to-transmission case bolts and remove the housing (4) and offset lever (2) as an assembly.
C A U T I O N: Do not attempt to remove the offset lever while the adapter housing is still bolted in place. The lever has a positioning lug (7) 86229
7
Remove and retain the countershaft rear thrust bearing (8) and race (8A). Remove the transmission cover and shift fork assembly attaching bolts and remove the cover.
NOTE: Two of the transmission cover bolts are dowel-type alignment bolts. Note the location of these bolts for assembly reference.
U6231
Remove the C-clip (9) attaching the reverse gear lever to the reverse gear lever pivot pin bolt.
86230
Q 62 3 2
8
Remove the reverse gear lever pivot pin bolt (10) and remove the reverse gear lever and reverse gear lever fork (11) as an assembly.
B6234
86233
Mark the position of the front bearing cap (12) on the transmission case with a center punch, remove the front bearing cap bolts and remove the front bearing cap (12). Remove the front bearing race (13) and endplay shims (14) from the front bearing cap. Remove the oil sea! from the bearing cap with a pry tool. Rotate the clutch shaft (15) until the flat on the gear teeth is facing the countershaft and remove the clutch shaft.
9
86235
Remove the thrust bearing race and bearing (16) and the 15 needle roller bearings (17) from the clutch shaft. Remove the output shaft bearing race (18). Tap the front of the output shaft with a rubber or plastic mallet, if necessary. Tilt the output shaft assembly upward and remove it from the transmission case.
86237
86236
86238
10
Remove the countershaft rear bearing (19) with a brass drift (20) and arbor press. Note the posi tion of the bearing for assembly reference. The bearing identification numbers face outward when the bearing is correctly installed.
Move the countershaft rearward, tilt it upward and remove it from the case. Remove the countershaft front thrust washer from the case. Note the position of the washer for assembly reference. Remove the countershaft rear bearing spacer (21).
86240
11
Remove the reverse idler gear shaft roll pin (22) with a hammer and pin punch. Remove the reverse gear idler shaft (23) and gear (24). Note the position of the gear for assembly reference.
Disassembly - Output Shaft Geartrain Remove the thrust bearing washer from the front end of the output shaft. Scribe alignment marks (25) on the third-fourth gear synchronizer hub and sleeve for assembly reference. Remove the countershaft front bearing with an arbor press. Remove the clutch shaft front bearing with Bearing Removal Tools J-29721 and
J-22912-01.
Remove the adapter housing rear oil seal with a flat drift and hammer. Remove the backup lamp switch from the transmission case.
12
Position the jaws of a split-type puller (e.g., Tool J-22912-01) between the third and second gears on the output shaft. Ensure that the puller jaws exert force firmly against the back of the third gear (26).
Remove the snap ring (29) that retains the second gear (30) on the shaft. Remove the tabbed second gear thrust washer (31) and second gear (30).
Place the output shaft (27) geartrain assembly in an arbor press and remove the third-fourth gear synchronizer hub and sleeve (28) and third gear (26) as an assembly.
86246
13
Remove the output shaft bearing with Puller Set NOTE: The first gear journal may have the J-29721 and Adapter J-29721 -9. recently adopted hour glass shape. Scribe alignment marks (35) on the first-second gear synchronizer sleeve and output shaft hub for assembly reference.
Remove the first gear thrust washer (32), first gear roll pin, first gear (33) and blocking ring (34). Use diagonal (side) cutters to remove the roll pin. Remove the insert spring and inserts from the first-reverse sliding gear and remove the gear from the output shaft hub.
CAUTION: Do not attempt to remove the firstsecond-reverse gear hub from the output shaft. The hub and shaft are machined and assembled as a matched set during manufacture to ensure concentricity.
86248
14
Disassembly - Transmission Cover Components Place the selector arm plates (36) and shift rail (37) in a neutral position (centered).
Remove the shift rail oil seal (41) and O-ring (42) with a pry tool. Remove the shift rail plug (43) with a hammer and punch.
86250
Remove the nylon inserts (44) and selector arm Rotate the shift rail (37) counterclockwise until plates (45) from the shift forks (46). Note the the selector arm (38) disengages from the position of the inserts and plates for assembly selector arm plates (36) and the selector arm rollreference. pin (38) is accessible. Pull the shift rail (37) rearward until the selector arm (38) contacts the first-second gear shift fork (39). Remove the selector arm roll pin (38) with a 5-mm (3/16-in.) diameter pin punch and remove the shift rail (37). Remove the shift forks (39 and 40), selector arm plates (36), selector arm, roll pin, and interlock plate (38).
15
CLEANING AND INSPECTION
Thoroughly clean all the components in solvent and dry them with compressed air. Do not dry the front or rear bearing with compressed air. Allow them to air dry or wipe them dry with a clean shop cloth. Clean the needle thrust and roller bearings by wrapping them in a cloth and submerging the cloth and bearings in solvent. Or, place them in a shallow parts cleaning tray and cover them with solvent. Allow the bearings to air dry or wipe them with a clean shop cloth. Inspect the transmission case, cover and adapter housing. Replace any of these components if they have any of the following defects. ® cracks in the bores, sides, bosses or bolt holes
worn or loss of surface metal from the counter shaft and hub, clutch shaft or reverse idler gear shaft worn thrust washers nicked, broken or worn output or clutch shaft splines bent, distorted or weak snap rings worn bushing in the reverse idler gear rough, loss of surface metal or broken front/ rear bearing worn shift fork inserts broken, cracked or worn shift forks bent, worn or loss of surface metal from the shift rail
® stripped threads in the bolt holes
® nicks, burrs, or rough surfaces in the shaft worn, bent or broken selector arms, plates or bores or on the gasket surfaces interlock Inspect the geartrain and shift mechanism. Replace any components that have any of the following defects. » broken, chipped or worn gear teeth ® bent or broken inserts ® weak or broken insert springs ® damaged roller thrust or needle bearings, or damaged bearing bores in the countershaft gear or clutch shaft
16
worn, bent, broken or stripped offset lever, or worn lever insert
NOTE: The first-second gear shift fork is the larger of the two forks.
TRANSMISSION ASSEMBLY
Assembly - Transmission Cover Components Position the selector arm and C-shaped interlock plate (38) in the cover and insert the Install the nylon inserts (44) and selector armshift rail (37) through the arm. The widest part of the interlock plate must face away from the plates (45) in the shift forks (46). cover, and the selector arm roll pin must face downward and toward the rear of the cover. Position the third-fourth gear shift fork (40) in the cover with the fork offset facing the rear of the cover. The third-fourth gear shift fork selector arm plate must be positioned under the firstsecond gear shift fork selector plate. Insert the shift rail (37) through the third-fourth gear shift fork (40) and into the shift rail front bore in the cover.
86253
Coat the edges with sealant and install the shift rail plug (43). Coat the shift rail (37) and shift rail bores with petroleum jelly and insert the shift rail in the cover. Insert the rail until the end is flush with the inside edge of the cover. Position the first-second gear shift fork (39) in the cover with the fork offset facing the rear of the cover and insert the shift rail through the fork.
17
86254
Rotate the shift rail (37) until the selector arm plate (36) at the forward end of the rail faces away from (but parallel with) the cover.
Install the shift rail oil seal according to the following procedure: • position Oil Seal Protector Tool J-26628-2 over the threaded end of the shift rail
Align the roll pin holes in the selector arm (38) and shift rail and install the roll pin. Ensure that the roll pin is installed flush with the surface of • lubricate the oil seal lip (41) with petroleum the selector arm to prevent the pin from con jelly and slide the seal over the protector tool tacting the selector arm plates during shifts. and onto the shift rail
Install the O-ring (42) in the groove in the shift • seat the oil sea! (41) in the transmission cover rail oil seal. with Oil Seal installation Too! J-26628-1
86255
18
Assembly - Output Shaft Geartrin NOTE: If any output shaft gear is replaced, the countershaft gear must also be replaced to maintain proper gear mesh and avoid noisy operation.
Install the tabbed thrust washer (31) and the second gear snap ring (29) on the output shaft. Ensure that the washer tab is properly seated in the output shaft notch. Install the blocking ring and first gear on the output shaft.
Coat the output shaft and gear bores with transmission lubricant. Install and align the first-second gear synchronizer sleeve on the output shaft hub. Use the reference marks scribed during disassembly. Install the 3 first-second gear synchronizer inserts (A) and the 2 insert springs (B) in the first-reverse gear synchronizer sleeve. Engage the tang end of each insert spring in the same synchronizer insert but position the open ends of the springs so that they face 180 degrees (opposite) from each other. Ensure that the sleeve and hub are aligned. Use the reference marks scribed during disassembly.
88256
8625B
Install the blocking ring and second gear on the output shaft. 19
Install the first gear roll pin (C) in the output shaft.
86259
Install the first gear thrust washer (32). Install the rear bearing on the output shaft with Tool J-6133-01.
86260
20
Install the third gear (26) on the output shaft and install the blocking ring on the third gear. Align the scribe marks on the third-fourth gear synchronizer hub and sleeve (28) and output shaft, and start the hub onto the output shaft. Press the third-fourth gear synchronizer hub and sleeve (28) onto the output shaft (until seated) with an arbor press.
NOTE: Ensure that the blocking ring is aligned with the third-fourth gear synchronizer sleeve before seating the hub and sleeve. Install the fourth gear blocking ring in the thirdfourth gear synchronizer sleeve.
86261
21
Assembly - Transmission Case C A U T I O N : Except for the gearshift lever attaching bolts and filler plug, all bolts and threaded holes used in the T4 transmission have metric dimensions. Do not attempt to substitute with a different thread-type or size bolt if an original bolt is damaged or lost. Coat the countershaft front bearing outer cage with Loctite 601, or equivalent, and install the countershaft front bearing (flush with the case) with an arbor press.
Coat the countershaft rear bearing with petroleum jelly and install the bearing with Installation Tool J-28895 and a hammer.
NOTE: When correctly installed, the counter shaft rear bearing extends 3 mm (0.125 in.) beyond the case surface.
86262
Coat the countershaft tabbed thrust washer with petroleum jelly. Install the thrust washer so that the tab engages the corresponding depression in the case. Turn the transmission case so that it is on its end and install the countershaft in the front bearing bore. Install the countershaft rear bearing spacer (21).
22
Position the reverse idler gear (24) in the transmission case with the shift lever groove facing the rear of the case. Install the reverse idler gear shaft (23) from the rear of the case and install the retaining roll pin (22) in the shaft. Install the assembled output shaft in the transmission case.
Install the clutch shaft front bearing on the clutch shaft with Tool J-6133-01 and an arbor press. Coat the 15 pilot roller bearings (17) with petroleum jelly and install them on the clutch shaft. 66235
Install the thrust bearing and race (16) on the clutch shaft.
23
Install the fourth gear blocking ring on the output shaft. Install the output shaft rear bearing race. Install the clutch shaft in the transmission case and engage the shaft in the third-fourth gear synchronizer sleeve and blocking ring. Install a replacement oil seat in the front bearing cap with Tool J-26625.
86266
J-26625
Coat the reverse gear shift lever pivot pin bolt threads with Loctite sealant. Install the reverse gear shift lever, pivot pin bolt and retaining C-clip (9). Ensure that the reverse gear shift lever fork is engaged in the reverse idler gear. Tighten the shift lever pivot pin bolt with 58 N-m (43 ft-ibs) torque.
86265
Install a replacement rear oil seal in the adapter housing with Tool J-29184. Install the front bearing race in the front bearing cap. Do not install the shims at this time. Install the front bearing cap. Do not apply sealant at this time.
86232
24
Coat the countershaft rear bearing race and thrust bearing with petroleum jelly and install them in the adapter housing.
Select a shim pack that is 0.03 to 0.13 mm (0.001 to 0.005 in.) thicker than the end play measured above.
Temporarily install the adapter housing. Do not Place the transmission horizontally on a work apply sealant or tighten the bolts with the final bench and remove the front bearing cap and torque at this time. front bearing race. Turn the transmission case on its end. Position Add shims to the bearing cap to obtain the Dial Indicator Tool J-8001 on the adapter necessary preload. Install the bearing race in housing with the indicator stylus on the end of the cap. the output shaft. Apply a bead of RTV sealant on the trans mission case mating surface for the front bear Rotate the clutch and output shafts and zero the dial indicator pointer. ing cap. Install the front bearing cap with the reference marks (scribed during disassembly) aligned. Tighten the retaining bolts with 18 N-m (13 ft-lbs) torque. Measure the end play. There must be no end play. Remove Dial Indicator Tool J-8001 from the adapter housing. Remove the adapter housing. Move the shift forks on the transmission cover and synchronizer rings inside the transmission to the neutral position. Apply a bead of RTV sealant to the transmission case mating surface for the cover.
86267
Lower the cover, at a slightly off center attitude, Pull upward on the output shaft until the end play onto the transmission case while aligning the is eliminated. Note the end play on the dial shift forks and synchronizer sleeves. Center the indicator. cover on the transmission case to engage the reverse gear lever fork and install the two dowel NOTE: To completely eliminate the output shaft bolts in the cover. Install the remaining bolts and and clutch shaft end play, the bearings must be tighten all the cover bolts with 12 N-m (9 ft-lbs) preloaded from 0.03 to 0.13 mm (0.001 to torque. 0.005 in.).
25
Install and tighten the adapter housing retaining NOTE: The offset lever-to-shift rail roll pin hole will be in a vertical position when the cover is bolts with 27 N-m (20 ft-lbs) torque. installed correctly. Install the roil pin (1) in the offset lever (2) and Apply a bead of RTV sealant on the adapter shift rail (3). housing-to-transmission case mating surface. Install the damper sleeve in the offset lever.
Install the adapter housing over the output shaft and shift rail at a position where the shift rail just Coat the backup lamp switch threads with RTV enters the shift cover opening. sealant, install the switch in the transmission case and tighten with 20 N-m (15 ft-lbs). Install the detent spring (6) in the offset lever (2). Place the detent ball (5) in the neutral guide plate detent. Apply force on the detent ball with the detent spring and offset lever, slide the offset lever onto the shift rail and seat the adapter housing against the transmission case.
NOTE: The offset lever and shift rail roll pin holes should be aligned and in a vertical position at this time.
Install the drain bolt.
86229
26
SPECIAL TOOLS Description
Required
J-26625
Front Bearing Cap Sea! Installation Tool
•
J-29895
Rear Countershaft Bearing Installation Tool
•
J-25215
Puller Assembly
J-33032
Protector Sleeve
J-29721
Bearing Removal Set
•
J-29721-9
Adapter-P/O J-29721
•
J-22912-01
Bearing Removal Tool
•
J-26628-1
Oil Seal Installation Tool
•
J-26628-2
Oil Seal Protector
•
J-6133-01
Bearing Installation Tool
J-29184
Seal Installation Tool
J-8001
Dial Indicator
Tool Ref.
Recommended
• •
• • •
TORQUE SPECIFICATIONS Component
Service Set-To Torque
Service Recheck Torque
Adapter Housing Bolt
27 N-m (20 ft-ibs)
20-34 N-m (15-25 ft-lbs)
Backup Lamp Switch
20 N-m (15 ft-lbs)
16-24 N-m (12-18 ft-lbs)
Filler Plug
31 N-m (23 ft-lbs)
20-41 N-m (15-30 ft-lbs)
Front Bearing Cap Bolt
18 N-m (13 ft-lbs)
15-20 N-m (11-15 ft-lbs)
Shift Control Housing Bolt
18 N-m (13 ft-lbs)
15-20 N-m (11-15 ft-lbs)
Fifth-Reverse Gear Shift Lever Pivot Pin Bolt
58 N-m (43 ft-lbs)
47-68 N-m (35-50 ft-lbs)
Transmission Cover Bolt
12 N-m ( 9 ft-lbs)
8-15 N-m ( 6-11 ft-lbs)
27
T5 MANUAL TRANSMISSION (EXPLODED)
T5 MANUAL TRANSMISSION (EXPLODED)
LEGEND 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58.
O-RING TRANSMISSION COVER SHIFT RAIL FIRST-SECOND GEAR SHIFT FORK SELECTOR PLATE SELECTOR ARM, INTERLOCK PLATE AND PIN THIRD-FOURTH GEAR SHIFT FORK PLUG SNAP RING FIFTH DRIVEN GEAR THRUST WASHER, REAR BEARING AND CUP FIRST GEAR FIRST GEAR BLOCKING RING OUTPUT SHAFT REVERSE SLIDING GEAR AND INSERT SPRINGS ROLL PIN SYNCHRONIZER INSERT SECOND GEAR BLOCKING RING SECOND GEAR AND THRUST WASHER SNAP RING THIRD GEAR THIRD GEAR BLOCKING RING THIRD-FOURTH GEAR SYNCHRONIZER SPRINGS, HUB, INSERT AND SLEEVE FOURTH GEAR BLOCKING RING NEEDLE THRUST BEARING AND RACE CLUTCH SHAFT NEEDLE ROLLER BEARING FUNNEL SNAP RING THRUST BEARING RACE COUNTERSHAFT NEEDLE THRUST BEARING AND RACE INSERT RETAINER FIFTH GEAR SYNCHRONIZER SLEEVE AND INSERT SPRINGS FIFTH GEAR SYNCHRONIZER INSERT, HUB AND BLOCKING RING FIFTH GEAR SNAP RING AND SPACER COUNTERSHAFT REAR BEARING AND SPACER COUNTERSHAFT GEAR COUNTERSHAFT FRONT BEARING AND THRUST WASHER OFFSET LEVER DAMPER SLEEVE DETENT SPRING AND BALL IDENTIFICATION TAG ADAPTER HOUSING SEAL ADAPTER HOUSING VENT ROLL PIN FIFTH GEAR SHIFT FORK FIFTH GEAR AND REVERSE GEAR RAIL FIFTH GEAR-REVERSE GEAR SHIFT LEVER ROLL PIN REVERSE IDLER GEAR, BUSHING AND SHAFT FIFTH GEAR LEVER PIVOT PIN BOLT AND BACKUP LAMP SWITCH TRANSMISSION CASE DRAIN PLUG CLUTCH SHAFT FRONT BEARING FRONT BEARING CAP OIL SEAL, SHIM AND RACE FRONT BEARING CAP
66268B
29
TRANSMISSION DISASSEMBLY
C A U T I O N : Except for the gearshift lever attaching bolts and filler plug, all the bolts and threaded holes used in the T5 transmission have metric dimensioned threads and sizes. If replacement bolts are required during service, use only those having the same thread type and size as the original bolts.
engaged in the housing detent plate that prevents moving the lever far enough forward for removal.
Remove the drain bolt from the transmission case and drain the lubricant. Use a pin punch and hammer to remove the roll pin (1) that attaches the offset lever (2) to the shift rail (3).
Remove the detent ball (5) and spring (6) from the offset lever (2) and remove the roll pin (1) from the adapter housing or the offset lever.
Remove the adapter housing-to-transmission case bolts and remove the housing (4) and offset lever (2) as an assembly.
C A U T I O N: Do not attempt to remove the offset lever while the adapter housing is bolted in place. The lever has a positioning lug (9) 86229
30
Remove the plastic funnel (7), thrust bearing Remove the bolts attaching the transmission race (8) and thrust bearing (9) from the rear of cover and shift fork assembly and remove the the countershaft. cover.
NOTE: The countershaft rear thrust bearing, bearing race and plastic funnel will be located either on the end of the countershaft or inside the adapter housing.
NOTE: Two of the transmission cover attaching bolts are alignment-type dowel bolts. Note the location of these bolts for assembly reference.
8 62 3 1
31
C A U T I O N: Place a wood block (11) under the fifth gear shift fork during roll pin removal to prevent damage to the fifth-reverse gear shift rail.
Remove the roll pin (10) from the fifth gear shift fork with a hammer and punch.
Remove the fifth gear synchronizer snap ring (12), shift fork (13), fifth gear synchronizer sleeve (14), blocking ring (15) and fifth gear (16) from the rear of the countershaft (17).
32
Remove the fifth gear insert retainer synchro nizer springs and inserts from the sleeve and hub. Scribe a mark to indicate the position of the hub and sleeve for assembly reference.
For assembly reference, mark the position of the front bearing cap on the front of the transmission case. Use a hammer and punch to mark both the bearing cap and case.
Remove the snap ring (18) and fifth driven gear (19) from the rear of the output shaft (20) with Puller Assembly J-25215.
Remove the front bearing cap bolts and the front bearing cap. Remove the front bearing race (21) and end play shim(s) (22) from the front bearing cap (23). Remove the oil seal from the bearing cap with a pry tool.
86278
33
Rotate the clutch shaft until the flat surface on the mam drive gear faces the countershaft and remove the clutch shaft from the transmission case. Remove the 15 clutch shaft needle bearings (24), bearing (25) and race (26).
86277
34
Remove the output shaft rear bearing race and tilt the output shaft assembly upward and remove it from the transmission case.
Release the overcenter link spring from the rear of the transmission case.
NOTE: Use a mechanic's wire or welding rod (D) to fabricate a spring removal tool similar to that illustrated.
8628
Remove the C-clip (E) attaching the fifth-reverse gear shift lever and fork assembly to the pivot pin bolt. Rotate the fifth-reverse gear shift rail (27) clockwise (when viewed from the top of the transmission case) to disengage it from the fifthreverse gear shift lever assembly. Remove the shift rail from the rear of the transmission case.
35
Insert a brass drift (F) through the clutch shaft Remove the fifth-reverse gear shift lever and opening in front of the transmission case and, fork assembly (28) pivot pin bolt, detach the fifth-reverse gear shift lever from the reverse with an arbor press, carefully press the idler gear and remove the fifth-reverse gear shiftcountershaft assembly rearward to remove the lever and fork assembly from the transmission countershaft rear bearing (31). case.
NOTE: For assembly reference, the bearing Remove the countershaft rear snap ring (29) identification numbers face outward when the and spacer (30). bearing is correctly installed.
8 62 8 4
86286
Move the countershaft assembly rearward inside the transmission case, tilt the assembly upward and remove it from the case. Note the position the countershaft front thrust washer for assembly reference and remove it from the case.
8 62 8 5
36
Remove the countershaft rear bearing spacer (32).
Remove the countershaft front bearing from the transmission case with an arbor press.
86288
Remove the clutch shaft front bearing with Tools Use a hammer and punch to remove the roll pin J-29721 and J-22912-01. (33) from the forward end of the reverse idier gear shaft. Remove the reverse idier gear shaft (34) and gear (35) from the transmission case. Note the position of the idier gear for assembly reference.
Remove the adapter housing rear oil seal with a flat drift and hammer.
37
Disassembly - Output Shaft Geartrain Remove the thrust bearing washer from the front end of the output shaft. Scribe alignment marks (A) on the third-fourth gear synchronizer hub and sleeve for assembly reference.
Remove the snap ring (39) retaining the second gear on the shaft and remove the tabbed second gear thrust washer (40) and second gear (41).
Position the jaws of a spiit-type puller (e.g., Tool J-22912-01) between the third and second gears on the output shaft. Ensure that the puller jaws exert force firmly against the back of the third gear. Position the output shaft (37) geartrain assembly in an arbor press and remove the third-fourth gear synchronizer hub and sleeve (38) and third gear (36) as an assembly. 86293
38
Remove the first gear thrust washer (42), first gear and blocking ring. Use diagonal (side) cutters to remove the roll pin.
86294
Remove the output shaft rear bearing with Puller Set J-29721 and Adapter J-29721-9.
86296
NOTE: Some first gear journals have an hour glass shape. Scribe alignment marks on the first-second gear synchronizer sleeve and output shaft hub for assembly reference. Remove the insert spring and inserts from the first-reverse sliding gear and remove the gear from the output shaft hub.
CAUTION: Do not attempt to remove the firstsecond-reverse gear hub from the output shaft. The hub and shaft are machined and assembled as a matched set during manufacture to ensure concentricity.
86295
39
Disassembly - Transmission Cover Components
Remove the shift rail plug (49) with a hammer and punch.
Remove the nylon inserts (50) and selector arm Place the selector arm plates and shift rail in the neutral position (centered). plates (44) from the shift forks (43). Note the position of the inserts and plates for assembly reference. Rotate the shift rail counterclockwise until the selector arm disengages from the selector arm plates and the selector arm roll pin is accessible. Pull the shift rail rearward until the selector arm contacts the first-second gear shift fork. Remove the selector arm roll pin with a 5-mm (3/16-in.) diameter pin punch and remove the shift rail.
CLEANING AND INSPECTION
Thoroughly clean all the components in solvent and dry them with compressed air. Do not dry the front or rear bearings with compressed air. Allow them to air dry or wipe them dry with a clean shop cloth. Clean the needle thrust and and roller bearings Remove the shift forks (43), selector arm plates by wrapping them in a cloth and submerging the (44), selector arm (45), roll pin and interlock cloth and bearings in solvent. Or, place them in a plate (46). shallow parts cleaning tray and cover them with solvent. Allow the bearings to air dry or wipe them dry with a clean shop cloth. Remove the shift rail oil seal (47) and O-ring (48) with a pry tool.
40
Inspect the transmission case, cover and • worn shift fork inserts adapter housing. Replace these components if they have any of the following defects. • broken, cracked or worn shift forks • cracks in the bores, sides, bosses or bolt holes • bent, worn or loss of surface metal from the shift rail • stripped threads in the bolt holes • worn, bent "or broken selector arms, plates or • nicks, burrs, or rough surfaces in the shaft interlock bores or on the gasket surfaces Inspect the geartrain and shift mechanism. Replace any components that have any of the following defects.
• worn, bent, broken or stripped offset lever, or worn lever insert
TRANSMISSION ASSEMBLY
• broken, chipped or worn gear teeth • bent or broken inserts
Assembly-Transmission Cover Components
• weak or broken insert springs
Install the nylon inserts (50) and selector arm plates (44) in the shift forks (43).
• damaged roller thrust or needle bearings, or damaged bearing bores in the countershaft gear or clutch shaft • worn or loss of surface metal from the countershaft and hub, clutch shaft or reverse idler gear shaft • worn thrust washers • nicked, broken or worn output or clutch shaft splines • bent, distorted or weak snap rings • worn bushing in the reverse idler gear • rough, loss of surface metal or broken front/ rear bearing
41
Coat the edges of the shift rail plug (49) with Install the O-ring (48) in the groove in the shift sealant. Install the shift rail plug. rail oil seal. Coat the shift rail and shift rail bores with petro Install the shift rail oil seal (47) according to the leum jelly and insert the shift rail in the cover.following procedure: Position the first-second gear shift fork (43) in • position Oil Seal Protector Tool J-26628-2 the cover with the fork offset facing the rear of over the threaded end of the shift rail the cover. Insert the shift rail through the fork .
NOTE: The first-second gear shift fork is the larger of the two forks.
• lubricate the oil seal lip with petroleum jelly and slide the seal over the protector and onto the shift rail
Position the selector arm (45) and C-shaped • seat the oil seal in the transmission cover with interlock plate (46) in the cover and insert the Oil Seal installation Tool J-26628-1 shift rail through the arm. The widest part of the interlock plate must face away from the cover and the selector arm roll pin hole must face downward and toward the rear of the cover. Position the third-fourth gear shift fork (43) in the cover with the fork offset facing the rear of the cover. The third-fourth gear shift fork selector arm plate (44) must be positioned under the first-second gear shift fork selector arm plate. Insert the shift rail through the third-fourth gear shift fork (43) and into the shift rail front bore in the cover. Rotate the shift rail until the selector arm plate at the forward end of the rail faces away from (but parallel with) the cover. Align the roll pin holes in the selector arm (45) and shift rail and install the roll pin. Ensure that the roll pin is flush with the surface of the selector arm to prevent the pin from contacting the selector arm plates during shifts.
42
Assembly - Output Shaft Geartrain NOTE: If any output shaft gear is replaced, the countershaft gear must also be replaced to maintain the proper gear mesh and prevent noisy operation. Coat the output shaft and gear bores with transmission lubricant. Install and align the first-second gear synchronizer sleeve on the output shaft hub using the reference marks scribed during disassembly. Install the 3 first-second gear synchronizer inserts (50) and the 2 insert springs (51) in the first-reverse gear synchronizer sleeve. Engage the tang of each insert spring in the same synchronizer insert but position the open ends of the springs to face 180 degrees (opposite) from each other. Ensure that the sleeve and hub reference marks are aligned.
43
Install the blocking ring and second gear (41) on the output shaft. Install the tabbed thrust washer (40) and second gear retaining snap ring (39) on the output shaft. Ensure that the washer tab is properly seated in the output shaft. Install the blocking ring and first gear on the output shaft. Install the first gear roll pin (A) in the output shaft. Install the first gear thrust washer (42). Press the rear bearing on the output shaft with Tool J-6133-01.
44
86304
86303
NOTE: Ensure that the blocking ring is aligned Install the third gear on the output shaft. Install with the synchronizer sleeve before seating the the third-fourth gear blocking ring on the third hub and sleeve. gear. Install Align the reference scribe marks on the thirdfourth fourth gear synchronizer hub and sleeve (38) and the output shaft. Start the hub on the output shaft. Press the hub and sleeve on the output Install shaft (until seated) with an arbor press. end of
45
the fourth gear blocking ring in the thirdgear synchronizer sleeve. the thrust bearing washer on the forward the output shaft.
Coat the countershaft tabbed thrust washer with petroleum jelly and install it so that the tab engages the corresponding depression in the case.
Assembly - Transmission Case
C A U T I O N : Except for the gearshift lever attaching bolts and filler plug, all bolts and threaded holes used in the T5 transmission Turn the transmission case on its end and install have metric dimensions. Do not attempt to the countershaft in the front bearing bore. substitute with a different thread-type or size bolt if an original bolt is damaged or lost. Install the countershaft rear bearing spacer (32). Coat the countershaft front bearing outer cage with Loctite 601, or equivalent. Use an arbor press to install the countershaft front bearing flush with the case.
C A U T I O N: The protector sleeve tool must be used to provide clearance for the needle bearings between the countershaft shoulder and bearing bore.
86262
46
Coat the countershaft rear bearing with Position the reverse idler gear (35) in the case with the shift lever groove facing the rear of the petroleum jelly and install it with installation Tool case. Install the reverse idler gear shaft (34) J-29895 and Protector Sleeve Tool J-33032. from the rear of the case. Install the retaining roll pin (33) in the shaft. N O T E : When correctly installed with Tools J-33032 and J-29895, the countershaft rear bearing will extend 3 mm (0.125 in.) beyond the case surface.
J-29895
66263
47
Install the clutch shaft front bearing on the clutch Coat the fifth-reverse gear shift lever pivot pin bolt threads with RTV sealant. Install the fifthshaft with Tool J-6133-01 and an arbor press. reverse gear shift lever (28), pivot pin bolt and C-clip retainer. Ensure that the reverse gear shift lever fork is engaged with the reverse idler gear. Tighten the shift lever pivot pin bolt with 58 N-m (43 ft-lbs) torque.
S6264
Coat the 15 pilot roller bearings (24) with petroleum jelly and install them on the clutch shaft. Install the thrust bearing (25) and race (26) on Install the assembled output shaft in the trans the clutch shaft. mission case.
48
Install the output shaft rear bearing race cap. Install the front bearing race in the front bearing cap. Do not install any shims in the front bearing cap at this time. Install the fourth gear blocking ring on the output shaft. Temporarily install the front bearing cap. Do not apply sealant at this time. Position the clutch shaft in the case and engage it in the third-fourth gear synchronizer sleeve and blocking ring. Install a replacement oil seal in the front bearing cap with Tool J-26625.
49
Install the fifth driven gear (19) and retaining Install the countershaft rear bearing spacer (30) snap ring (18) on the rear of the output shaftand retaining snap ring (29). (20).
86285 86274
Insert the fifth-reverse gear shift rail through the Install the fifth gear on the countershaft. opening in the rear of the case and install it in the fifth-reverse gear shift lever. Rotate the rail (27) Install the fifth-reverse gear shift lever overduring installation to simplify engagement with center link spring (B). the lever.
86305
50
Assemble the fifth gear synchronizer sleeve, Place the assembled fifth-reverse gear shift rail insert springs and insert retainer. Use the and shift fork on a block of wood (11) and install reference marks scribed during disassembly for the retaining roil pin (10). alignment. install the plastic inserts in the notches on each side of the fifth gear shift fork. Position the assembled fifth gear synchronizer sleeve on the fifth gear shift fork (13) and slide it onto the countershaft (17) and the fifth-reverse gear shift rail.
NOTE: Ensure that the roll pin hole in the fifthreverse gear shift rail and fifth gear shift fork are aligned.
install the thrust bearing race adjacent to the fifth gear synchronizer hub and install the retaining snap ring (12).
C A U T I O N: Place a wood block (11) under the fifth gear shift fork during roll pin installation to prevent damage to the fifth-reverse gear shift rail.
51
Install the needle-type thrust bearing (9) against Temporarily install the adapter housing. Do not the thrust bearing race on the countershaft. Coat seal the housing and the case or tighten the both the thrust bearing and race with petroleum bolts with the final torque at this time. jelly. Position the transmission case on its end. Attach Install the lipped thrust race (8) over the needle- a dial indicator (J-8001) on the adapter housing type thrust bearing. Install the plastic funnel (7) with the indicator stylus located on the end of the in the hole at the end of the countershaft gear. output shaft. Rotate the clutch and output shafts and zero the dial indicator pointer. Pull upward on the output shaft until the output shaft end play is eliminated. Note the end play dimension indicated on the dial indicator.
NOTE: To completely eliminate the output shaft and clutch shaft end play, the bearings must be preloaded from 0.03 to 0.13 mm (0.001 to 0.005 in.).
J-8001
52
Select a shim pack that is 0.03 to 0.13 mm (0.001 to 0.005 in.) thicker than the end play measured above.
Move the shift forks on the transmission cover and the synchronizer rings inside the transmission case to the neutral position.
Place the transmission horizontally on a workbench and remove the front bearing cap and front bearing race.
Apply a bead of RTV sealant to the cover mating surface on the transmission case.
Lower the cover, at a slightly off center attitude, Add shims to the bearing cap to obtain the onto the transmission case while aligning the necessary preload and install the bearing race inshift forks and synchronizer sleeves. Center the the cap. cover on the case to engage the reverse gear lever fork and install the two dowel bolts in the cover. Apply a bead of RTV sealant on the case mating surface for the cap. Install the front bearing cap. Ensure the reference marks scribed during Install the remaining bolts and tighten all the disassembly are aligned. Tighten the retaining cover bolts with 12 N-m (9 ft-lbs) torque. bolts with 18 N-m (13 ft-lbs) torque.
NOTE: The offset lever-to-shift rail roll pin hole Measure the end play. There must be no end should be in a vertical position at this time. play. Remove the dial indicator from the adapter housing. Remove the adapter housing and install the adapter housing rear seal with Tool J-29184.
B6266
53
Apply a bead of RTV sealant on the adapter Install and tighten the adapter housing retaining housing-to-transmission case mating surface. bolts with 27 N-m (20 ft-lbs) torque. Install the adapter housing over the output shaft and the shift rail at a position where the shift rail just enters the shift cover opening. Install the detent spring (6) in the offset lever (2). Place the detent bail (5) in the neutral guide plate detent. Apply force on the detent bail with the detent spring and offset lever and slide the offset lever onto the shift rail.
Install the roll pin (1) in the offset lever (2) and shift rail (3). Install the damper sleeve in the offset lever. Coat the backup lamp switch threads with RTV sealant, install the switch in the transmission case and tighten with 20 N-m (15 ft-lbs) torque.
Seat the adapter housing on the transmission case.
NOTE: The offset lever and shift rail roll pin holes should be aligned and in the vertical position at this time.
Install the drain bolt.
86229
54
INFORMATIONS SERVICE SERVICE INFORMATION SERVICE INFORMATIONEN SERVICE INFORMATION IfJFORMACiONES SERVICIO INFORMAZI0NI SERVIZIO
1 E
SERVICEINFORMASJONER
SERVICE INFORMATIE
SERVICEINFORMATSON
INFORMAQAO SERVIQO
JANUARY 1985 ENGLISH EDITION EAGLE - CJ/SCRAMBLER CHEROKEE/WAGONEER
G E A R B OX E S
Attention: Workshop, Parts Department
TRANSMISSION LUBRICANT
A second lubricant has been approved for Wagoneer T4 and T5 transmissions.
limited
use in Eagle, CJ/Scrambler, and Cherokee/
The newly approved second lubricant is SAE Filing Instructions 85W-90, API Grade GL-5. It is to be used only for the purpose of t o p p i n g o f f the transmission • Record this I.S. Note on page 2 of B.V. T4/5 b e t w e e n dram and refill intervals; and, only if Component Service Manual. regular approved manual transmission lubri cant, P/N 8983 000 000 and P/N 9122 in Canada, is NOT available. • Fife it in the B.V T4/5 Component Service Manual binder. When refilling T4 and T5 transmissions after overhaul or at the recommended drain intervals, the only approved manual transmission lubri cant is P/N 8983 000 000 and P/N 9122 in Canada.
Copyright © 1985 American Motors Sales Corporation and Regie Nationale des Usmes Renault. All Rights Reserved Litho in U.S.A
8960 000 501
