Datasheet EXJ_21 Datasheet

XJ TRANSMISSION AND TRANSFER CASE 21 - 1

TRANSMISSION AND TRANSFER CASE

CONTENTS

page page

AUTOMATIC TRANSMISSION—30RH ........ 73

AW–4 AUTOMATIC TRANSMISSION ........ 163

AX15 MANUAL TRANSMISSION ............ 37

AX5 MANUAL TRANSMISSION

INDEX

page page

GENERAL INFORMATION

AX5 MANUAL TRANSMISSION .............. 1

GEAR RATIOS ........................... 1

RECOMMENDED LUBRICANT ............... 1

TRANSMISSION ASSEMBLY INFORMATION ....2

TRANSMISSION IDENTIFICATION ............ 1

DIAGNOSIS AND TESTING

HARD SHIFTING ......................... 3

LOW LUBRICANT LEVEL ................... 3

TRANSMISSION NOISE .................... 4

REMOVAL AND INSTALLATION

ADAPTER HOUSING SEAL ................. 7

EXTENSION HOUSING SEAL ............... 7

FRONT BEARING RETAINER SEAL ........... 6

TRANSMISSION .......................... 4

AX5 MANUAL TRANSMISSION .............. 1

NV231 TRANSFER CASE ................. 280

NV242 TRANSFER CASE ................. 306

DISASSEMBLY AND ASSEMBLY

ADAPTER/EXTENSION HOUSING AND FRONT

BEARING RETAINER .................... 8

COUNTERSHAFT ........................ 26

INPUT SHAFT ..........................26

OUTPUT SHAFT ........................ 27

SEMI-SYNCHRONIZED REVERSE

IDLER GEAR .......................... 32

SHIFT MECHANISM AND GEARTRAIN ........15

CLEANING AND INSPECTION

AX5 MANUAL TRANSMISSION COMPONENTS

SPECIFICATIONS

TORQUE .............................. 35

SPECIAL TOOLS

AX5 ..................................35

... 32

GENERAL INFORMATION

AX5 MANUAL TRANSMISSION

The AX5 is a five speed manual transmission with
fifth gear being the overdrive range. An adapter
housing is used to attach the transmission to the
transfer case on 4-wheel drive applications. A stan­dard style extension housing is used for the 2-wheel
drive applications. The shift mechanism is integral to
the transmission assembly and mounted in the shift
tower portion of the adapter/extension housing (Fig.

1).

TRANSMISSION IDENTIFICATION

The AX5 identification code is on the bottom sur­face of the transmission case near the fill plug (Fig.

2). The first number is year of manufacture. The sec­ond and third numbers indicate month of manufac-

ture. The next series of numbers is the transmission
serial number.

GEAR RATIOS

Gear ratios for the AX5 manual transmission are

as follows:

• First gear: 3.93:1

• Second gear: 2.33:1

• Third gear: 1.45:1

• Fourth gear: 1.00:1

• Fifth gear: 0.85:1

• Reverse gear: 4.74:1

RECOMMENDED LUBRICANT

Recommended lubricant for AX5 transmissions is
Mopart 75W–90, API Grade GL–3 gear lubricant, or
equivalent.

21 - 2 TRANSMISSION AND TRANSFER CASE XJ

GENERAL INFORMATION (Continued)

Fig. 1 AX5 Manual Transmission

Fig. 2 Transmission Identification

Correct lubricant level is from the bottom edge, to
no more than 6 mm (1/4 in.) below the bottom edge of
the fill plug hole.

The fill plug is on the passenger side of the
adapter housing (Fig. 3). The drain plug is on the
bottom of the case.

Approximate dry fill lubricant capacity is:

• 3.3 liters (3.49 quarts) for 4–wheel drive applica-

tions.

• 3.5 liters (3.70 quarts) for 2–wheel drive applica-

tions.

Fig. 3 Fill Plug Location

TRANSMISSION ASSEMBLY INFORMATION

Lubricate the transmission components with
Mopart 75W–90, GL 3 gear lubricant during assem­bly. Use petroleum jelly to lubricate seal lips and/or
hold parts in place during installation.

Refer to (Fig. 4) during assembly for AX5 gear
assembly identification.

XJ TRANSMISSION AND TRANSFER CASE 21 - 3

GENERAL INFORMATION (Continued)

Fig. 4 Geartrain Components

DIAGNOSIS AND TESTING

LOW LUBRICANT LEVEL

A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill, or an incor­rect lubricant level check.

Leaks can occur at the mating surfaces of the gear
case, intermediate plate and adaptor or extension
housing, or from the front/rear seals. A suspected
leak could also be the result of an overfill condition.

Leaks at the rear of the extension or adapter hous­ing will be from the housing oil seals. Leaks at com­ponent mating surfaces will probably be the result of
inadequate sealer, gaps in the sealer, incorrect bolt
tightening, or use of a non–recommended sealer.

A leak at the front of the transmission will be from
either the front bearing retainer or retainer seal.
Lubricant may be seen dripping from the clutch
housing after extended operation. If the leak is
severe, it may also contaminate the clutch disc caus­ing the disc to slip, grab, and/or chatter.

A correct lubricant level check can only be made
when the vehicle is level. Also allow the lubricant to
settle for a minute or so before checking. These rec­ommendations will ensure an accurate check and
avoid an underfill or overfill condition. Always check

the lubricant level after any addition of fluid to avoid
an incorrect lubricant level condition.

HARD SHIFTING

Hard shifting is usually caused by a low lubricant
level, improper, or contaminated lubricants. The con­sequence of using non–recommended lubricants is
noise, excessive wear, internal bind, and hard shift­ing. Substantial lubricant leaks can result in gear,
shift rail, synchro, and bearing damage. If a leak
goes undetected for an extended period, the first indi­cations of component damage are usually hard shift­ing and noise.

Component damage, incorrect clutch adjustment,
or a damaged clutch pressure plate or disc are addi­tional probable causes of increased shift effort. Incor­rect adjustment or a worn/damaged pressure plate or
disc can cause incorrect release. If the clutch problem
is advanced, gear clash during shifts can result.
Worn or damaged synchro rings can cause gear clash
when shifting into any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to
stick slightly causing hard or noisy shifts. In most
cases, this condition will decline as the rings wear–
in.

21 - 4 TRANSMISSION AND TRANSFER CASE XJ

DIAGNOSIS AND TESTING (Continued)

TRANSMISSION NOISE

Most manual transmissions make some noise dur­ing normal operation. Rotating gears generate a mild
whine that is audible, but generally only at extreme
speeds.

Severe, highly audible transmission noise is gener­ally the initial indicator of a lubricant problem.
Insufficient, improper, or contaminated lubricant will
promote rapid wear of gears, synchros, shift rails,
forks and bearings. The overheating caused by a
lubricant problem, can also lead to gear breakage.

REMOVAL AND INSTALLATION

TRANSMISSION

REMOVAL

(1) Shift transmission into first or third gear.

(2) Raise and support vehicle on suitable safety
stands.

(3) Disconnect necessary exhaust system compo­nents.

(4) Remove skid plate, if equipped.

(5) Remove slave cylinder from clutch housing.

(6) Mark rear propeller shaft and rear axle yokes
for installation alignment (Fig. 5).

(13) Secure transfer case, if equipped, to jack with

safety chains.

(14) Disconnect transfer case shift linkage at

transfer case, if equipped.

(15) Remove nuts attaching transfer case to trans-

mission, if equipped.

(16) Remove transfer case, if equipped.
(17) Remove crankshaft position sensor (Fig. 6),

(Fig. 7).

Fig. 5 Marking Propeller Shaft And Axle Yokes

(7) Mark front propeller shaft, axle, and transfer
case yokes for installation alignment, if equipped.

(8) Remove propeller shaft(s).

(9) Unclip wire harnesses from transmission and
transfer case, if equipped.

(10) Disconnect transfer case vent hose, if
equipped.

(11) Disengage any wire connectors attached to
transmission or transfer case, if equipped, compo­nents.

(12) Support transfer case, if equipped, with trans­mission jack.

Fig. 6 Crankshaft Position Sensor—2.5L Engine

Fig. 7 Crankshaft Position Sensor —4.0L Engine

XJ TRANSMISSION AND TRANSFER CASE 21 - 5

REMOVAL AND INSTALLATION (Continued)

CAUTION: It is important that the crankshaft posi­tion sensor be removed prior to transmission
removal. The sensor can easily be damaged if left
in place during removal operations.

(18) Support engine with adjustable jack stand.
Position wood block between jack and oil pan to
avoid damaging pan.

(19) Support transmission with transmission jack.

(20) Secure transmission to jack with safety
chains.

(21) Disconnect rear cushion and bracket from
transmission.

(22) Remove rear crossmember.

(23) Disconnect transmission shift lever as follows:

(a) Lower transmission–transfer case assembly
approximately 7–8 cm (3 in.) for access to shift
lever.

(b) Reach up and around transmission case and
unseat shift lever dust boot from transmission shift
tower (Fig. 8). Move boot upward on shift lever for
access to retainer that secures lever in shift tower.

(c) Reach up and around transmission case and
press shift lever retainer downward with finger
pressure. Turn retainer counterclockwise to release
it.

(d) Lift lever and retainer out of shift tower (Fig.

8). Do not remove the shift lever from the floor con­sole shifter boots. Leave the lever in place for
transmission installation.

Fig. 8 Removing/Installing Shift Lever

(24) Remove clutch housing brace rod.
(25) Remove clutch housing-to-engine bolts.
(26) Pull transmission jack rearward until input

shaft clears clutch. Then slide transmission out from
under vehicle.

(27) Remove clutch release bearing, release fork,

and retainer clip.

(28) Remove clutch housing from transmission

(Fig. 9).

INSTALLATION

(1) Install clutch housing on transmission. Tighten

housing bolts to 37 N·m (27 ft. lbs.) torque.

(2) Lubricate contact surfaces of release fork pivot

ball stud and release fork with high temp grease.

(3) Install release bearing, fork, and retainer clip.
(4) Position and secure transmission on transmis-

sion jack.

(5) Lightly lubricate pilot bearing and transmis­sion input shaft splines with Mopart high temp
grease.

(6) Raise transmission and align transmission
input shaft and clutch disc splines. Then slide trans­mission into place.

(7) Install and tighten clutch housing-to-engine
bolts to 38 N·m (28 ft. lbs.) torque (Fig. 9). Be sure

the housing is properly seated on engine block
before tightening bolts.

(8) Install clutch housing brace rod.

(9) Lower transmission approximately 7–8 cm (3
in.) for access to shift tower. Be sure transmission is
in first or third gear.

(10) Reach up and around transmission and insert
shift lever in shift tower. Press lever retainer down­ward and turn it clockwise to lock it in place. Then
install lever dust boot on shift tower.

Fig. 9 Clutch Housing

21 - 6 TRANSMISSION AND TRANSFER CASE XJ

REMOVAL AND INSTALLATION (Continued)

(11) Install rear crossmember. Tighten crossmem-

ber-to-frame bolts to 41 N·m (31 ft. lbs.) torque.

(12) Install fasteners to hold rear cushion and
bracket to transmission. Then tighten transmission­to-rear support bolts/nuts to 45 N·m (33 ft. lbs.)
torque.

(13) Remove support stands from engine and
transmission.

(14) Install and connect crankshaft position sensor.

(15) Position transfer case on transmission jack, if
equipped.

(16) Secure transfer case to jack with safety
chains, if equipped.

(17) Raise transfer case, if equipped, and align
transfer case input shaft to the transmission output
shaft.

(18) Slide transfer case forward until case is
seated on transmission, if necessary.

(19) Install nuts to attach transfer case to trans­mission, if equipped. Tighten transfer case-to-trans­mission nuts to 35 N·m (26 ft. lbs.) torque.

(20) Connect transfer case shift linkage at transfer
case, if equipped.

(21) Connect transfer case vent hose, if equipped.

(22) Secure wire harnesses in clips/tie straps on
transmission and transfer case, if equipped.

(23) Engage wire connectors attached to all neces­sary transmission or transfer case, if equipped, com­ponents.

(24) Install rear propeller shaft slip yoke to trans­mission or transfer case, if equipped, output shaft.

(25) Align marks on rear propeller shaft and rear
axle yokes (Fig. 10).

(28) Install and tighten propeller shaft U–joint

clamp bolts to 19 N·m (170 in. lbs.) torque.

(29) Install slave cylinder in clutch housing.

(30) Install skid plate, if equipped. Tighten bolts to
42 N·m (31 ft. lbs.) torque. Tighten stud nuts to 17
N·m (150 in. lbs.) torque.

(31) Fill transmission and transfer case, if
equipped, with recommended lubricants. Refer to the
Lubricant Recommendation sections of the appropri­ate component for correct fluid.

(32) Lower vehicle.

FRONT BEARING RETAINER SEAL

REMOVAL

(1) Remove release bearing and lever from the
transmission.

(2) Remove the bolts holding the front bearing
retainer to the transmission case.

(3) Remove the front bearing retainer from the
transmission case.

(4) Using a suitable pry tool, remove the front
bearing retainer seal.

INSTALLATION

(1) Using Tool Handle C-4171 and Seal Installer
8211, install new seal in to the front bearing retainer
(Fig. 11).

Fig. 10 Align Propeller Shaft And Rear Axle Yokes

Alignment Marks

(26) Install and tighten propeller shaft U–joint

clamp bolts to 19 N·m (170 in. lbs.) torque.

(27) Align marks on front propeller shaft, axle,

and transfer case yokes, if equipped.

Fig. 11 Install Front Bearing Retainer Seal

(2) Remove any residual gasket material from the
sealing surfaces of the bearing retainer and the
transmission case.

(3) Install new front bearing retainer gasket to the
front bearing retainer.

XJ TRANSMISSION AND TRANSFER CASE 21 - 7

REMOVAL AND INSTALLATION (Continued)

(4) Install the front bearing retainer onto the

transmission case.

(5) Install the bolts to hold the bearing retainer

onto the transmission case.

(6) Tighten the bolts to 17 N·m (12 ft. lbs.).
(7) Install release bearing and lever onto the

transmission.

EXTENSION HOUSING SEAL

REMOVAL

(1) Raise and support vehicle.
(2) Remove propeller shaft. Refer to Group 3, Dif-

ferential and Driveline, for proper procedures.

(3) Using a suitable seal puller or screw with a
slide hammer, remove the extension housing seal
(Fig. 12).

Fig. 13 Install Extension Housing Seal

Fig. 12 Remove Extension Housing Seal

INSTALLATION

(1) Clean seal bore of extension housing of any
residual sealer material from original seal.

(2) Using Tool Handle C-4171 and Seal Installer
8212, install new extension housing seal so that the
seal is located 0 6 0.5 mm (0 6 0.02 in.) to the face
of the extension housing (Fig. 13).

(3) Install propeller shaft. Refer to Group 3, Differ­ential and Driveline, for proper procedures.

(4) Check and add fluid to transmission as neces­sary. Refer to the Recommended Lubricant section for
proper fluid requirements.

(5) Lower vehicle.

ADAPTER HOUSING SEAL

REMOVAL

(1) Hoist and support vehicle.

(2) Remove transfer case.

(3) Using a suitable pry tool, or a slide hammer
mounted screw, remove the adapter housing seal
(Fig. 14).

Fig. 14 Remove Adapter Housing Seal

INSTALLATION

(1) Clean seal bore of adapter housing of any

residual sealer material from original seal.

(2) Using Tool Handle C-4171 and Seal Installer

8208, install new seal so that the seal is located 0 6

0.2 mm (0 6 0.008 in.) to the seal bore face of
adapter housing (Fig. 15).

(3) Install transfer case.

(4) Check and add fluid to transmission as neces­sary. Refer to the Recommended Lubricant section for
proper fluid requirements.

(5) Lower vehicle.

21 - 8 TRANSMISSION AND TRANSFER CASE XJ

REMOVAL AND INSTALLATION (Continued)

Fig. 17 Remove Shift Tower Gasket

(8) Remove detent ball plug (Fig. 19).

(9) Remove detent spring and ball with pencil
magnet (Fig. 20), (Fig. 21).

Fig. 15 Install Adapter Housing Seal

DISASSEMBLY AND ASSEMBLY

ADAPTER/EXTENSION HOUSING AND FRONT BEARING RETAINER

DISASSEMBLY

(1) Drain transmission lubricant, if necessary.
(2) Remove release bearing and lever.
(3) Remove clutch housing bolts and remove hous-

ing (Fig. 18).

(4) Remove vehicle speed sensor and speedometer

adapter, if necessary.

(5)

Remove bolts holding shift tower to transmission case.

(6)

Remove shift tower from transmission case (Fig. 16).

(7) Remove shift tower gasket from shift tower or

transmission case (Fig. 17).

Fig. 16 Remove Shift Tower

Fig. 18 Clutch Housing

XJ TRANSMISSION AND TRANSFER CASE 21 - 9

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 19 Remove Detent Ball Plug

Fig. 20 Remove Detent Spring

(10) Remove shift arm retainer bolt (Fig. 22).
(11) Remove shift arm restrictor pins (Fig. 23).
(12) Remove shift lever shaft plug (Fig. 24).
(13) Remove shifter shaft with large magnet

(Fig. 25).

(14) Remove the shift arm from the adapter hous-

ing.

(15) Remove adapter/extension housing bolts.

Fig. 21 Remove Detent Ball

Fig. 22 Shift Arm Retainer Bolt Removal

Fig. 23 Shift Arm Rstrictor Pins

21 - 10 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 26 Loosen Adapter/Extension Housing

Fig. 24 Removing Shift Lever Shaft Plug

Fig. 25 Remove Shifter Shaft

(16) Loosen adapter/extension housing by tapping

it loose with plastic mallet (Fig. 26).

(17) Remove adapter/extension housing (Fig. 27).
(18) On 4x2 transmissions;

(a) Remove speedometer gear retaining snap-

ring from output shaft.

(b) Remove speedometer gear from output shaft
and remove speedometer gear lock ball from output
shaft.

(c) Remove speedometer drive gear locating
snap-ring (Fig. 28).
(19) Remove the bolts holding the front bearing

retainer to the transmission case.

(20) Remove the bearing retainer from transmis-

sion case (Fig. 29).

Fig. 27 Remove Adapter/Extension Housing–Typical

Fig. 28 Speedometer Drive Gear Assembly

(21) Remove input shaft bearing snap-ring (Fig.

30).
(22) Remove countershaft front bearing snap-ring.

XJ TRANSMISSION AND TRANSFER CASE 21 - 11

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 29 Remove Front Bearing Retainer

Fig. 30 Remove Input Shaft Bearing Snap-ring

(23) Separate intermediate plate and transmission

case by tapping them loose with plastic mallet (Fig.

31).
(24) Separate the intermediate plate from the

transmission case (Fig. 32).

Fig. 31 Separate Intermediate Plate and

Transmission Case

Fig. 32 Remove Intermediate Plate from

Transmission Case

ASSEMBLY

(1) Remove any residual sealer from transmission

case, intermediate plate, and adapter/extension hous­ing.

(2) Apply a 1/8 to 3/16 inch wide bead of Threeb-

ondt Liquid Gasket TB1281, P/N 83504038, as
shown, making sure to keep sealer bead to inside of
bolt holes (Fig. 33).

(3) Align geartrain and shift rails with mating

holes in transmission case and install transmission
case to the intermediate plate (Fig. 34). Verify that
the transmission case is seated on the intermediate
plate locating pins.

Fig. 33 Apply Sealer to Transmission Gear Case

21 - 12 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 34 Install Transmission Gear Case to the

Intermediate Plate

(4) Install new front bearing snap rings (Fig. 35).

Fig. 36 Install Front Bearing Retainer

(8) Apply a 1/8 to 3/16 inch wide bead of Threeb­ondt Liquid Gasket TB1281, P/N 83504038, to seal­ing surface of adapter/extension housing, making
sure to keep sealer bead to inside of bolt holes.

(9) Install adapter or extension housing on inter­mediate plate (Fig. 38). Tighten housing bolts to 34
N·m (25 ft. lbs.) torque.

(10) Position shift arm in shifter tower opening of
adapter or extension housing (Fig. 39). Be sure that
the shifter arm is engaged into the shift rails.

Fig. 35 Install Front Bearing Snap-rings

(5) Install front bearing retainer gasket to front

bearing retainer.

(6) Install the front bearing retainer (Fig. 36) and

tighten bolts to 17 N·m (12 ft. lbs.).

(7) On 4x2 transmissions;

(a) Install speedometer drive gear locating snap-

ring (Fig. 37).

(b) Install speedometer gear lock ball in output
shaft and install speedometer gear onto output
shaft.

(c) Install speedometer gear retaining snap-ring
onto output shaft.

Fig. 37 Speedometer Drive Gear Assembly

(11) Start shifter arm shaft in hole in back of
adapter or extension housing. Align shift arm and
shifter arm shaft and insert shifter arm shaft
through the shifter arm and into the forward portion
of the adapter or extension housing (Fig. 40).

(12) Rotate the shifter arm shaft until the hole in
the shift arm is aligned with the hole in the shaft.

(13) Install the shift arm retainer bolt and tighten
to 38 N·m (28 ft. lbs.) (Fig. 41).

(14) Install and tighten shifter arm shaft plug to
18 N·m (13 ft. lbs.) torque (Fig. 42).

(15) Install shift restrictor pins in shift tower and
tighten to 27 N·m (20 ft. lbs.) (Fig. 43).

XJ TRANSMISSION AND TRANSFER CASE 21 - 13

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 38 Install Adapter/Extension Housing–Typical

Fig. 39 Position Shift Arm in Adapter or Extension

Housing

Fig. 41 Install Shift Arm Retainer Bolt

Fig. 42 Shifter Arm Shaft Plug Installation

Fig. 40 Install Shifter Arm Shaft

Fig. 43 Install Shifter Restrictor Pins

21 - 14 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

(16) Install shift detent ball in detent opening of

case (Fig. 44).

(17) Install detent spring in case (Fig. 45).
(18) Install detent plug and tighten to 19 N·m (14

ft. lbs.) (Fig. 46).

Fig. 46 Install Detent Ball Plug

Fig. 44 Install Detent Ball

Fig. 45 Install Detent Spring

(19) Install shift tower gasket onto shift tower.
(20) Install the shift tower oil deflector and gasket

onto the adapter or extension housing.

(21) Install shift tower onto transmission case

(Fig. 47).

(22) Install bolts to hold shift tower to transmis­sion case. Tighten tower bolts to 18 N·m (13 ft. lbs.)
torque.

(23) Install new metal o-ring onto the backup lamp
switch.

(24) Install backup lamp switch (Fig. 48). Tighten
switch to 44 N·m (32.5 ft. lbs.) torque.

Fig. 47 Install Shift Tower

Fig. 48 Install Backup Lamp Switch

(25) Install new seal in adapter/extension housing.
(26) Install vehicle speed sensor, if necessary.

XJ TRANSMISSION AND TRANSFER CASE 21 - 15

DISASSEMBLY AND ASSEMBLY (Continued)

(27) Install clutch housing, release bearing, release
fork and retainer clip.

SHIFT MECHANISM AND GEARTRAIN

DISASSEMBLY

(1) Install suitable bolts and washers in intermedi­ate plate (Fig. 49). Then clamp plate and gear assem­bly in vise. Use enough washers to prevent bolts
from touching. Also be sure vise jaws are clamped on
bolt heads.

Fig. 50 Remove Fifth Gear Snap-ring

Fig. 49 Positioning Intermediate Plate In Vise

(2) Remove countershaft fifth gear retaining snap­ring (Fig. 50).

(3) Remove bolt holding fifth gear shift fork to
shift rail (Fig. 51).

(4) Remove fifth gear blocker ring from counter­shaft assembly with Puller L-4407 (Fig. 52).

(5) Remove fifth gear synchro ring (Fig. 53).

(6) Remove the countershaft fifth gear assembly
from countershaft (Fig. 54).

(7) Remove fifth gear thrust ring from counter­shaft (Fig. 55).

(8) Remove fifth gear thrust ring lock ball from
countershaft (Fig. 56).

Fig. 51 Remove Shift Fork Retainer Bolt

NOTE: There are many lock balls, check balls,
interlock balls, and interlock pins used in various
places in the transmission. Whenever a pin or ball
is removed, it should be identified in such a way
that it can be reinstalled in the same location from
which it was removed.

(9) Remove bolt holding reverse idler gear shaft

lock plate to the intermediate plate.

(10) Remove reverse idler gear shaft and reverse

idler gear assembly (Fig. 57).

NOTE: Be sure to retrieve the pin and compression
spring from the reverse idler shaft.

21 - 16 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 55 Remove Fifth Gear Thrust Ring

Fig. 52 Remove Fifth Gear Blocker Ring

Fig. 53 Remove Fifth Gear Synchro Ring

Fig. 56 Remove Fifth Gear Thrust Ring Lock Ball

(11) Remove bolts holding output shaft rear bear­ing retainer to the intermediate plate and remove
retainer (Fig. 58).

Fig. 54 Remove Fifth Gear and Synchro Assembly

Fig. 57 Remove Reverse Idler Shaft

(12) Remove bolts holding 1–2 and 3–4 shift forks
to the shift rails (Fig. 59) and discard bolts.

XJ TRANSMISSION AND TRANSFER CASE 21 - 17

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 58 Remove Output Shaft Rear Bearing Retainer

(13) Remove bolts holding reverse shift arm

bracket to intermediate plate (Fig. 60).

Fig. 59 Remove Shift Fork To Shift Rail Bolts

(14) Remove snap-ring holding output shaft rear

bearing into the intermediate plate (Fig. 61).

(15) Remove countershaft rear bearing snap-ring.

(16) With aid of an assistant, support the main­shaft and countershaft. Tap on the rear of the main­shaft and countershaft with a suitable plastic mallet.
This will release the countershaft from the counter­shaft rear bearing and the mainshaft rear bearing
from the intermediate plate. The countershaft will
release from the countershaft bearing first and can
be removed by moving the countershaft rearward and
downward (Fig. 62).

Fig. 60 Remove Reverse Shift Arm Bracket Bolts

Fig. 61 Remove Output Shaft Rear Bearing

Snap-ring

(17) Remove the mainshaft by moving the main­shaft forward until the mainshaft rear bearing is
clear of the intermediate plate and then rotating the
mainshaft downward out of the shift forks (Fig. 63).

(18) Remove the 3–4 shift fork from the 3–4 shift
rail (Fig. 64).

21 - 18 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 62 Remove Countershaft and Countershaft

Rear Bearing

Fig. 63 Remove Mainshaft

(19) Remove the snap-ring from near the end of
the 1–2 shift rail to allow the removal of the 1–2
shift fork.

(20) Remove the 1–2 shift fork from the 1–2 and
the 3–4 shift rails (Fig. 65).

(21) Remove threaded plugs from intermediate
plate. Then remove lock ball and spring from plug
holes with pencil magnet (Fig. 66). Note that the bot­tom spring is shorter in length than the other two
springs.

(22) Remove the intermediate plate from the vise,
rotate the plate 180°, and reinstall the plate in the
vise using the same bolt and washer mounting set­up.

CAUTION: The interlock balls and pins are different
sizes and shapes. Be sure to correctly identify
which position an item is removed from to ensure
that it is reinstalled in the same location.

Fig. 64 Remove 3–4 Shift Fork

Fig. 65 Remove 1–2 Shift Fork

(23) Remove fifth gear shift rail (Fig. 67).
(24) Remove fifth gear check ball (Fig. 68) and

interlock pin.

(25) Remove reverse shift head and rail assembly

(Fig. 69).

(26) Remove snap-ring holding reverse shift rail

into intermediate plate.

(27) Remove reverse shift rail and reverse shift

fork and arm assembly from intermediate plate (Fig.

70).

XJ TRANSMISSION AND TRANSFER CASE 21 - 19

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 68 Remove Fifth Gear Check Ball

Fig. 66 Remove Lock Ball And Spring

Fig. 67 Remove Fifth Gear Shift Rail

(28) Remove interlock pin from reverse shift rail
(Fig. 71).

(29) Remove reverse elongated check ball (Fig. 72).

(30) Remove snap-ring on 3–4 shift rail.

(31) Remove 1–2 shift rail from intermediate plate.

(32) Remove interlock pin from 1–2 shift rail (Fig.

73).

(33) Remove 1–2 shift rail elongated check ball
from intermediate plate (Fig. 74).

(34) Remove 3–4 shift rail from intermediate plate.

Fig. 69 Remove Reverse Shift Head And Rail

Assembly

Fig. 70 Remove Reverse Shift Rail

21 - 20 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 71 Remove Interlock Pin From Reverse Shift

Rail

Fig. 73 Remove 1–2 Shift Rail Interlock Pin

Fig. 72 Remove Reverse Check Ball

ASSEMBLY

Refer to (Fig. 75) while assembling and installing
the shift rail components. Also, verify that all shift
rail components are in their neutral position when
installing the check balls and interlock pins.

(1) Install the 3–4 shift rail into the intermediate
plate.

Fig. 74 Remove 1–2 Check Ball

(2) Install the 1–2 elongated check ball into the

intermediate plate (Fig. 76).

(3) Install the interlock pin into the 1–2 shift rail

(Fig. 77).

(4) Install the 1–2 shift rail into the intermediate

plate.

XJ TRANSMISSION AND TRANSFER CASE 21 - 21

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 75 Shift Rail Components

Fig. 76 Install 1–2 Check Ball Fig. 77 Install 1–2 Shift Rail Interlock Pin

(5) Install snap-ring onto 3–4 shift rail.

(6) Install the reverse check ball into the interme­diate plate (Fig. 78).

(7) Install the interlock pin into the reverse shift

rail (Fig. 79).

(8) Assemble the reverse arm bracket to the

reverse fork (Fig. 80).

21 - 22 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 80 Install Reverse Arm Bracket to Fork

Fig. 78 Install Reverse Check Ball

Fig. 79 Install Reverse Interlock Pin

(9) Install reverse shift rail into intermediate plate
and position reverse arm bracket to intermediate
plate (Fig. 81).

(10) Install snap-ring onto reverse shift rail (Fig.

82).

(11) Install reverse shift head and rail assembly
into the intermediate plate.

(12) Install the fifth gear interlock ball and check
ball (Fig. 83).

(13) Install fifth gear shift rail (Fig. 84).

(14) Remove the intermediate plate from the vise,
rotate the plate 180°, and reinstall the plate in the

Fig. 81 Install Reverse Shift Rail

Fig. 82 Install Reverse Snap-ring

vise using the same bolt and washer mounting set­up.

(15) Install the shift rail detent balls in the inter-

mediate plate.

XJ TRANSMISSION AND TRANSFER CASE 21 - 23

DISASSEMBLY AND ASSEMBLY (Continued)

(19) Install the snap-ring onto the 1–2 shift rail.
(20) Install the 3–4 shift fork onto the 3–4 shift

rail (Fig. 86).

Fig. 83 Install Fifth Gear Check Ball

Fig. 84 Install Fifth Gear Shift Rail

(16) Install the shift rail detent springs in the
intermediate plate. Note that the bottom detent
spring is shorter than the others.

(17) Install the shift rail detent plugs in the inter­mediate plate.

(18) Install the 1–2 shift fork onto the 1–2 and 3–4
shift rails (Fig. 85).

Fig. 85 Install 1–2 Shift Fork

Fig. 86 Install 3–4 Shift Fork

(21) Install mainshaft into the intermediate plate
by guiding the output shaft through opening in inter­mediate plate until the shift forks are aligned with
the appropriate synchronizer sleeves. The mainshaft
rear bearing will be started in the intermediate plate
but not fully driven in at this point.

(22) While an assistant supports the mainshaft,
align rear of countershaft with inner race of counter­shaft rear bearing.

(23) Raise countershaft upward until gears mesh
with the mating gears on the mainshaft.

(24) Using a suitable rubber mallet, tap on the
input shaft and the front of the countershaft equally
to install the mainshaft rear bearing into the inter­mediate plate and the rear of the countershaft into
the rear countershaft bearing. It may be necessary to
occasionally hold the countershaft into the intermedi­ate plate and tap the countershaft rear bearing onto
the countershaft and into the intermediate plate.

(25) Install snap-rings onto the rear mainshaft and
countershaft bearings.

(26) Install the bolts to hold the reverse shift arm
bracket to the intermediate plate.

(27) Install new bolts to hold the shift forks to the
shift rails (Fig. 87).

(28) Position the mainshaft rear bearing retainer
over the output shaft and onto the intermediate
plate.

(29) Install new bolts to hold the bearing retainer
to the intermediate plate.

21 - 24 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 87 Install Shift Fork Bolts

(30) Move the reverse shift arm into the reverse
gear position. The reverse gear position is with the
arm moved away from the intermediate plate (Fig.

88).

(31) Install the reverse idler gear assembly into
position on the mainshaft and reverse shift arm.

(32) Install the compression spring and pin into
the reverse idler gear shaft (Fig. 89).

(33) Install the reverse idler shaft through the
intermediate plate and reverse idler gear assembly
(Fig. 90) until the idler shaft pin contacts the gear
assembly. Make sure that the notched cut-out in the
idler shaft is to the rear of the transmission.

Fig. 89 Install Compression Spring And Pin

Fig. 90 Install Reverse Idler Shaft

shaft and will need to be disassembled in order to be
removed.

(35) Depress compression spring and pin in

reverse idler gear shaft (Fig. 92).

Fig. 88 Reverse Shift Arm Position

(34) Align the pin with the alignment notch in the
reverse idler gear assembly (Fig. 91). The alignment
notch in the reverse idler gear race/hub is a small
relief cut above one of the main longitudinal slots. Be
sure that the pin is aligned with the proper slot, the
opposite slot has an oil drain hole which the pin will
drop into. The assembly will then be locked onto the

Fig. 91 Align Idler Shaft Pin

XJ TRANSMISSION AND TRANSFER CASE 21 - 25

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 92 Depress Pin In Reverse Idler Gear Shaft

(36) Install the reverse idler gear shaft the
remainder of the way through the reverse idler gear
assembly.

(37) Position the reverse idler gear shaft lock plate
onto the intermediate plate.

(38) Install a new bolt to hold the idler gear shaft
lock plate to the intermediate plate.

(39) Install the fifth gear thrust ring lock ball to
the countershaft (Fig. 93).

(40) Install the fifth gear thrust ring onto the
countershaft and over the lock ball (Fig. 94).

Fig. 94 Install Fifth Gear Thrust Ring

(46) Using a suitable mallet and spacer, tap the

fifth gear blocker ring onto the countershaft.

(47) Install new bolt to hold fifth gear shift fork to

the fifth gear shift rail (Fig. 95).

Fig. 93 Install Fifth Gear Thrust Ring Lock Ball

(41) Install fifth gear shift fork to the countershaft
fifth gear assembly.

(42) Install the countershaft fifth gear bearings
into the countershaft fifth gear assembly.

(43) Position the countershaft fifth gear assembly
on the countershaft. Ensure that the fifth gear fork is
installed onto the fifth gear shift rail.

(44) Install the fifth gear synchro ring.

(45) Position the fifth gear blocker ring onto the
countershaft.

Fig. 95 Install Fifth Gear Retainer Bolt

(48) Measure countershaft fifth gear thrust clear-

ance.

(49) Select a snap-ring so that the thrust clearance

is 0.10–0.30 mm (0.004–0.010 in.).

(50) Install snap-ring to hold fifth gear blocker

ring onto countershaft.

(51) Remove intermediate plate from vise and

remove bolts and washers from intermediate.

21 - 26 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

COUNTERSHAFT

DISASSEMBLY

(1) Remove select fit snap-ring holding the coun­tershaft front bearing onto the countershaft (Fig. 96).

(2) Using Bearing Splitter P-334, a suitable spacer
on center of countershaft, and a shop press, remove
the countershaft front bearing from the countershaft.

Fig. 97 Separate Input and Output Shafts

Fig. 96 Countershaft Front Bearing Snap-ring

ASSEMBLY

(1) Remove any nicks or burrs on countershaft hub
with fine emery or crocus cloth.

(2) Position countershaft front bearing on end of
countershaft.

(3) Using Special Tool 8109 and a shop press,
press bearing onto countershaft.

(4) Select the thickest snap-ring that will fit into
the snap-ring groove of the countershaft (Fig. 96).

(5) Install snap-ring to hold countershaft front
bearing onto countershaft.

INPUT SHAFT

DISASSEMBLY

(1) Verify that the 3–4 synchronizer is in the neu­tral position.

(2) Separate input shaft from output shaft (Fig.

97). Note that the output shaft pilot bearing is an
uncaged roller type bearing.

(3) Remove the output shaft pilot bearing rollers
from the input shaft and the output shaft.

(4) Remove the fourth gear synchronizer ring from
the input shaft (Fig. 98).

Fig. 98 Input Shaft Components

(5) Remove the select fit snap-ring holding the

input shaft bearing onto the input shaft.

(6) Using Bearing Splitter P-334 and a shop press,

remove the bearing from the input shaft.

ASSEMBLY

(1) Position input shaft bearing onto input shaft.
(2) Using Driver L-4507, drive bearing onto input

shaft.

(3) Select the thickest snap-ring that will fit into

the snap-ring groove of the input shaft (Fig. 99).

(4) Lubricate output shaft pilot bearing bore of

input shaft with petroleum jelly.

(5) Install output shaft pilot bearing rollers in
input shaft bore (Fig. 100). Ensure to use sufficient
petroleum jelly to hold rollers in position.

(6) Install the fourth gear synchronizer ring onto
the input shaft.

(7) Install input shaft to output shaft. Use care
when mating the two shafts not to displace any out­put shaft pilot bearing rollers.

XJ TRANSMISSION AND TRANSFER CASE 21 - 27

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 100 Install Output Shaft Pilot Bearing Rollers

OUTPUT SHAFT

DISASSEMBLY

(1) Remove input shaft and output shaft pilot
bearing rollers from output shaft.

(2) Measure and note thrust clearance of output
shaft gears (Fig. 101). Clearance should be 0.10 –

0.25 mm (0.004 – 0.010 in.).

Fig. 99 Select Input Shaft Bearing Snap-ring

Fig. 101 Check Output Shaft Gear Thrust Clearance

(3) Remove output shaft fifth gear snap ring with
two screwdrivers (Fig. 102).

(4) Using Bearing Splitter P-334 or suitable press
plates positioned under first gear, press fifth gear,
rear bearing, first gear, and first gear bearing inner
race off output shaft (Fig. 103).

21 - 28 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 102 Remove Fifth Gear Snap-ring

Fig. 103 Remove Fifth Gear, First Gear Bearing, And

Race

(5) Remove first gear needle roller bearing from

output shaft.

(6) Remove first gear bearing inner race lock ball

with pencil magnet (Fig. 104).

(7) Remove first gear synchronizer ring.

(8) Using Bearing Splitter P-334 or suitable press
plates positioned under second gear, press 1–2 syn­chronizer, reverse gear, and second gear from output
shaft (Fig. 105).

Fig. 104 Remove First Gear Bearing Inner Race

Lock Ball

Fig. 105 Remove Second Gear, Reverse Gear, And

1–2 Synchronizer

(9) Remove second gear needle roller bearing from

the output shaft or second gear.

(10) Remove select fit snap-ring holding the 3–4

synchronizer onto the output shaft (Fig. 106).

(11) Using Bearing Splitter P-334 or suitable press
plates positioned under third gear, press the 3–4 syn­chronizer and third gear from output shaft (Fig. 107).

XJ TRANSMISSION AND TRANSFER CASE 21 - 29

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 106 Remove 3–4 Synchronizer Snap Ring

Fig. 107 Remove 3–4 Synchronizer And Third Gear

(12) Remove third gear needle roller bearing from

output shaft or gear.

Fig. 108 Synchronizer Identification

(4) Install third gear over bearing and onto output
shaft flange.

(5) Install third gear synchronizer ring to third
gear.

(6) Position the 3–4 synchronizer onto the output
shaft.

(7) Using Adapter 6747-1A and a shop press, press
the 3–4 synchronizer onto the output shaft.

(8) Select the thickest snap-ring that will fit into
the snap-ring groove of the output shaft (Fig. 109).

ASSEMBLY

(1) Lubricate transmission components with speci-

fied gear lubricant.

(2) If necessary, assemble 1–2 and 3–4 synchro-

nizer hubs, sleeves, springs and key inserts (Fig.

108).
(3) Install third gear needle bearing onto the out-

put shaft.

Fig. 109 Select 3–4 Synchronizer Snap-ring

21 - 30 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

(9) Install snap-ring to hold 3–4 synchronizer onto

output shaft.

(10) Verify third gear thrust clearance with feeler

gauge (Fig. 110). Clearance should be 0.10 – 0.25 mm
(0.004 – 0.010 in.). If clearance is out of specification,
refer to Cleaning and Inspection section within this
group.

(14) Position 1–2 synchronizer assembly onto

splines of output shaft.

(15) Using Driver MD-998805, Adapter 6747-1A,
and a shop press, press the 1–2 synchronizer onto
the output shaft.

(16) Install first gear synchronizer ring into 1–2
synchronizer.

(17) Install first gear bearing inner race lock ball
in output shaft (Fig. 111).

(18) Install first gear needle bearing onto output
shaft (Fig. 112).

(19) Install first gear onto output shaft and over
bearing.

(20) Install first gear bearing inner race onto out­put shaft and inside first gear bearing. Rotate bear­ing race until race installs over lock ball.

(21) Position output shaft rear bearing onto output
shaft. Ensure that the snap ring groove in bearing
outer race is toward rear of output shaft.

(22) Using Driver L-4507 and suitable mallet,
drive bearing onto output shaft.

(23) Install snap-ring onto output shaft rear bear­ing outer race.

Fig. 110 Check Third Gear Clearance

(11) Install second gear needle bearing onto output

shaft.

(12) Install second gear over bearing and onto out-

put shaft flange.

(13) Install second gear synchronizer ring onto sec-

ond gear.

Fig. 112 First Gear Components

Fig. 111 Install First Gear Bearing Inner Race Lock

Ball

XJ TRANSMISSION AND TRANSFER CASE 21 - 31

DISASSEMBLY AND ASSEMBLY (Continued)

(24) Check first–second gear thrust clearance (Fig.

113). Standard clearance is 0.10 – 0.25 mm (0.004 –

0.010 in.). If clearance is out of specification, refer to
Cleaning and Inspection section within this group.

Fig. 113 Check First–Second Gear Thrust Clearance

(25) Position fifth gear onto output shaft with the
gear’s short shoulder toward the rear of shaft.
Ensure that the gear and output shaft splines are
aligned.

(26) Using Adapter 6747-1A, Driver L-4507, and a
shop press, press fifth gear onto output shaft.

(27) Select the thickest snap-ring that will fit into
the snap-ring groove of the output shaft (Fig. 114).

(28) Install snap-ring to hold fifth gear onto output
shaft.

Fig. 114 Select/Install Fifth Gear Snap Ring

21 - 32 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

SEMI-SYNCHRONIZED REVERSE IDLER GEAR

DISASSEMBLY

(1) Remove snap-ring holding the reverse idler
gear onto the reverse idler gear hub/race (Fig. 115).

(2) Remove the plate washer from the reverse idler
gear hub/race (Fig. 116).

Fig. 117 Remove Reverse Idler Gear

Fig. 115 Remove Reverse Idler Gear Snap-ring

Fig. 116 Remove Reverse Idler Gear Plate Washer

(3) Remove the reverse idler gear from the reverse
idler gear hub/race (Fig. 117).

(4) Remove the reverse idler gear synchronizer
ring from the reverse idler gear hub/race (Fig. 118).

ASSEMBLY

(1) Install the reverse idler gear synchronizer ring
onto the reverse idler gear hub/race. Apply a film of
75W-90 GL-3 transmission oil to the contact surface
of the synchronizer ring prior to assembly.

(2) Install the reverse idler gear onto the reverse
idler gear hub/race. Apply a film of 75W-90 GL-3
transmission oil to the reverse idler gear bushing
prior to assembly.Verify that the teeth on the syn-

Fig. 118 Remove Reverse Idler Gear Synchronizer

Ring

chronizer ring are properly engaged into the recesses
of the reverse idler gear.

(3) Install the plate washer over the reverse idler

gear hub/race and onto the reverse idler gear.

(4) Install the snap-ring to hold the reerse idler

gear onto the reverse idler hub/race.

CLEANING AND INSPECTION

AX5 MANUAL TRANSMISSION COMPONENTS

GENERAL INFORMATION

Clean the transmission components in solvent. Dry
the cases, gears, shift mechanism and shafts with
compressed air. Dry the bearings with clean, dry
shop towels only. Never use compressed air on the
bearings. This could cause severe damage to the
bearing roller and race surfaces.

If output shaft or inner race flange thickness is
within specification but any gear thrust clearance is

XJ TRANSMISSION AND TRANSFER CASE 21 - 33

CLEANING AND INSPECTION (Continued)

out of specification, replace the necessary gear and
gear needle bearing as an assembly.

GEAR CASE, ADAPTER/EXTENSION HOUSING, INTERMEDIATE PLATE

Clean the case, housing, and intermediate plate
with solvent and dry with compressed air. Replace
the case if cracked, porous, or if any of the bearing
and gear bores are damaged.

Inspect the threads in the case, housing, and plate.
Minor thread damage can be repaired with steel
thread inserts, if necessary. Do not attempt to repair
any threads which show evidence of cracks around
the threaded hole.

OUTPUT SHAFT

Check thickness of the output shaft and inner
bearing race flanges with a micrometer or vernier
calipers (Fig. 119).

• Second gear surface minimum diameter is

37.964 mm (1.495 in.)

• Third gear surface minimum diameter is 34.984

mm (1.377 in.)

Measure diameter of the first gear bearing inner

race. Minimum diameter is 38.985 mm (1.535 in.).

Measure output shaft runout with a dial indicator
(Fig. 120). Runout should not exceed 0.05 mm (0.002
in.).

Fig. 119 Check Shaft And Bearing Race Flange

Thickness

• Minimum thickness for shaft flange is 4.80 mm

(0.189 in.)

• Minimum thickness for first gear bearing inner

race flange is 3.99 mm (0.157 in.)

Measure diameter of the output shaft journal sur­faces with a micrometer. Replace the shaft if either of
these surfaces are worn beyond specified limits.

Fig. 120 Check Output Shaft Runout

Replace output shaft or first gear inner bearing
race if measurement of any surface is out of specifi­cation. Do not attempt to repair out of specification
components.

COUNTERSHAFT

Inspect the countershaft gear teeth. Replace the
countershaft if any teeth are worn or damaged.
Inspect the bearing surfaces and replace shaft if any
surface shows damage or wear.

Check condition of the countershaft front bearing.
Replace the bearing if worn, noisy, or damaged.

GEAR AND SYNCHRONIZER

Install the needle bearing and inner race in the
first gear. Then check oil clearance between the gear
and inner race (Fig. 121). Clearance should be 0.009
– 0.032 mm (0.0004 – 0.0013 in.).

Install the needle bearings and the second, third
and counter fifth gears on the output shaft. Then
check oil clearance between the gears and shaft with
a dial indicator (Fig. 122). Oil clearance for all three
gears is 0.009 – 0.0013 mm (0.0004 – 0.0013 in.).

Check synchronizer ring wear (Fig. 123). Insert
each ring in matching gear. Measure clearance
between each ring and gear with feeler gauge.
Replace ring if clearance exceeds 2.0 mm (0.078 in.).

21 - 34 TRANSMISSION AND TRANSFER CASE XJ

CLEANING AND INSPECTION (Continued)

Fig. 121 Check Gear–To–Race Clearance

Fig. 122 Check Gear–To–Shaft Oil Clearance

Check shift fork–to–synchronizer hub clearance
with a feeler gauge (Fig. 124). Replace the fork if
clearance exceeds 1.0 mm (0.039 in.).

(1) Inspect all mainshaft gear teeth. Replace any
gear which shows any worn or damaged teeth.

Fig. 123 Check Synchronizer Ring Wear

Fig. 124 Check Fork–To–Hub Clearance

XJ TRANSMISSION AND TRANSFER CASE 21 - 35

SPECIFICATIONS

TORQUE

DESCRIPTION TORQUE

Plugs, Access ................19N·m(14ft.lbs.)

Bolts, Adapter Housing ........34N·m(25ft.lbs.)

Switch, Back-up Light .......44N·m(32.5 ft.lbs.)

Plugs, Drain and Fill ........44N·m(32.5 ft.lbs.)

Bolts, Front Bearing Retainer . . . 17 N·m (12 ft.lbs.)

Plugs, Interlock and Detent.....19N·m(14ft.lbs.)

Screws, Propeller Shaft Clamp ........16–23 N·m

(140–200 in.lbs.)

Bolts, Rear Mount to Transmission ....33–60 N·m

(24–44 ft.lbs.)
Nut, Rear Mount Clevis . . 54–75 N·m (40–55 ft.lbs.)

Nuts, Rear Mount to Crossmember ....33–49 N·m

(24–36 ft.lbs.)

Pins, Restrictor .............27.4 N·m (20 ft.lbs.)

Bolts, Reverse Shift Arm Bracket .........18N·m

(13 ft.lbs.)

Screw, Shift Arm Set ..........38N·m(28ft.lbs.)

Screws, Shift Fork Set .........20N·m(15ft.lbs.)

Nut, Shift Knob ........20–34 N·m (15–25 ft.lbs.)

Screws, Shifter Floor Cover ............2–3N·m

(17–30 in.lbs.)

Bolts, Shift Tower ............18N·m(13ft.lbs.)

Nuts, Transfer Case Mounting ........30–41 N·m

(22–30 ft.lbs.)

C-3995-A Installer, Extension Housing Seal

C-4171 Handle, Universal Tool

SPECIAL TOOLS

AX5

C-3339 Dial Indicator Set

8211 Installer, Seal

8212 Installer, Seal

21 - 36 TRANSMISSION AND TRANSFER CASE XJ

SPECIAL TOOLS (Continued)

8208 Installer, Seal

L-4507 Tube, Driver

P-334 Splitter, Bearing

8109 Cup, Installer

6747–1A Adapter, Fixture

MD-998805 Installer, Seal

XJ TRANSMISSION AND TRANSFER CASE 21 - 37

AX15 MANUAL TRANSMISSION

INDEX

page page

GENERAL INFORMATION

AX15 MANUAL TRANSMISSION ............. 37

RECOMMENDED LUBRICANT .............. 37

TRANSMISSION ASSEMBLY INFORMATION . . . 38

TRANSMISSION GEAR RATIOS ............. 37

TRANSMISSION IDENTIFICATION ........... 37

DIAGNOSIS AND TESTING

HARD SHIFTING ........................ 39

LOW LUBRICANT LEVEL ..................38

TRANSMISSION NOISE ................... 40

REMOVAL AND INSTALLATION

ADAPTER HOUSING SEAL ................43

EXTENSION HOUSING SEAL ............... 43

FRONT BEARING RETAINER SEAL .......... 42

TRANSMISSION ......................... 40

GENERAL INFORMATION

AX15 MANUAL TRANSMISSION

The AX15 is a 5–speed, synchromesh, manual
transmission. Fifth gear is an overdrive range with a
ratio of 0.79:1. An adapter housing is used to attach
the transmission to the transfer case on 4–wheel
drive models. A standard extension housing is used
on 2–wheel drive models. The shift mechanism is
integral and mounted in the shift tower portion of
the adapter housing (Fig. 1).

TRANSMISSION IDENTIFICATION

The AX15 identification code numbers are on the
bottom surface of the intermediate plate (Fig. 2).

The first number is year of manufacture. The sec­ond and third numbers indicate month of manufac­ture. The next series of numbers is the transmission
serial number.

DISASSEMBLY AND ASSEMBLY

ADAPTER/EXTENSION HOUSING AND FRONT

BEARING RETAINER ................... 44

COUNTERSHAFT ........................ 63

INPUT SHAFT ..........................64

OUTPUT SHAFT ........................ 64

SHIFT MECHANISM AND GEARTRAIN ........51

CLEANING AND INSPECTION

AX15 MANUAL TRANSMISSION

COMPONENTS ........................ 69

SPECIFICATIONS

TORQUE .............................. 71

SPECIAL TOOLS

AX15 ................................. 71

TRANSMISSION GEAR RATIOS

Gear ratios for the AX15 manual transmission are

as follows:

• First gear: 3.83:1

• Second gear: 2.33:1

• Third gear: 1.44:1

• Fourth gear: 1.00:1

• Fifth gear: 0.79:1

• Reverse: 4.22:1

RECOMMENDED LUBRICANT

Recommended lubricant for AX15 transmissions is
Mopart 75W–90, API Grade GL–3 gear lubricant, or
equivalent.

Correct lubricant level is from the bottom edge, to
no more than 6 mm (1/4 in.) below the bottom edge of
the fill plug hole.

The fill plug is located on the driver’s side of the
transmission case (Fig. 3). The drain plug is located
on the passenger side of the transmission case near
the bottom (Fig. 4).

21 - 38 TRANSMISSION AND TRANSFER CASE XJ

GENERAL INFORMATION (Continued)

Fig. 1 AX15 Manual Transmission

Fig. 2 Identification Code Number Location

Approximate dry fill lubricant capacity is:

• 3.10 liters (3.27 qts.) for 4–wheel drive applica-

tions.

• 3.15 liters (3.32 qts.) for 2–wheel drive applica-

tions.

TRANSMISSION ASSEMBLY INFORMATION

Lubricate the transmission components with
Mopart 75W–90, GL 3 gear lubricant during assem­bly. Use petroleum jelly to lubricate seal lips and/or
hold parts in place during installation.

Refer to (Fig. 5) during assembly for AX15 gear
assembly identification.

Fig. 3 Fill Plug Location

DIAGNOSIS AND TESTING

LOW LUBRICANT LEVEL

A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill, or an incor­rect lubricant level check.

Leaks can occur at the mating surfaces of the gear
case, intermediate plate and adaptor or extension
housing, or from the front/rear seals. A suspected
leak could also be the result of an overfill condition.

Leaks at the rear of the extension or adapter hous­ing will be from the housing oil seals. Leaks at com­ponent mating surfaces will probably be the result of
inadequate sealer, gaps in the sealer, incorrect bolt
tightening, or use of a non–recommended sealer.

XJ TRANSMISSION AND TRANSFER CASE 21 - 39

DIAGNOSIS AND TESTING (Continued)

avoid an underfill or overfill condition. Always check
the lubricant level after any addition of fluid to avoid
an incorrect lubricant level condition.

HARD SHIFTING

Hard shifting is usually caused by a low lubricant
level, improper, or contaminated lubricants. The con­sequence of using non–recommended lubricants is
noise, excessive wear, internal bind, and hard shift­ing. Substantial lubricant leaks can result in gear,
shift rail, synchro, and bearing damage. If a leak
goes undetected for an extended period, the first indi­cations of component damage are usually hard shift­ing and noise.

Component damage, incorrect clutch adjustment,
or a damaged clutch pressure plate or disc are addi-

Fig. 4 Drain Plug Location

A leak at the front of the transmission will be from
either the front bearing retainer or retainer seal.
Lubricant may be seen dripping from the clutch
housing after extended operation. If the leak is
severe, it may also contaminate the clutch disc caus­ing the disc to slip, grab, and/or chatter.

A correct lubricant level check can only be made
when the vehicle is level. Also allow the lubricant to
settle for a minute or so before checking. These rec­ommendations will ensure an accurate check and

tional probable causes of increased shift effort. Incor­rect adjustment or a worn/damaged pressure plate or
disc can cause incorrect release. If the clutch problem
is advanced, gear clash during shifts can result.
Worn or damaged synchro rings can cause gear clash
when shifting into any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to
stick slightly causing hard or noisy shifts. In most
cases, this condition will decline as the rings wear–
in.

Fig. 5 Output Shaft and Gears

21 - 40 TRANSMISSION AND TRANSFER CASE XJ

DIAGNOSIS AND TESTING (Continued)

TRANSMISSION NOISE

Most manual transmissions make some noise dur­ing normal operation. Rotating gears generate a mild
whine that is audible, but generally only at extreme
speeds.

Severe, highly audible transmission noise is gener­ally the initial indicator of a lubricant problem.
Insufficient, improper, or contaminated lubricant will
promote rapid wear of gears, synchros, shift rails,
forks and bearings. The overheating caused by a
lubricant problem, can also lead to gear breakage.

REMOVAL AND INSTALLATION

TRANSMISSION

REMOVAL

(1) Shift transmission into first or third gear.

(2) Raise and support vehicle on suitable safety
stands.

(3) Disconnect necessary exhaust system compo­nents.

(4) Remove skid plate, if equipped.

(5) Remove slave cylinder from clutch housing.

(6) Mark rear propeller shaft and rear axle yokes
for installation alignment (Fig. 6).

(13) Secure transfer case, if equipped, to jack with

safety chains.

(14) Disconnect transfer case shift linkage at

transfer case, if equipped.

(15) Remove nuts attaching transfer case to trans-

mission, if equipped.

(16) Remove transfer case, if equipped.
(17) Remove crankshaft position sensor (Fig. 7),

(Fig. 8).

Fig. 6 Marking Propeller Shaft And Axle Yokes

(7) Mark front propeller shaft, axle, and transfer
case yokes for installation alignment, if equipped.

(8) Remove propeller shaft(s).

(9) Unclip wire harnesses from transmission and
transfer case, if equipped.

(10) Disconnect transfer case vent hose, if
equipped.

(11) Disengage any wire connectors attached to
transmission or transfer case, if equipped, compo­nents.

(12) Support transfer case, if equipped, with trans­mission jack.

Fig. 7 Crankshaft Position Sensor—2.5L Engine

Fig. 8 Crankshaft Position Sensor —4.0L Engine

XJ TRANSMISSION AND TRANSFER CASE 21 - 41

REMOVAL AND INSTALLATION (Continued)

CAUTION: It is important that the crankshaft posi­tion sensor be removed prior to transmission
removal. The sensor can easily be damaged if left
in place during removal operations.

(18) Support engine with adjustable jack stand.
Position wood block between jack and oil pan to
avoid damaging pan.

(19) Support transmission with transmission jack.

(20) Secure transmission to jack with safety
chains.

(21) Disconnect rear cushion and bracket from
transmission.

(22) Remove rear crossmember.

(23) Disconnect transmission shift lever as follows:

(a) Lower transmission–transfer case assembly
approximately 7–8 cm (3 in.) for access to shift
lever.

(b) Reach up and around transmission case and
unseat shift lever dust boot from transmission shift
tower (Fig. 9). Move boot upward on shift lever for
access to retainer that secures lever in shift tower.

(c) Reach up and around transmission case and
press shift lever retainer downward with finger
pressure. Turn retainer counterclockwise to release
it.

(d) Lift lever and retainer out of shift tower (Fig.

9). Do not remove the shift lever from the floor con­sole shifter boots. Leave the lever in place for
transmission installation.

Fig. 9 Removing/Installing Shift Lever

(24) Remove clutch housing brace rod.
(25) Remove clutch housing-to-engine bolts.
(26) Pull transmission jack rearward until input

shaft clears clutch. Then slide transmission out from
under vehicle.

(27) Remove clutch release bearing, release fork,

and retainer clip.

(28) Remove clutch housing from transmission

(Fig. 10).

INSTALLATION

(1) Install clutch housing on transmission. Tighten

housing bolts to 37 N·m (27 ft. lbs.) torque.

(2) Lubricate contact surfaces of release fork pivot

ball stud and release fork with high temp grease.

(3) Install release bearing, fork, and retainer clip.
(4) Position and secure transmission on transmis-

sion jack.

(5) Lightly lubricate pilot bearing and transmis­sion input shaft splines with Mopart high temp
grease.

(6) Raise transmission and align transmission
input shaft and clutch disc splines. Then slide trans­mission into place.

(7) Install and tighten clutch housing-to-engine
bolts to 38 N·m (28 ft. lbs.) torque (Fig. 10). Be sure

the housing is properly seated on engine block
before tightening bolts.

(8) Install clutch housing brace rod.

(9) Lower transmission approximately 7–8 cm (3
in.) for access to shift tower. Be sure transmission is
in first or third gear.

(10) Reach up and around transmission and insert
shift lever in shift tower. Press lever retainer down­ward and turn it clockwise to lock it in place. Then
install lever dust boot on shift tower.

Fig. 10 Clutch Housing

21 - 42 TRANSMISSION AND TRANSFER CASE XJ

REMOVAL AND INSTALLATION (Continued)

(11) Install rear crossmember. Tighten crossmem-

ber-to-frame bolts to 41 N·m (31 ft. lbs.) torque.

(12) Install fasteners to hold rear cushion and
bracket to transmission. Then tighten transmission­to-rear support bolts/nuts to 45 N·m (33 ft. lbs.)
torque.

(13) Remove support stands from engine and
transmission.

(14) Install and connect crankshaft position sensor.

(15) Position transfer case on transmission jack, if
equipped.

(16) Secure transfer case to jack with safety
chains, if equipped.

(17) Raise transfer case, if equipped, and align
transfer case input shaft to the transmission output
shaft.

(18) Slide transfer case forward until case is
seated on transmission, if necessary.

(19) Install nuts to attach transfer case to trans­mission, if equipped. Tighten transfer case-to-trans­mission nuts to 35 N·m (26 ft. lbs.) torque.

(20) Connect transfer case shift linkage at transfer
case, if equipped.

(21) Connect transfer case vent hose, if equipped.

(22) Secure wire harnesses in clips/tie straps on
transmission and transfer case, if equipped.

(23) Engage wire connectors attached to all neces­sary transmission or transfer case, if equipped, com­ponents.

(24) Install rear propeller shaft slip yoke to trans­mission or transfer case, if equipped, output shaft.

(25) Align marks on rear propeller shaft and rear
axle yokes (Fig. 11).

(29) Install slave cylinder in clutch housing.

(30) Install skid plate, if equipped. Tighten bolts to
42 N·m (31 ft. lbs.) torque. Tighten stud nuts to 17
N·m (150 in. lbs.) torque.

(31) Fill transmission and transfer case, if
equipped, with recommended lubricants. Refer to the
Lubricant Recommendation sections of the appropri­ate component for correct fluid.

(32) Lower vehicle.

FRONT BEARING RETAINER SEAL

REMOVAL

(1) Remove release bearing and lever from the
transmission.

(2) Remove the bolts holding the front bearing
retainer to the transmission case.

(3) Remove the front bearing retainer from the
transmission case.

(4) Using a suitable pry tool, remove the front
bearing retainer seal.

INSTALLATION

(1) Using Tool Handle C-4171 and Seal Installer
8209, install new seal in to the front bearing retainer
(Fig. 12).

Fig. 11 Align Propeller Shaft And Rear Axle Yokes

Alignment Marks

(26) Install and tighten propeller shaft U–joint

clamp bolts to 19 N·m (170 in. lbs.) torque.

(27) Align marks on front propeller shaft, axle,

and transfer case yokes, if equipped.

(28) Install and tighten propeller shaft U–joint

clamp bolts to 19 N·m (170 in. lbs.) torque.

Fig. 12 Install Front Bearing Retainer Seal

(2) Remove any residual gasket material from the
sealing surfaces of the bearing retainer and the
transmission case.

(3) Install new front bearing retainer gasket to the
front bearing retainer.

(4) Install the front bearing retainer onto the
transmission case.

XJ TRANSMISSION AND TRANSFER CASE 21 - 43

REMOVAL AND INSTALLATION (Continued)

(5) Install the bolts to hold the bearing retainer

onto the transmission case.

(6) Tighten the bolts to 17 N·m (12 ft. lbs.).
(7) Install release bearing and lever onto the

transmission.

EXTENSION HOUSING SEAL

REMOVAL

(1) Raise and support vehicle.
(2) Remove propeller shaft. Refer to Group 3, Dif-

ferential and Driveline, for proper procedures.

(3) Using a suitable seal puller or screw with a
slide hammer, remove the extension housing seal
(Fig. 13).

(3) Install propeller shaft. Refer to Group 3, Differ-

ential and Driveline, for proper procedures.

(4) Check and add fluid to transmission as neces­sary. Refer to the Recommended Lubricant section for
proper fluid requirements.

(5) Lower vehicle.

ADAPTER HOUSING SEAL

REMOVAL

(1) Hoist and support vehicle.

(2) Remove transfer case.

(3) Using a suitable pry tool, or a slide hammer
mounted screw, remove the adapter housing seal
(Fig. 15).

Fig. 13 Remove Extension Housing Seal

INSTALLATION

(1) Clean seal bore of extension housing of any

residual sealer material from original seal.

(2) Using Tool Handle C-4171 and Seal Installer
8212, install new extension housing seal so that the
seal is located 0 6 0.5 mm (0 6 0.02 in.) to the face
of the extension housing (Fig. 14).

Fig. 14 Install Extension Housing Seal

Fig. 15 Remove Adapter Housing Seal

INSTALLATION

(1) Clean seal bore of adapter housing of any

residual sealer material from original seal.

(2) Using Tool Handle C-4171 and Seal Installer

8208, install new seal so that the seal is located 0 6

0.2 mm (0 6 0.008 in.) to the seal bore face of
adapter housing (Fig. 16).

(3) Install transfer case.

(4) Check and add fluid to transmission as neces­sary. Refer to the Recommended Lubricant section for
proper fluid requirements.

(5) Lower vehicle.

21 - 44 TRANSMISSION AND TRANSFER CASE XJ

REMOVAL AND INSTALLATION (Continued)

(7) Remove shift tower gasket from shift tower or
transmission case (Fig. 18).

Fig. 18 Remove Shift Tower Gasket

(8) Remove reverse shift head detent ball plug
(Fig. 20).

Fig. 16 Install Adapter Housing Seal

(9) Remove detent ball spring and ball with pencil
magnet (Fig. 21), (Fig. 22).

DISASSEMBLY AND ASSEMBLY

ADAPTER/EXTENSION HOUSING AND FRONT BEARING RETAINER

DISASSEMBLY

(1) Drain transmission lubricant, if necessary.
(2) Remove release bearing and lever.
(3) Remove clutch housing bolts and remove hous-

ing (Fig. 19).

(4) Remove vehicle speed sensor and speedometer

adapter, if necessary.

(5) Remove bolts holding shift tower to transmis-

sion case.

(6) Remove shift tower from transmission case

(Fig. 17).

Fig. 17 Remove Shift Tower

Fig. 19 Clutch Housing

XJ TRANSMISSION AND TRANSFER CASE 21 - 45

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 20 Remove Detent Ball Plug

Fig. 21 Remove Detent Spring

Fig. 23 Shift Arm Retainer Bolt Removal

Fig. 24 Shift Arm Rstrictor Pins

Fig. 22 Remove Detent Ball

(10) Remove shift arm retainer bolt (Fig. 23).
(11) Remove shift arm restrictor pins (Fig. 24).
(12) Remove shift lever shaft plug (Fig. 25).
(13) Remove shifter shaft with large magnet (Fig.

26).
(14) Remove the shift arm from the adapter hous-

ing.

Fig. 25 Removing Shift Lever Shaft Plug

21 - 46 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 26 Remove Shifter Shaft

(15) Remove adapter/extension housing bolts (Fig.

27).
(16) Loosen adapter/extension housing by tapping

it loose with plastic mallet (Fig. 28).

(17) Remove adapter/extension housing (Fig. 29).
(18) On 4x2 transmissions;

(a) Remove speedometer gear retaining snap-

ring from output shaft.

(b) Remove speedometer gear from output shaft
and remove speedometer gear lock ball from output
shaft.

(c) Remove speedometer drive gear locating
snap-ring (Fig. 30).
(19) Remove the bolts holding the front bearing

retainer to the transmission case.

(20) Remove the bearing retainer from transmis-

sion case (Fig. 31).

(21) Remove input shaft bearing snap-ring (Fig.

32).
(22) Remove cluster gear bearing snap-ring (Fig.

33).
(23) Separate intermediate plate and transfer case

by tapping them loose with plastic mallet (Fig. 34).

(24) Separate the intermediate plate from the

transmission case (Fig. 35).

Fig. 27 Adapter/Extension Housing Bolts

XJ TRANSMISSION AND TRANSFER CASE 21 - 47

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 28 Loosen Adapter/Extension Housing

Fig. 29 Remove Adapter/Extension Housing

Fig. 31 Remove Front Bearing Retainer

Fig. 32 Remove Input Shaft Bearing Snap-ring

Fig. 30 Speedometer Drive Gear Assembly

ASSEMBLY

(1) Remove any residual sealer from transmission

case, intermediate plate, adapter/extension housing,
and front bearing retainer.

Fig. 33 Remove Cluster Gear Snap-ring

(2) Apply a 1/8 to 3/16 inch wide bead of Threeb­ondt Liquid Gasket TB1281, P/N 83504038, as
shown, making sure to keep sealer bead to inside of
bolt holes (Fig. 36).

21 - 48 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 34 Separate Intermediate Plate and

Transmission Case

Fig. 35 Remove Intermediate Plate from

Transmission Case

(3) Align geartrain and shift rails with mating
holes in transmission case and install transmission
case to the intermediate plate (Fig. 37). Verify that
the transmission case is seated on the intermediate
plate.

Fig. 37 Install Transmission Gear Case to the

Intermediate Plate

(4) Install new front bearing snap rings (Fig. 38).

Fig. 36 Apply Sealer to Transmission Gear Case

Fig. 38 Install Front Bearing Snap-rings

(5) Apply 1/8 inch wide bead of Threebondt Liquid
Gasket TB1281, P/N 83504038, to the front bearing
retainer sealing surface.

(6) Install the front bearing retainer (Fig. 39) and
tighten bolts to 17 N·m (12 ft. lbs.).

(7) On 4x2 transmissions;

(a) Install speedometer drive gear locating snap-

ring (Fig. 40).

(b) Install speedometer gear lock ball in output
shaft and install speedometer gear onto output
shaft.

(c) Install speedometer gear retaining snap-ring
onto output shaft.

XJ TRANSMISSION AND TRANSFER CASE 21 - 49

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 39 Install Front Bearing Retainer

(8) Apply a 1/8 to 3/16 inch wide bead of Threeb­ondt Liquid Gasket TB1281, P/N 83504038, to seal­ing surface of adapter/extension housing, making
sure to keep sealer bead to inside of bolt holes.

(9) Install adapter or extension housing on inter­mediate plate (Fig. 41). Tighten housing bolts to 37
N·m (27 ft. lbs.) torque.

(10) Position shift arm in shifter tower opening of
adapter[e]xtension housing (Fig. 42). Be sure that
the shifter arm is engaged into the shift rails.

Fig. 41 Install Adapter/Extension Housing

Fig. 42 Position Shift Arm in Transmission Case

Fig. 40 Speedometer Drive Gear Assembly

(11) Start shifter arm shaft in hole in back of
adapter[e]xtension housing. Align shift arm and
shifter arm shaft and insert shifter arm shaft
through the shifter arm and into the forward portion
of the adapter[e]xtension housing (Fig. 43).

(12) Rotate the shifter arm shaft until the hole in
the shift arm is aligned with the hole in the shaft.

(13) Install the shift arm retainer bolt and tighten
to 38 N·m (28 ft. lbs.) (Fig. 44).

(14) Install and tighten shifter arm shaft plug to
18 N·m (13 ft. lbs.) torque (Fig. 45).

Fig. 43 Install Shifter Arm Shaft

21 - 50 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 44 Install Shift Arm Retainer Bolt

Fig. 45 Shifter Arm Shaft Plug Installation

(15) Install shifter restrictor pins in shift tower
and tighten to 27 N·m (20 ft. lbs.) (Fig. 46).

(16) Install shift detent ball in detent opening (Fig.

47).

(17) Install detent spring (Fig. 48).

(18) Install detent plug and tighten to 19 N·m (14
ft. lbs.) (Fig. 49).

Fig. 46 Install Shifter Restrictor Pins

Fig. 47 Install Detent Ball

Fig. 48 Install Detent Spring

XJ TRANSMISSION AND TRANSFER CASE 21 - 51

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 49 Install Detent Ball Plug

(19) Install shift tower and new gasket on housing
(Fig. 50). Tighten tower bolts to 18 N·m (13 ft. lbs.)
torque.

(20) Install new metal o-ring to the backup lamp
switch.

(21) Install backup lamp switch (Fig. 50). Tighten
switch to 37 N·m (27 ft. lbs.) torque.

(22) Install new seal in adapter/extension housing.

(23) Install vehicle speed sensor, if necessary.

(24) Install clutch housing, release bearing, release
fork and retainer clip.

Fig. 50 Installing Shift Tower And Backup Lamp

Switch

SHIFT MECHANISM AND GEARTRAIN

DISASSEMBLY

(1) Install suitable bolts and washers in intermedi­ate plate (Fig. 51). Then clamp plate and gear assem­bly in vise. Use enough washers to prevent bolts
from touching. Also be sure vise jaws are clamped on
bolt heads.

Fig. 51 Positioning Intermediate Plate In Vise

21 - 52 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

(2) Measure thrust clearance between countershaft
fifth gear and thrust ring with feeler gauge. Clear­ance should be 0.10 to 0.40 mm (0.003 to 0.019 in.).
If clearance exceeds limits, gear and/or ring will have
to be replaced.

(3) Remove countershaft fifth gear retaining snap­ring (Fig. 52).

Fig. 54 Remove Fifth Gear Shift Fork

(7) Remove the reverse shift head and rail assem-

bly from the intermediate plate (Fig. 55).

(8) Remove fifth gear blocker ring from counter-

shaft assembly with Puller L-4407 (Fig. 56).

Fig. 52 Remove Fifth Gear Snap-ring

(4) Remove bolt holding fifth gear shift fork to
shift rail (Fig. 53).

Fig. 53 Remove Fifth Gear Shift Fork Retainer Bolt

(5) Move fifth gear shift rail forward until the rail
is clear of the shift fork.

(6) Remove the fifth gear shift fork from the syn­chronizer sleeve (Fig. 54).

Fig. 55 Remove Reverse Shift Head Assembly

(9) Remove fifth gear synchro ring (Fig. 57).
(10) Remove the countershaft fifth gear assembly

from countershaft (Fig. 58).

XJ TRANSMISSION AND TRANSFER CASE 21 - 53

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 58 Remove Fifth Gear And Synchro Assembly

Fig. 56 Remove Fifth Gear Blocker Ring

Fig. 57 Remove Fifth Gear Synchro Ring

(11) Remove fifth gear thrust ring from counter­shaft (Fig. 59).

(12) Remove fifth gear thrust ring lock ball from
countershaft (Fig. 60).

NOTE: There are many lock balls, check balls,
interlock balls, and interlock pins used in various
places in the transmission. Whenever a pin or ball
is removed, it should be identified in such a way
that it can be reinstalled in the same location from
which it was removed.

Fig. 59 Remove Fifth Gear Thrust Ring

Fig. 60 Remove Fifth Gear Thrust Ring Lock Ball

21 - 54 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

(13) Remove bolts holding output shaft rear bear­ing retainer to intermediate plate (Fig. 61).

Fig. 63 Remove Reverse Idler Shaft And Gear

Fig. 61 Remove Output Shaft Rear Bearing Retainer

Bolts

(14) Remove rear bearing retainer (Fig. 62).

Fig. 62 Remove Output Shaft Rear Bearing Retainer

(15) Remove reverse idler gear shaft and gear (Fig.

63).

(16) Remove bolts holding reverse shift arm
bracket to intermediate plate (Fig. 64).

(17) Remove threaded lock ball plugs from inter­mediate plate (Fig. 65).

(18) Then remove lock ball and spring from plug
holes with pencil magnet (Fig. 66).

Fig. 64 Reverse Shift Arm Components

Fig. 65 Lock Ball Plug Locations

XJ TRANSMISSION AND TRANSFER CASE 21 - 55

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 68 Remove Fifth Gear Shift Rail Lock Ball

Fig. 66 Remove Lock Ball And Spring

(19) Remove the fifth gear shift rail (Fig. 67).

(20) Retrieve the fifth gear shift rail lock ball from
the intermediate plate using a magnet (Fig. 68).

Fig. 67 Shift Rail Identification

21 - 56 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

(21) Remove the 1–2 and 3–4 shift rail c-rings
using two equally sized screwdrivers (Fig. 69).

(23) Remove the 3–4 shift rail from the 1–2 and

3–4 shift forks and the intermediate plate (Fig. 71).

Fig. 71 Remove 3–4 Shift Rail

(24) Remove the 3–4 shift rail interlock plug from

the intermediate plate with a small magnet (Fig. 72).

(25) Remove the 3–4 shift fork (Fig. 73).

Fig. 69 Remove Shift Rail C-rings

(22) Remove bolts holding 1–2 and 3–4 shift forks
to the shift rails (Fig. 70) and discard bolts.

Fig. 70 Remove Shift Fork To Shift Rail Bolts

Fig. 72 Remove 3–4 Shift Rail Interlock Plug

XJ TRANSMISSION AND TRANSFER CASE 21 - 57

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 75 Remove 1–2 Shift Rail Interlock Pin

Fig. 73 Remove Shift Forks

(26) Remove the 1–2 shift rail from the 1–2 shift
fork and the intermediate plate (Fig. 74).

(27) Remove the 1–2 shift rail interlock pin from
the 1–2 shift rail (Fig. 75).

(28) Remove the 1–2 shift rail interlock plug from
the intermediate plate (Fig. 76).

(29) Remove the 1–2 shift fork (Fig. 73).

Fig. 74 Remove 1–2 Shift Rail

Fig. 76 Remove 1–2 Shift Rail Interlock Plug

(30) Remove the c-ring holding the reverse shift
rail into the intermediate plate using two equally
sized screwdrivers (Fig. 77).

(31) Remove the reverse shift rail and fork from
the intermediate plate (Fig. 78).

(32) Remove the interlock pin from the reverse
shift rail (Fig. 79).

(33) Remove snap-ring holding output shaft rear
bearing into the intermediate plate (Fig. 80).

(34) Remove countershaft rear bearing snap-ring.

(35) With aid of an assistant, support the main­shaft and countershaft. Tap on the rear of the main­shaft and countershaft with a suitable rubber mallet.
This will release the countershaft from the counter­shaft rear bearing and the mainshaft rear bearing
from the intermediate plate. The mainshaft will
release from the intermediate plate first and can be
removed by moving the mainshaft rearward and
upward (Fig. 81).

21 - 58 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 79 Remove Reverse Shift Rail Interlock Pin

Fig. 77 Remove Reverse Shift Rail C-ring

Fig. 78 Remove Reverse Shift Rail

(36) Remove the countershaft by moving the coun­tershaft rearward until the countershaft is clear of
the intermediate plate.

(37) Remove the countershaft rear bearing from
the intermediate plate.

ASSEMBLY

(1) Lubricate countershaft journal and rear bear­ing with petroleum jelly or gear lubricant.

Fig. 80 Remove Output Shaft Rear Bearing

Snap-ring

Fig. 81 Remove Mainshaft

(2) Position the mainshaft into the intermediate

plate.

XJ TRANSMISSION AND TRANSFER CASE 21 - 59

DISASSEMBLY AND ASSEMBLY (Continued)

(3) Tap the mainshaft assembly rear bearing into
the intermediate plate with a suitable rubber mallet.

(4) Install the countershaft thru the countershaft
rear bearing journal of the intermediate plate.

(5) Align and mesh the mainshaft and counter­shaft gears as much as possible.

(6) Install the countershaft bearing over the coun­tershaft bearing boss and into the intermediate plate.
Be sure to leave the snap-ring groove in the bearing
facing the rear of the unit. It may be necessary to tap
on the bearing with a plastic mallet to fully seat the
bearing into intermediate plate.

(7) Verify that the mainshaft and countershaft
gears are correctly meshed and rotate properly.

(8) Install snap-ring to hold output shaft rear
bearing into the intermediate plate (Fig. 66).

(9) Install countershaft rear bearing snap-ring.

NOTE: Coat all shift components with petroleum
jelly during assembly. Petroleum jelly will hold com­ponents in position during installation.

Fig. 83 Install Reverse Shift Rail

(10) Install interlock pin in reverse shift rail (Fig.

82).

(11) Install the reverse shift rail in the intermedi­ate plate (Fig. 83).

Fig. 82 Install Reverse Shift Rail Interlock Pin

(12) Install c-ring to hold the reverse shift rail into
the intermediate plate.

(13) Install the 1–2 and 3–4 shift forks into the
synchronizer sleeves (Fig. 84).

(14) Install 1–2 shift rail interlock plug in the
intermediate plate (Fig. 85).

(15) Install interlock pin in 1–2 shift rail (Fig. 86).

(16) Install 1–2 shift rail through intermediate
plate and 1–2 shift fork (Fig. 87).

Fig. 84 Install Shift Forks

(17) Install 3–4 shift rail interlock plug into the

intermediate plate (Fig. 88).

(18) Install the 3–4 shift rail through the interme-

diate plate, 1–2 and 3–4 shift forks (Fig. 89).

21 - 60 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 85 Install 1–2 Shift Rail Interlock Plug

Fig. 86 Install 1–2 Shift Rail Interlock Pin

Fig. 88 Install 3–4 Shift Rail Interlock Plug

Fig. 89 Install 3–4 Shift Rail

Fig. 87 Install 1–2 Shift Rail

(19) Install new bolts to hold the shift forks to the
shift rails (Fig. 90).

(20) Install c-rings to 1–2 and 3–4 shift rails (Fig.

91).

Fig. 90 Install Shift Fork To Shift Rail Bolts

(21) Install the fifth gear shift rail lock ball in the

intermediate plate (Fig. 94).

(22) Install the fifth gear shift rail into the inter-

mediate plate.

XJ TRANSMISSION AND TRANSFER CASE 21 - 61

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 91 Install Shift Rail C-rings

(23) Install reverse idler gear and idler gear shaft
(Fig. 92). Verify that the notch in the idler shaft is to
the rear of the transmission.

(24) Position output shaft rear bearing retainer on
intermediate plate and into reverse idler shaft notch.

(25) Install new bolts to hold retainer to interme­diate plate (Fig. 93).

Fig. 92 Install Reverse Idler Gear And Shaft

(26) Install the fifth gear thrust ring lock ball into
the countershaft (Fig. 95).

(27) Install fifth gear thrust ring onto countershaft
and over lock ball (Fig. 96).

(28) Install countershaft fifth gear bearing halves
into countershaft fifth gear assembly (Fig. 97).

(29) Install countershaft fifth gear assembly onto
countershaft (Fig. 98).

(30) Install fifth gear synchronizer ring (Fig. 99).

(31) Position fifth gear blocker ring onto counter­shaft. Verify that blocker ring and countershaft
splines are aligned.

(32) Using a suitable driver and mallet, seat the
blocker ring onto the countershaft.

(33) Select the thickest snap-ring the will fit into
the snap–ring groove of the countershaft.

Fig. 93 Install Output Shaft Rear Bearing Retainer

Fig. 94 Install Fifth Gear Shift Rail Lock Ball

Fig. 95 Install Fifth Gear Thrust Ring Lock Ball

(34) Install snap-ring to hold the countershaft fifth

gear assembly onto the countershaft (Fig. 100).

21 - 62 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 96 Install Fifth Gear Thrust Ring

Fig. 97 Install Countershaft Fifth Gear Bearings

Fig. 99 Install Fifth Gear Synchronizer Ring

Fig. 98 Install Countershaft Fifth Gear Assembly

(35) Install the reverse shift head and rail assem­bly (Fig. 101).

Fig. 100 Install Fifth Gear Snap-ring

(36) Move reverse shift rail forward as far as pos­sible and install fifth gear shift fork onto synchro­nizer sleeve (Fig. 102).

(37) Install new bolt to hold fifth gear shift fork to
shift rail (Fig. 103).

(38) Install detent balls and springs into openings
in the intermediate plate (Fig. 104).

(39) Install new lock ball plugs into the intermedi­ate plate. Tighten plugs to 19 N·m (14 ft. lbs.).

XJ TRANSMISSION AND TRANSFER CASE 21 - 63

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 101 Install Reverse Shift Head And Rail

Assembly

Fig. 102 Install Fifth Gear Shift Fork

Fig. 103 Install Fifth Gear Shift Fork Retainer Bolt

(40) Install bolts to hold reverse shift arm to the
intermediate plate. Tighten bolts to 18 N·m (13 ft.
lbs.).

Fig. 104 Install Detent Balls And Springs

COUNTERSHAFT

DISASSEMBLY

(1) Remove select fit snap-ring holding the coun-

tershaft front bearing onto the countershaft (Fig.

105).
(2) Using Bearing Splitter P-334, a suitable spacer

on center of countershaft, and a shop press, remove
the countershaft front bearing from the countershaft.

ASSEMBLY

(1) Remove any nicks or burrs on countershaft hub

with fine emery or crocus cloth.

(2) Position countershaft front bearing on end of

countershaft. Be sure the snap-ring groove in bearing
is facing forward.

(3) Using Special Tool 8109 and a shop press,

press bearing onto countershaft.

(4) Select the thickest snap-ring that will fit into

the snap-ring groove of the countershaft (Fig. 105).

(5) Install snap-ring to hold countershaft front

bearing onto countershaft.

21 - 64 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 107 Remove Output Shaft Pilot Bearing

Fig. 105 Countershaft Front Bearing Snap-ring

INPUT SHAFT

DISASSEMBLY

(1) Verify that the 3–4 synchronizer is in the neu-

tral position.

(2) Separate input shaft from output shaft (Fig.

106).

Fig. 106 Separate Input and Output Shafts

(3) Remove the output shaft pilot bearing from the

input shaft or output shaft (Fig. 107).

(4) Remove the fourth gear synchronizer ring from

the input shaft (Fig. 108).

(5) Remove the select fit snap-ring holding the

input shaft bearing onto the input shaft.

(6) Using Bearing Splitter P-334 and a shop press,

remove the bearing from the input shaft.

Fig. 108 Input Shaft Components

ASSEMBLY

(1) Position input shaft bearing onto input shaft.

Be sure that the snap-ring groove in the bearing is
facing forward.

(2) Using Driver 6052, drive bearing onto input

shaft.

(3) Select the thickest snap-ring that will fit into

the snap-ring groove of the input shaft (Fig. 109).

(4) Lubricate output shaft pilot bearing bore of

input shaft with petroleum jelly.

(5) Install output shaft pilot bearing in input shaft

bore (Fig. 107).

(6) Install the fourth gear synchronizer ring onto

the input shaft.

(7) Install input shaft to output shaft.

OUTPUT SHAFT

Refer to (Fig. 110) for parts identification during

disassembly and assembly of the output shaft.

XJ TRANSMISSION AND TRANSFER CASE 21 - 65

DISASSEMBLY AND ASSEMBLY (Continued)

(2) Measure and note thrust clearance of output

shaft gears (Fig. 112). First gear clearance should be

0.10 – 0.40 mm (0.004 – 0.0197 in.). Second and third

gear clearance should be 0.10 – 0.30 mm (0.003 –

0.0118 in.).

Fig. 109 Select Input Shaft Bearing Snap-ring

DISASSEMBLY

(1) Remove input shaft and output shaft pilot

bearing from output shaft (Fig. 111), if necessary.

Fig. 111 Remove Output Shaft Pilot Bearing

(3) Remove output shaft fifth gear snap ring with

two screwdrivers (Fig. 113).

(4) Using Bearing Splitter P-334 or suitable press

plates positioned under first gear, press fifth gear,

Fig. 110 Output Shaft And Gears

21 - 66 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 112 Check Output Shaft Gear Thrust Clearance

Fig. 113 Remove Fifth Gear Snap-ring

rear bearing, first gear, and first gear thrust washer
off output shaft (Fig. 114).

(5) Remove first gear thrust washer locating pin

from output shaft.

(6) Remove first gear needle roller bearing from

output shaft.

(7) Remove first gear spacer from output shaft.
(8) Remove first gear synchronizer ring.
(9) Remove select fit snap-ring holding the 1–2

synchronizer/reverse gear onto the output shaft.

Fig. 114 Remove Fifth Gear, First Gear Bearing, And

Thrust Washer

(10) Using Bearing Splitter P-334 or suitable press

plates positioned under second gear, press 1–2 syn­chronizer/reverse gear and second gear from output
shaft (Fig. 115).

Fig. 115 Remove Second Gear And 1–2

Synchronizer/Reverse Gear

(11) Remove second gear needle roller bearing

from the output shaft or second gear.

XJ TRANSMISSION AND TRANSFER CASE 21 - 67

DISASSEMBLY AND ASSEMBLY (Continued)

(12) Remove select fit snap-ring holding the 3–4

synchronizer onto the output shaft (Fig. 116).

Fig. 116 Remove 3–4 Synchronizer Snap Ring

(13) Using Bearing Splitter P-334 or suitable press
plates positioned under third gear, press the 3–4 syn­chronizer and third gear from output shaft (Fig. 117).

Fig. 117 Remove 3–4 Synchronizer And Third Gear

(14) Remove third gear needle roller bearing from
output shaft or gear.

ASSEMBLY

(1) Lubricate transmission components with speci-

fied gear lubricant during assembly.

(2) If necessary, assemble 1–2 and 3–4 synchro-

nizer hubs, sleeves, springs and key inserts (Fig.

118).

Fig. 118 Synchronizer Identification

(3) Install third gear needle bearing onto the out-

put shaft.

(4) Install third gear over bearing and onto output

shaft flange.

(5) Install third gear synchronizer ring to third

gear.

(6) Position the 3–4 synchronizer onto the output

shaft.

(7) Using Adapter 6761 and a shop press, press

the 3–4 synchronizer onto the output shaft.

(8) Select the thickest snap-ring that will fit into

the snap-ring groove of the output shaft (Fig. 119).

(9) Install snap-ring to hold 3–4 synchronizer onto

output shaft.

(10) Verify third gear thrust clearance with feeler
gauge (Fig. 120). Clearance should be 0.10 – 0.30 mm
(0.003 – 0.0118 in.). If clearance is out of specifica­tion, refer to Cleaning and Inspection section within
this group.

(11) Install second gear needle bearing onto output
shaft.

(12) Install second gear over bearing and onto out­put shaft flange.

(13) Install second gear synchronizer ring onto sec­ond gear.

(14) Position 1–2 synchronizer/reverse gear assem­bly onto splines of output shaft.

(15) Using Driver MD-998805, Adapter 6761, and
a shop press, press the 1–2 synchronizer/reverse gear
onto the output shaft.

(16) Select the thickest snap-ring that will fit into
the snap-ring groove of the output shaft (Fig. 121).

21 - 68 TRANSMISSION AND TRANSFER CASE XJ

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 119 Select 3–4 Synchronizer Snap-ring

Fig. 120 Check Third Gear Clearance

(17) Install snap-ring to hold 1–2 synchronizer/re-

verse gear onto output shaft.

(18) Install first gear synchronizer ring into 1–2

synchronizer/reverse gear.

(19) Install the first gear spacer onto the input
shaft and against the 1–2 synchronizer/reverse gear
snap-ring.

(20) Install first gear needle bearing onto output
shaft (Fig. 122).

(21) Install first gear onto output shaft and over
bearing.

(22) Install the first gear thrust washer locating
pin into the output shaft.

Fig. 121 Second Gear And Synchronizer Assembly

(23) Install the first gear thrust washer onto the
output shaft. Rotate the thrust washer until the
washer locating pin aligns with the notch in the
washer.

(24) Position output shaft rear bearing onto output
shaft. Ensure that the snap ring groove in bearing
outer race is toward rear of output shaft.

(25) Using Driver L-4507 and suitable mallet,
drive bearing onto output shaft.

(26) Install snap-ring onto output shaft rear bear­ing outer race.

Fig. 122 First And Fifth Gear Components

(27) Check first and second gear thrust clearance
(Fig. 123). First gear clearance should be 0.10 – 0.40
mm (0.003 – 0.0197 in.). Second gear clearance
should be 0.10 – 0.30 mm (0.003 – 0.0118 in.). If

XJ TRANSMISSION AND TRANSFER CASE 21 - 69

DISASSEMBLY AND ASSEMBLY (Continued)

clearance is out of specification, refer to Cleaning and
Inspection section within this group.

Fig. 123 Check First–Second Gear Thrust Clearance

(28) Position fifth gear onto output shaft with the
gear’s long shoulder toward the rear of shaft. Ensure
that the gear and output shaft splines are aligned.

(29) Using Adapter 6761, Driver L-4507, and a
shop press, press fifth gear onto output shaft.

(30) Select the thickest snap-ring that will fit into
the snap-ring groove of the output shaft (Fig. 124).

(31) Install snap-ring to hold fifth gear onto output
shaft.

(32) Install output shaft pilot bearing into the
input shaft.

(33) Install the input shaft to the output shafts.

CLEANING AND INSPECTION

AX15 MANUAL TRANSMISSION COMPONENTS

GENERAL INFORMATION

Clean the transmission components in solvent. Dry
the cases, gears, shift mechanism and shafts with
compressed air. Dry the bearings with clean, dry
shop towels only. Never use compressed air on the
bearings. This could cause severe damage to the
bearing roller and race surfaces.

If output shaft flange thickness is within specifica­tion but any gear thrust clearance is out of specifica­tion, replace the necessary gear and gear needle
bearing as an assembly.

Fig. 124 Select/Install Fifth Gear Snap Ring

GEAR CASE, ADAPTER/EXTENSION HOUSING, INTERMEDIATE PLATE

Clean the case, housing, and intermediate plate
with solvent and dry with compressed air. Replace
the case if cracked, porous, or if any of the bearing
and gear bores are damaged.

Inspect the threads in the case, housing, and plate.
Minor thread damage can be repaired with steel
thread inserts, if necessary. Do not attempt to repair
any threads which show evidence of cracks around
the threaded hole.

OUTPUT SHAFT

Check thickness of the output shaft flange with a
micrometer or vernier calipers (Fig. 125). Minimum
allowable flange thickness is 4.70 mm (0.185 in.).

Check diameter of the first, second, and third gear
bearing surfaces on the output shaft. Minimum
diameters are as follows:

• First gear bearing surface is 38.86 mm (1.529

in.).

• Second gear bearing surface is 46.86 mm (1.844

in.).

• Third gear bearing surface is 37.86 mm (1.490

in.).

21 - 70 TRANSMISSION AND TRANSFER CASE XJ

CLEANING AND INSPECTION (Continued)

Check synchronizer ring wear (Fig. 127). Insert
each ring in matching gear. Measure clearance
between each ring and gear with feeler gauge. Clear­ance should be 0.06 – 1.6 mm (0.024 – 0.063 in.).

Fig. 125 Check Output Shaft Tolerances

Measure output shaft runout with a dial indicator

and V-blocks (Fig. 125). Runout should not exceed

0.06 mm (0.0024 in.).
Replace output shaft if measurement of any sur-

face is out of specification. Do not attempt to repair
out of specification components.

COUNTERSHAFT

Inspect the countershaft gear teeth. Replace the

countershaft if any teeth are worn or damaged.
Inspect the bearing surfaces and replace shaft if any
surface shows damage or wear.

Check condition of the countershaft front bearing.

Replace the bearing if worn, noisy, or damaged.

Fig. 127 Check Synchronizer Ring Wear

GEAR AND SYNCHRONIZER

Install the needle bearings in the first, second,

third and counter fifth gears. Install the gears on the
output shaft. Then check oil clearance between the
gears and shaft with a dial indicator (Fig. 126). Oil
clearance for all three gears is 0.16 mm (0.0063 in.)
maximum.

Check shift fork–to–synchronizer hub clearance
with a feeler gauge (Fig. 128). Replace the fork if
clearance exceeds 1.0 mm (0.039 in.).

Fig. 126 Check Gear–To–Shaft Oil Clearance

Fig. 128 Check Fork–To–Hub Clearance

Check the condition of the reverse idler gear bush­ing (Fig. 129). Replace the gear if the bushing is
damaged or worn.

XJ TRANSMISSION AND TRANSFER CASE 21 - 71

SPECIFICATIONS (Continued)

SPECIAL TOOLS

AX15

C-3339 Dial Indicator Set

Fig. 129 Reverse Idler Gear Bushing

SPECIFICATIONS

TORQUE

DESCRIPTION TORQUE

Plugs, Access ................19N·m(14ft.lbs.)

Bolts, Adapter Housing ........34N·m(25ft.lbs.)

Switch, Back-up Light .......44N·m(32.5 ft.lbs.)

Plugs, Drain and Fill ........44N·m(32.5 ft.lbs.)

Bolts, Front Bearing Retainer . . . 17 N·m (12 ft.lbs.)

Plugs, Interlock and Detent.....19N·m(14ft.lbs.)

Screws, Propeller Shaft Clamp ........16–23 N·m

(140–200 in.lbs.)

Bolts, Rear Mount to Transmission ....33–60 N·m

(24–44 ft.lbs.)
Nut, Rear Mount Clevis . . 54–75 N·m (40–55 ft.lbs.)

Nuts, Rear Mount to Crossmember ....33–49 N·m

(24–36 ft.lbs.)

Pins, Restrictor .............27.4 N·m (20 ft.lbs.)

Bolts, Reverse Shift Arm Bracket .........18N·m

(13 ft.lbs.)

Screw, Shift Arm Set ..........38N·m(28ft.lbs.)

Screws, Shift Fork Set .........20N·m(15ft.lbs.)

Nut, Shift Knob ........20–34 N·m (15–25 ft.lbs.)

Screws, Shifter Floor Cover ............2–3N·m

(17–30 in.lbs.)

Bolts, Shift Tower ............18N·m(13ft.lbs.)

Nuts, Transfer Case Mounting ........30–41 N·m

(22–30 ft.lbs.)

C-4171 Handle, Universal Tool

8209 Installer, Seal

8212 Installer, Seal

21 - 72 TRANSMISSION AND TRANSFER CASE XJ

SPECIAL TOOLS (Continued)

8208 Installer, Seal

6052 Tube, Driver

L-4407A Puller, Gear

P-334 Splitter, Bearing

8109 Cup, Installer

6761 Adapter, Installer

MD-998805 Tube, Driver

L-4507 Tube, Driver

XJ TRANSMISSION AND TRANSFER CASE 21 - 73

AUTOMATIC TRANSMISSION—30RH

INDEX

page page

GENERAL INFORMATION

30RH AUTOMATIC TRANSMISSION ..........74

CAUSES OF BURNT FLUID ................ 74

EFFECTS OF INCORRECT FLUID LEVEL ..... 74

FLUID CONTAMINATION .................. 74

GEARSHIFT MECHANISM ................. 76

RECOMMENDED FLUID ................... 74

TORQUE CONVERTER—ELECTRONIC

CLUTCH .............................76

TRANSMISSION GEAR RATIOS ............. 76

TRANSMISSION IDENTIFICATION ........... 74

DESCRIPTION AND OPERATION

BRAKE TRANSMISSION SHIFT INTERLOCK

MECHANISM .......................... 77

CONVERTER CLUTCH ENGAGEMENT .......77

CONVERTER DRAINBACK VALVE ........... 77

HYDRAULIC CONTROL SYSTEM ............76

DIAGNOSIS AND TESTING

AIR TESTING TRANSMISSION CLUTCH AND

BAND OPERATION ..................... 82

ANALYZING ROAD TEST .................. 79

AUTOMATIC TRANSMISSION DIAGNOSIS ..... 77

CONVERTER HOUSING FLUID LEAK

DIAGNOSIS ........................... 83

CONVERTER STALL TEST ................. 81

DIAGNOSIS CHARTS ..................... 83

GEARSHIFT CABLE ......................79

HYDRAULIC PRESSURE TEST ............. 80

PARK/NEUTRAL POSITION SWITCH .........78

PRELIMINARY DIAGNOSIS ................ 77

ROAD TESTING ......................... 79

STALL TEST ANALYSIS ...................82

THROTTLE VALVE CABLE .................79

SERVICE PROCEDURES

ALUMINUM THREAD REPAIR .............. 93

CONVERTER DRAINBACK CHECK VALVE

SERVICE ............................. 92

FLUID AND FILTER REPLACEMENT ......... 91

FLUID LEVEL CHECK .................... 91

FLUSHING COOLERS AND TUBES .......... 93

OIL PUMP VOLUME CHECK ............... 92

TRANSMISSION FILL PROCEDURE .......... 92

REMOVAL AND INSTALLATION

BRAKE TRANSMISSION SHIFT INTERLOCK . . 100

EXTENSION HOUSING ................... 98

EXTENSION HOUSING BUSHING ........... 97

GEARSHIFT CABLE ..................... 100

GOVERNOR AND PARK GEAR ............ 102

OUTPUT SHAFT REAR BEARING .......... 102

PARK LOCK ........................... 103

PARK/NEUTRAL POSITION SWITCH .........99

SPEEDOMETER ADAPTER ................ 98

TORQUE CONVERTER ................... 96

TRANSMISSION ......................... 94

VALVE BODY .......................... 100

YOKE SEAL REPLACEMENT ............... 97

DISASSEMBLY AND ASSEMBLY

FRONT CLUTCH ....................... 126

FRONT SERVO PISTON .................. 121

GOVERNOR AND PARK GEAR ............ 104

OIL PUMP AND REACTION SHAFT SUPPORT
OVERRUNNING CLUTCH/LOW-REVERSE

DRUM .............................. 121

PLANETARY GEARTRAIN/OUTPUT SHAFT . . . 130

REAR CLUTCH ........................ 127

REAR SERVO PISTON ................... 122

TRANSMISSION ........................ 112

VALVE BODY .......................... 105

CLEANING AND INSPECTION

EXTENSION HOUSING AND PARK LOCK .... 136

FRONT CLUTCH ....................... 139

FRONT SERVO ........................ 138

GOVERNOR AND PARK GEAR ............ 134

OIL PUMP AND REACTION SHAFT

SUPPORT ........................... 139

OVERRUNNING CLUTCH/LOW-REVERSE

DRUM/OVERDRIVE PISTON RETAINER ....138

PLANETARY GEARTRAIN/OUTPUT SHAFT . . . 140

REAR CLUTCH ........................ 139

REAR SERVO ......................... 138

TRANSMISSION ........................ 137

VALVE BODY .......................... 136

ADJUSTMENTS

BRAKE TRANSMISSION SHIFT INTERLOCK

CABLE ADJUSTMENT .................. 141

FRONT BAND ADJUSTMENT .............. 142

GEARSHIFT CABLE ..................... 140

REAR BAND ADJUSTMENT ............... 143

TRANSMISSION THROTTLE VALVE CABLE

ADJUSTMENT ........................ 141

VALVE BODY .......................... 143

SCHEMATICS AND DIAGRAMS

HYDRAULIC SCHEMATICS ............... 144

SPECIFICATIONS

30RH AUTOMATIC TRANSMISSION ......... 157

TORQUE ............................. 158

SPECIAL TOOLS

30RH TRANSMISSIONS ..................158

. . 123

21 - 74 TRANSMISSION AND TRANSFER CASE XJ

GENERAL INFORMATION

30RH AUTOMATIC TRANSMISSION

The 30RH automatic transmission is used with the

2.5L engine (Fig. 1). The 30RH is a three speed
transmissions with a lock-up clutch in the torque
converter. The torque converter clutch is controlled
by the Powertrain Control Module (PCM). The torque
converter clutch is hydraulically applied and is
released when fluid is vented from the hydraulic cir­cuit by the torque converter control (TCC) solenoid
on the valve body. The torque converter clutch
engages in third gear when the vehicle is cruising on
a level plane after the vehicle has warmed up. The
torque converter clutch will disengage when the vehi­cle begins to go uphill or the accelerator is applied.
The torque converter clutch feature increases fuel
economy and reduces the transmission fluid temper­ature. The 30RH transmission is cooled by an inte­gral fluid cooler inside the radiator.

TRANSMISSION IDENTIFICATION

Transmission identification numbers are stamped
on the left side of the case just above the oil pan gas­ket surface (Fig. 2). Refer to this information when
ordering replacement parts.

RECOMMENDED FLUID

Mopart ATF Plus 3, Type 7176 automatic trans­mission fluid is the recommended fluid for Chrysler
automatic transmissions.

Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.

EFFECTS OF INCORRECT FLUID LEVEL

A low fluid level allows the pump to take in air
along with the fluid. Air in the fluid will cause fluid
pressures to be low and develop slower than normal.
If the transmission is overfilled, the gears churn the
fluid into foam. This aerates the fluid and causing
the same conditions occurring with a low level. In
either case, air bubbles cause fluid overheating, oxi­dation and varnish buildup which interferes with
valve, clutch and servo operation. Foaming also
causes fluid expansion which can result in fluid over­flow from the transmission vent or fill tube. Fluid
overflow can easily be mistaken for a leak if inspec­tion is not careful.

CAUSES OF BURNT FLUID

Burnt, discolored fluid is a result of overheating
which has two primary causes.

(1) A result of restricted fluid flow through the
main and/or auxiliary cooler. This condition is usu­ally the result of a faulty or improperly installed

drainback valve, a damaged main cooler, or severe
restrictions in the coolers and lines caused by debris
or kinked lines.

(2) Heavy duty operation with a vehicle not prop­erly equipped for this type of operation. Trailer tow­ing or similar high load operation will overheat the
transmission fluid if the vehicle is improperly
equipped. Such vehicles should have an auxiliary
transmission fluid cooler, a heavy duty cooling sys­tem, and the engine/axle ratio combination needed to
handle heavy loads.

FLUID CONTAMINATION

Transmission fluid contamination is generally a
result of:

• adding incorrect fluid

• failure to clean dipstick and fill tube when

checking level

• engine coolant entering the fluid

• internal failure that generates debris

• overheat that generates sludge (fluid break-

down)

• failure to reverse flush cooler and lines after

repair

• failure to replace contaminated converter after

repair.

The use of non recommended fluids can result in
transmission failure. The usual results are erratic
shifts, slippage, abnormal wear and eventual failure
due to fluid breakdown and sludge formation. Avoid
this condition by using recommended fluids only.

The dipstick cap and fill tube should be wiped
clean before checking fluid level. Dirt, grease and
other foreign material on the cap and tube could fall
into the tube if not removed beforehand. Take the
time to wipe the cap and tube clean before withdraw­ing the dipstick.

Engine coolant in the transmission fluid is gener­ally caused by a cooler malfunction. The only remedy
is to replace the radiator as the cooler in the radiator
is not a serviceable part. If coolant has circulated
through the transmission for some time, an overhaul
may also be necessary; especially if shift problems
had developed.

The transmission cooler and lines should be
reverse flushed whenever a malfunction generates
sludge and/or debris. The torque converter should
also be replaced at the same time.

Failure to flush the cooler and lines will result in
recontamination. Flushing applies to auxiliary cool­ers as well. The torque converter should also be
replaced whenever a failure generates sludge and
debris. This is necessary because normal converter
flushing procedures will not remove all contami­nants.

XJ TRANSMISSION AND TRANSFER CASE 21 - 75

GENERAL INFORMATION (Continued)

Fig. 1 30RH Automatic Transmission

21 - 76 TRANSMISSION AND TRANSFER CASE XJ

GENERAL INFORMATION (Continued)

GEARSHIFT MECHANISM

The shift mechanism is cable operated and pro­vides six shift positions. The shift indicator is located
on the console next to the gear shift. The shift posi­tions are:

• Park (P)

• Reverse (R)

• Neutral (N)

• Drive (D)

• Manual Second (2)

• Manual Low (1)

Manual low (1) range provides first gear only. Over
run braking is also provided in this range. Manual
second (2) range provides first and second gear only.
Drive range provides first, second, and third gear

Fig. 2 Transmission Part And Serial Number

Location

TORQUE CONVERTER—ELECTRONIC CLUTCH

The torque converter is a hydraulic device that
couples the engine crankshaft to the transmission.
The torque converter consists of an outer shell with
an internal turbine, a stator, an overrunning clutch,
an impeller and an electronically applied converter
clutch. Torque multiplication is created when the sta­tor directs the hydraulic flow from the turbine to
rotate the impeller in the direction the engine crank­shaft is turning. The turbine transfers power to the
planetary gear sets in the transmission. The transfer
of power into the impeller assists torque multiplica­tion. At low vehicle speed, the overrunning clutch
holds the stator (during torque multiplication) and
allows the stator to free wheel at high vehicle speed.
The converter clutch provides reduced engine speed
and greater fuel economy when engaged. Clutch
engagement also provides reduced transmission fluid
temperatures. The converter clutch engages in third
gear. The torque converter hub drives the transmis­sion oil (fluid) pump.

The torque converter is a sealed, welded unit that
is not repairable and is serviced as an assembly.

CAUTION: The torque converter must be replaced if
a transmission failure resulted in large amounts of
metal or fiber contamination in the fluid. If the fluid
is contaminated, flush the fluid cooler and lines.

ranges.

DESCRIPTION AND OPERATION

HYDRAULIC CONTROL SYSTEM

The transmission hydraulic control system per-

forms four basic functions.

• pressure supply

• pressure regulation

• flow control and lubrication

• clutch/band application

PRESSURE SUPPLY

The oil pump develops fluid pressure for clutch/
band application and for lubrication. The pump is
driven by the torque converter. The converter is
driven by a driveplate attached to the engine crank­shaft.

Pressure Regulation

The pressure regulator valve maintains line (oper­ating) pressure. The amount of pressure developed is
controlled by throttle pressure which is dependent on
the degree of throttle opening. The regulator valve is
located in the valve body.

The throttle valve determines throttle pressure
and shift speed. Governor pressure increases in pro­portion to vehicle speed. The throttle valve controls
upshift and downshift speeds by regulating pressure
according to throttle position.

TRANSMISSION GEAR RATIOS

Forward gear ratios are:

• 2.74:1 (first gear)

• 1.54:1 (second gear)

• 1.00:1 (third gear)

Flow Control And Lubrication

The manual valve is operated by the gearshift link­age and provides the operating range selected by the
driver.

The switch valve controls line pressure to the con­verter clutch. The valve also directs oil to the cooling
and lubrication circuits. The switch valve regulates
oil pressure to the torque converter by limiting max­imum oil pressure to 130 psi.

XJ TRANSMISSION AND TRANSFER CASE 21 - 77

DESCRIPTION AND OPERATION (Continued)

The 1-2 shift valve provide 1-2 and 2-1 shifts and

the 2-3 shift valve provide 2-3 and 3-2 shifts.

The 1-2 shift control valve transmits 1-2 shift pres­sure to the accumulator piston. This controls kick­down band capacity on 1-2 upshifts and 3-2
downshifts.

The 2-3 valve throttle pressure plug provides 3-2
downshifts at varying throttle openings depending on
vehicle speed.

The kickdown valve provides forced downshifts
depending on vehicle speed. Downshifts occur when
the throttle is opened beyond downshift detent posi­tion. Detent is reached just before wide open throttle
position.

The limit valve determines maximum speed at
which a 3-2 part throttle kickdown can be made.
Some transmissions do not have the limit valve and
maximum speed for a 3-2 kickdown is at the detent
position.

The shuttle valve has two functions. First is fast
front band release and smooth engagement during
“lift foot” 2-3 upshifts. Second is to regulate front
clutch release and band application during 3-2 down­shifts.

The fail safe valve restricts feed to the converter
clutch if front clutch pressure drops. It permits
clutch engagement only in direct (third) gear and
provides fast clutch release during kickdown.

Clutch/Band Application

The front/rear clutch pistons and servo pistons are
actuated by line pressure. When line pressure is
removed, the pistons are released by spring tension.

On 2-3 upshifts, the front servo piston is released
by spring tension and hydraulic pressure. The accu­mulator controls hydraulic pressure on the apply side
of the front servo during 1-2 upshifts and at all
throttle openings.

CONVERTER CLUTCH ENGAGEMENT

Converter clutch engagement in third gear is con­trolled by sensor inputs to the powertrain control
module. Inputs that determine clutch engagement
are: coolant temperature, vehicle speed and throttle
position. The torque converter clutch is engaged by
the clutch solenoid on the valve body. The clutch will
engage at approximately 56 km/h (35 mph) with light
throttle, after the shift to third gear.

CONVERTER DRAINBACK VALVE

The drainback valve is located in the transmission
cooler outlet (pressure) line. The valve prevents fluid
from draining from the converter into the cooler and
lines when the vehicle is shut down for lengthy peri­ods. Production valves have a hose nipple at one end,
while the opposite end is threaded for a flare fitting.

All valves have an arrow (or similar mark) to indi­cate direction of flow through the valve.

BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM

The Brake Transmission Shifter/Ignition Interlock
(BTSI), is a cable and solenoid operated system. It
interconnects the automatic transmission floor
mounted shifter to the steering column ignition
switch (Fig. 3). The system locks the shifter into the
PARK position. The Interlock system is engaged
whenever the ignition switch is in the LOCK or
ACCESSORY position. An additional electrically acti­vated feature will prevent shifting out of the PARK
position unless the brake pedal is depressed at least
one-half an inch. A magnetic holding device in line
with the park/brake interlock cable is energized
when the ignition is in the RUN position. When the
key is in the RUN position and the brake pedal is
depressed, the shifter is unlocked and will move into
any position. The interlock system also prevents the
ignition switch from being turned to the LOCK or
ACCESSORY position (Fig. 4) unless the shifter is
fully locked into the PARK position.

DIAGNOSIS AND TESTING

AUTOMATIC TRANSMISSION DIAGNOSIS

Automatic transmission problems can be a result of
poor engine performance, incorrect fluid level, incor­rect linkage or cable adjustment, band or hydraulic
control pressure adjustments, hydraulic system mal­functions or electrical/mechanical component mal­functions. Begin diagnosis by checking the easily
accessible items such as: fluid level and condition,
linkage adjustments and electrical connections. A
road test will determine if further diagnosis is neces­sary.

PRELIMINARY DIAGNOSIS

Two basic procedures are required. One procedure
for vehicles that are drivable and an alternate proce­dure for disabled vehicles (will not back up or move
forward).

VEHICLE IS DRIVEABLE

(1) Check for transmission fault codes using DRB
scan tool.

(2) Check fluid level and condition.

(3) Adjust throttle and gearshift linkage if com­plaint was based on delayed, erratic, or harsh shifts.

(4) Road test and note how transmission upshifts,
downshifts, and engages.

(5) Perform stall test if complaint is based on slug­gish acceleration. Or, if abnormal throttle opening is

21 - 78 TRANSMISSION AND TRANSFER CASE XJ

DIAGNOSIS AND TESTING (Continued)

Fig. 3 Ignition Interlock Cable Routing

Fig. 4 Ignition Key Cylinder Actuation

needed to maintain normal speeds with a properly
tuned engine.

(6) Perform hydraulic pressure test if shift prob-

lems were noted during road test.

(7) Perform air-pressure test to check clutch-band

operation.

VEHICLE IS DISABLED

(1) Check fluid level and condition.
(2) Check for broken or disconnected gearshift or

throttle linkage.

(3) Check for cracked, leaking cooler lines, or loose

or missing pressure-port plugs.

(4) Raise and support vehicle on safety stands,
start engine, shift transmission into gear, and note
following:

(a) If propeller shaft turns but wheels do not,

problem is with differential or axle shafts.

(b) If propeller shaft does not turn and transmis­sion is noisy, stop engine. Remove oil pan, and
check for debris. If pan is clear, remove transmis­sion and check for damaged drive plate, converter,
oil pump, or input shaft.

(c) If propeller shaft does not turn and transmis­sion is not noisy, perform hydraulic-pressure test to
determine if problem is hydraulic or mechanical.

PARK/NEUTRAL POSITION SWITCH

The center terminal of the park/neutral position

switch is the starter-circuit terminal. It provides the
ground for the starter solenoid circuit through the
selector lever in PARK and NEUTRAL positions only.
The outer terminals on the switch are for the backup
lamp circuit.

SWITCH TEST

To test the switch, remove the wiring connector.

Test for continuity between the center terminal and
the transmission case. Continuity should exist only
when the transmission is in PARK or NEUTRAL.

XJ TRANSMISSION AND TRANSFER CASE 21 - 79

DIAGNOSIS AND TESTING (Continued)

Shift the transmission into REVERSE and test
continuity at the switch outer terminals. Continuity
should exist only when the transmission is in
REVERSE. Continuity should not exist between the
outer terminals and the case.

Check gearshift linkage adjustment before replac­ing a switch that tests faulty.

GEARSHIFT CABLE

(1) The floor shifter lever and gate positions
should be in alignment with all transmission PARK,
NEUTRAL, and gear detent positions.

(2) Engine starts must be possible with floor shift
lever in PARK or NEUTRAL gate positions only.
Engine starts must not be possible in any other gear
position.

(3) With floor shift lever handle push-button not
depressed and lever in:

(a) PARK position—Apply forward force on cen­ter of handle and remove pressure. Engine starts
must be possible.

(b) PARK position—Apply rearward force on cen­ter of handle and remove pressure. Engine starts
must be possible.

(c) NEUTRAL position—Normal position. Engine
starts must be possible.

(d) NEUTRAL position—Engine running and
brakes applied, apply forward force on center of
shift handle. Transmission shall not be able to shift
from neutral to reverse.

THROTTLE VALVE CABLE

Transmission throttle valve cable adjustment is

extremely important to proper operation. This adjust­ment positions the throttle valve, which controls shift
speed, quality, and part-throttle downshift sensitivity.

If cable setting is too loose, early shifts and slip-

page between shifts may occur. If the setting is too
tight, shifts may be delayed and part throttle down­shifts may be very sensitive. Refer to the Adjust­ments section for the proper adjustment procedure.

ROAD TESTING

Before road testing, be sure the fluid level and con-

trol cable adjustments have been checked and
adjusted if necessary. Verify that diagnostic trouble
codes have been resolved.

Observe engine performance during the road test.

A poorly tuned engine will not allow accurate analy­sis of transmission operation.

Operate the transmission in all gear ranges. Check

for shift variations and engine flare which indicates
slippage. Note if shifts are harsh, spongy, delayed,
early, or if part throttle downshifts are sensitive.

Slippage indicated by engine flare, usually means

clutch, band or overrunning clutch problems. If the

condition is advanced, an overhaul will be necessary
to restore normal operation.

A slipping clutch or band can often be determined
by comparing which internal units are applied in the
various gear ranges. The Clutch and Band Applica­tion chart provides a basis for analyzing road test
results.

Fig. 5 Clutch And Band Application

ANALYZING ROAD TEST

Refer to the Clutch and Band Application chart
and note which elements are in use in the various
gear ranges.

Verify that the rear clutch is applied in all forward
ranges (D, 2, 1). The transmission overrunning clutch
is applied in first gear (D, 2 and 1 ranges) only. The
rear band is applied in 1 and R range only.

Verify that the overdrive clutch is applied only in
fourth gear and the overdrive direct clutch and over­running clutch are applied in all ranges except fourth
gear. For example: If slippage occurs in first gear in
D and 2 range but not in 1 range, the transmission
overrunning clutch is faulty. Similarly, if slippage
occurs in any two forward gears, the rear clutch is
slipping.

Applying the same method of analysis, verify that
the front and rear clutches are applied simulta­neously only in D range third gear. If the transmis­sion slips in third gear, either the front clutch or the
rear clutch is slipping.

If slippage occurs during the third gear and the
direct clutch were to fail, the transmission would lose
both reverse gear and overrun braking in 2 position
(manual second gear). If the transmission slips in
any other forward gears, the transmission rear clutch
is probably slipping.

21 - 80 TRANSMISSION AND TRANSFER CASE XJ

DIAGNOSIS AND TESTING (Continued)

This process of elimination can be used to identify
a slipping unit and check operation. Proper use of
the Clutch and Band Application Chart is the key.

Although road test analysis will help determine the
slipping unit, the actual cause of a malfunction usu­ally cannot be determined until hydraulic and air
pressure tests are performed. Practically any condi­tion can be caused by leaking hydraulic circuits or
sticking valves.

Unless a malfunction is obvious, such as no drive
in D range first gear, do not disassemble the trans­mission. Perform the hydraulic and air pressure tests
to help determine the probable cause.

Fig. 7 Pressure Test Ports At Rear Of Case—2WD

HYDRAULIC PRESSURE TEST

Hydraulic test pressures range from a low of one
psi (6.895 kPa) governor pressure, to 300 psi (2068
kPa) at the rear servo pressure port in reverse.

An accurate tachometer and two test gauges are
required for the pressure test. Test Gauge C-3292
has a 100 psi range and is used at the accumulator,
governor, and front servo pressure ports. Test Gauge
C-3293-SP has a 300 psi range and is used at the
rear servo port and overdrive test ports where pres­sures are higher. In cases where two test gauges are
required, the 300 psi gauge can be used at any of the
other test ports.

Pressure Test Port Locations

Pressure test ports locations are provided at the
accumulator, front servo, and rear servo, governor
passage, and overdrive clutch pressure passage (Fig.

6), (Fig. 7) and (Fig. 8).

Line pressure is checked at the accumulator port
on the right side of the case. The front servo pressure
port is at the right side of the case just behind the
filler tube opening.

Fig. 6 Pressure Test Ports At Side Of Case

Connect a tachometer to the engine. Position the
tachometer so it can be observed from under the
vehicle. Raise the vehicle on a hoist that will allow
the wheels to rotate freely.

Fig. 8 Pressure Test Ports At Rear Of Case—4WD

PRESSURE TEST PROCEDURE

Test One - Transmission In 1 Range

This test checks pump output, pressure regulation,
and condition of the rear clutch and servo circuit.
Test Gauges C-3292 and C-3293-SP are required for
this test. Gauge C-3292 has a 100 psi range. Gauge
C-3293-SP has a 300 psi range.

(1) Connect 100 psi Gauge C-3292 to accumulator
port.

(2) Connect 300 psi Gauge C-3293-SP to rear servo
port (Fig. 6) and (Fig. 7).

(3) Disconnect throttle and gearshift rods from
manual and throttle levers.

(4) Start and run engine at 1000 rpm.

(5) Move shift lever (on manual lever shaft) all the
way forward into 1 range.

(6) Move transmission throttle lever from full for­ward to full rearward position and note pressures on
both gauges.

(7) Line pressure at accumulator port should be
54-60 psi (372-414 kPa) with throttle lever forward
and gradually increase to 90-96 psi (621-662 kPa) as
lever is moved rearward.

(8) Rear servo pressure should be same as line
pressure within 3 psi (20.68 kPa).

Test Two - Transmission In 2 Range

This test checks pump output and pressure regula­tion. Use 100 psi Test Gauge C-3292 for this test.

(1) Connect test gauge to accumulator pressure
port (Fig. 6) and (Fig. 7).

XJ TRANSMISSION AND TRANSFER CASE 21 - 81

DIAGNOSIS AND TESTING (Continued)

(2) Start and run engine at 1000 rpm.

(3) Move shift lever on valve body manual lever
shaft, one detent rearward from full forward position.
This is 2 range.

(4) Move transmission throttle lever from full for­ward to full rearward position and read pressure at
both gauges.

(5) Line pressure should be 54-60 psi (372-414
kPa) with throttle lever forward and gradually
increase to 90-96 psi (621-662 kPa) as lever is moved
rearward.

Test Three - Transmission In D Range

This test checks pressure regulation and condition
of the clutch circuits. Use both pressure Test Gauges
C-3292 and C-3293-SP for this test.

(1) Connect test gauges to accumulator and front
servo ports (Fig. 6) and (Fig. 7). Use either test
gauge at the two ports.

(2) Start and run engine at 1600 rpm for this test.

(3) Move selector lever to D range. This is two
detents rearward from full forward position.

(4) Read pressures on both gauges as transmission
throttle lever is moved from full forward to full rear­ward position.

(5) Line pressure should be 54-60 psi (372-414
kPa) with throttle lever forward and gradually
increase as lever is moved rearward.

(6) Front servo is pressurized only in D range and
should be same as line pressure within 3 psi (21 kPa)
up to downshift point.

(3) Start and run engine at curb idle speed and
note pressure. At idle and with vehicle stopped, pres­sure should be zero to 1.5 psi maximum. If pressure
exceeds this figure, governor valve or weights are
sticking open.

(4) Slowly increase engine speed and observe
speedometer and pressure test gauge. Governor pres­sure should increase in proportion to vehicle speed.

(5) Pressure rise should be smooth and drop back
to 0 to 1.5 psi when wheels stop rotating.

(6) Compare results of pressure tests with analysis
charts (Fig. 9).

Test Four - Transmission In Reverse

This test checks pump output, pressure regulation
and the front clutch and rear servo circuits. Use 300
psi Test Gauge C-3293-SP for this test.

(1) Connect 300 psi gauge to rear servo port (Fig.

6) and (Fig. 7).

(2) Start and run engine at 1600 rpm for test.

(3) Move valve body selector lever four detents
rearward from the full forward position. This is
Reverse range.

(4) Move throttle lever all way forward then all
way rearward and note gauge readings.

(5) Pressure should be 145 - 175 psi (1000-1207
kPa) with lever forward and increase to 230 - 280 psi
(1586-1931 kPa) as lever is moved rearward.

Test Five - Governor Pressure

This test checks governor operation by measuring
governor pressure response to changes in engine
speed. It is usually not necessary to check governor
operation unless shift speeds are incorrect or if the
transmission will not downshift.

(1) Connect 100 psi Test Gauge C-3292 to governor
pressure port (Fig. 6) and (Fig. 7).

(2) Move shift lever to D range.

Fig. 9 Pressure Test Analysis

CONVERTER STALL TEST

Stall testing involves determining maximum
engine speed obtainable at full throttle with the rear
wheels locked and the transmission in D range. This
test checks the holding ability of the converter over­running and transmission clutches.

WARNING: NEVER ALLOW ANYONE TO STAND
DIRECTLY IN LINE WITH THE VEHICLE FRONT OR
REAR DURING A STALL TEST. ALWAYS BLOCK
THE WHEELS AND FULLY APPLY THE SERVICE
AND PARKING BRAKES DURING THE TEST.

21 - 82 TRANSMISSION AND TRANSFER CASE XJ

DIAGNOSIS AND TESTING (Continued)

STALL TEST PROCEDURE

(1) Connect tachometer to engine. Position tachom-

eter so it can be viewed from driver’s seat.

(2) Drive vehicle to bring transmission fluid up to
normal operating temperature. Vehicle can be driven
on road or on chassis dynamometer, if available.

(3) Check transmission fluid level. Add fluid if nec­essary.

(4) Block front wheels.

(5) Fully apply service and parking brakes.

(6) Open throttle completely and record maximum
engine speed registered on tachometer. It takes 4-10
seconds to reach max rpm. Once max rpm has

been achieved, do not hold wide open throttle
for more than 4-5 seconds.

CAUTION: Stalling the converter causes a rapid
increase in fluid temperature. To avoid fluid over­heating, hold the engine at maximum rpm for no
more than 5 seconds. If engine exceeds 2500 rpm
during the test, release the accelerator pedal imme­diately; transmission clutch slippage is occurring.

(7) If a second stall test is required, cool down
fluid before proceeding. Shift into NEUTRAL and run
engine at 1000 rpm for 20-30 seconds to cool fluid.

and listen for noise coming from the converter hous­ing.

AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATION

Air-pressure testing can be used to check transmis­sion front/rear clutch and band operation. The test
can be conducted with the transmission either in the
vehicle or on the work bench, as a final check, after
overhaul.

Air-pressure testing requires that the oil pan and
valve body be removed from the transmission. The
servo and clutch apply passages are shown (Fig. 10).

STALL TEST ANALYSIS

Stall Speed Too High

If the stall speed exceeds 2500 rpm, transmission

clutch slippage is indicated.

Stall Speed Low

Low stall speed with a properly tuned engine indi­cate a torque converter overrunning clutch problem.
The condition should be confirmed by road testing. A
stall speed 250-350 rpm below normal indicates the
converter overrunning clutch is slipping. The vehicle
also exhibits poor acceleration but operates normally
once highway cruise speeds are reached. Torque con­verter replacement will be necessary.

Stall Speed Normal But Acceleration Poor

If stall speeds are normal (1800-2300 rpm) but
abnormal throttle opening is required for accelera­tion, or to maintain cruise speed, the converter over­running clutch is seized. The torque converter will
have to be replaced.

Converter Noise During Test

A whining noise caused by fluid flow is normal dur­ing a stall test. However, loud metallic noises indi­cate a damaged converter. To confirm that the noise
is originating from the converter, operate the vehicle
at light throttle in DRIVE and NEUTRAL on a hoist

Fig. 10 Air Pressure Test Passages

Front Clutch Air Test

Place one or two fingers on the clutch housing and
apply air pressure through front clutch apply pas­sage. Piston movement can be felt and a soft thump
heard as the clutch applies.

Rear Clutch Air Test

Place one or two fingers on the clutch housing and
apply air pressure through rear clutch apply passage.
Piston movement can be felt and a soft thump heard
as the clutch applies.

Front Servo Apply Air Test

Apply air pressure to the front servo apply pas­sage. The servo rod should extend and cause the
band to tighten around the drum. Spring pressure
should release the servo when air pressure is
removed.

XJ TRANSMISSION AND TRANSFER CASE 21 - 83

DIAGNOSIS AND TESTING (Continued)

Rear Servo Air Test

Apply air pressure to the rear servo apply passage.
The servo rod should extend and cause the band to
tighten around the drum. Spring pressure should
release the servo when air pressure is removed.

CONVERTER HOUSING FLUID LEAK DIAGNOSIS

When diagnosing converter housing fluid leaks,
two items must be established before repair.

(1) Verify that a leak condition actually exists.

(2) Determined the true source of the leak.

Some suspected converter housing fluid leaks may
not be leaks at all. They may only be the result of
residual fluid in the converter housing, or excess
fluid spilled during factory fill or fill after repair.
Converter housing leaks have several potential
sources. Through careful observation, a leak source
can be identified before removing the transmission
for repair. Pump seal leaks tend to move along the
drive hub and onto the rear of the converter. Pump
O-ring or pump body leaks follow the same path as a
seal leak (Fig. 11). Pump vent or pump attaching bolt
leaks are generally deposited on the inside of the
converter housing and not on the converter itself
(Fig. 11). Pump seal or gasket leaks usually travel
down the inside of the converter housing. Front band
lever pin plug leaks are generally deposited on the
housing and not on the converter.

is tight around front clutch retainer. This prevents
front/rear clutches from coming out when oil pump is
removed.

Inspect pump housing drainback and vent holes for
obstructions. Clear holes with solvent and wire.

bushing is scored, replace it. If converter hub is
scored, either polish it with crocus cloth or replace
converter.

Replace oil pump if cracked, porous or damaged in
any way. Be sure to loosen the front band before
installing the oil pump, damage to the oil pump seal
may occur if the band is still tightened to the front
clutch retainer.

turns. Apply Loctite 592, or Permatex No. 2 to plug
threads and tighten plug to 17 N·m (150 in. lbs.)
torque.

transmission fluid or petroleum jelly and install con­verter.

dust shield.

Fig. 12 Converter Leak Points—Typical

(2) Tighten front band adjusting screw until band

(3) Remove oil pump and remove pump seal.

(4) Inspect pump bushing and converter hub. If

(5) Install new pump seal, O-ring, and gasket.

(6) Loosen kickdown lever pin access plug three

(7) Adjust front band.
(8) Lubricate pump seal and converter hub with

(9) Install transmission and converter housing
(10) Lower vehicle.

Fig. 11 Converter Housing Leak Paths

TORQUE CONVERTER LEAK POINTS

Possible sources of converter leaks are:

(1) Leaks at the weld joint around the outside
diameter weld (Fig. 12).

(2) Leaks at the converter hub weld (Fig. 12).

CONVERTER HOUSING AREA LEAK CORRECTION

(1) Remove converter.

DIAGNOSIS CHARTS

The diagnosis charts provide additional reference
when diagnosing a transmission fault. The charts
provide general information on a variety of transmis­sion, overdrive unit and converter clutch fault condi­tions.

The hydraulic flow charts, in the Schematics and
Diagrams section of this group, outline fluid flow and
hydraulic circuitry. Circuit operation is provided for
neutral, third, fourth and reverse gear ranges. Nor­mal working pressures are also supplied for each of
the gear ranges.

21 - 84 TRANSMISSION AND TRANSFER CASE XJ

DIAGNOSIS AND TESTING (Continued)

DIAGNOSIS CHART

CONDITION POSSIBLE CAUSES CORRECTION

HARSH ENGAGEMENT
FROM NEUTRAL TO
DRIVE OR REVERSE

DELAYED ENGAGEMENT
FROM NEUTRAL TO
DRIVE OR REVERSE

1. Fluid Level Low. 1. Add Fluid.

2. Throttle Linkage Misadjusted. 2. Adjust linkage - setting may be too long.

3. Mount and Driveline Bolts Loose. 3. Check engine mount, transmission
mount, propeller shaft, rear spring to body
bolts, rear control arms, crossmember and
axle bolt torque. Tighten loose bolts and
replace missing bolts.

4. U-Joint Worn/Broken. 4. Remove propeller shaft and replace
U-Joint.

5. Axle Backlash Incorrect. 5. Check per Service Manual. Correct as
needed.

6. Hydraulic Pressure Incorrect. 6. Check pressure. Remove, overhaul or
adjust valve body as needed.

7. Band Misadjusted. 7. Adjust rear band.

8. Valve Body Check Balls Missing. 8. Inspect valve body for proper check ball
installation.

9. Axle Pinion Flange Loose. 9. Replace nut and check pinion threads
before installing new nut. Replace pinion
gear if threads are damaged.

10. Clutch, band or planetary

component Damaged.

11. Converter Clutch (if equipped)

Faulty.

1. Fluid Level Low. 1. Correct level and check for leaks.

2. Filter Clogged. 2. Change filter.

3. Gearshift Linkage Misadjusted. 3. Adjust linkage and repair linkage if worn

4. Rear Band Misadjusted. 4. Adjust band.

5. Valve Body Filter Plugged. 5. Replace fluid and filter. If oil pan and old

6. Oil Pump Gears Worn/Damaged. 6. Remove transmission and replace oil

7. Hydraulic Pressure Incorrect. 7. Perform pressure test, remove

8. Reaction Shaft Seal Rings

Worn/Broken.

9. Rear Clutch/Input Shaft, Rear

Clutch Seal Rings Damaged.

10. Governor Valve Stuck. 10. Remove and inspect governor

11. Regulator Valve Stuck. 11. Clean.

12. Cooler Plugged. 12. Flush transmission cooler and inspect

10. Remove, disassemble and repair
transmission as necessary.

11. Replace converter and flush cooler and
line before installing new converter.

or damaged.

fluid were full of clutch disc material and/or
metal particles, overhaul will be necessary.

pump.

transmission and repair as needed.

8. Remove transmission, remove oil pump
and replace seal rings.

9. Remove and disassemble transmission
and repair as necessary.

components. Replace worn or damaged
parts.

convertor drainback valve.

XJ TRANSMISSION AND TRANSFER CASE 21 - 85

DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

NO DRIVE RANGE
(REVERSE OK)

NO DRIVE OR REVERSE
(VEHICLE WILL NOT
MOVE)

1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.

2. Gearshift Linkage/Cable

Loose/Misadjusted.

3. Rear Clutch Burnt. 3. Remove and disassemble transmission

4. Valve Body Malfunction. 4. Remove and disassemble valve body.

5. Transmission Overrunning Clutch

Broken.

6. Input Shaft Seal Rings Worn/

Damaged.

7. Front Planetary Failed Broken. 7. Remove and repair.

1. Fluid Level Low. 1. Add fluid and check for leaks if drive is

2. Gearshift Linkage/Cable

Loose/Misadjusted.

3. U-Joint/Axle/Transfer Case

Broken.

4. Filter Plugged. 4. Remove and disassemble transmission.

5. Oil Pump Damaged. 5. Perform pressure test to confirm low

6. Valve Body Malfunctioned. 6. Check press and inspect valve body.

7. Transmission Internal Component

Damaged.

8. Park Sprag not Releasing. 8. Remove, disassemble, repair.

9. Torque Converter Damage. 9. Check Stall Speed, Worn/Damaged/

2. Repair or replace linkage components.

and rear clutch and seals. Repair/replace
worn or damaged parts as needed.

Replace assembly if any valves or bores
are damaged.

5. Remove and disassemble transmission.
Replace overrunning clutch.

6. Remove and disassemble transmission.
Replace seal rings and any other worn or
damaged parts.

restored.

2. Inspect, adjust and reassemble linkage
as needed. Replace worn/damaged parts.

3. Perform preliminary inspection procedure
for vehicle that will not move. Refer to
procedure in diagnosis section.

Repair or replace failed components as
needed. Replace filter. If filter and fluid
contained clutch material or metal particles,
an overhaul may be necessary. Perform
lube flow test. Flush oil. Replace cooler as
necessary.

pressure. Replace pump body assembly if
necessary.

Replace valve body (as assembly) if any
valve or bore is damaged. Clean and
reassemble correctly if all parts are in good
condition.

7. Remove and disassemble transmission.
Repair or replace failed components as
needed. Remove and disassemble
transmission. Repair or replace failed
components as needed.

Stuck. Inspect and replace as required.

21 - 86 TRANSMISSION AND TRANSFER CASE XJ

DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

SHIFTS DELAYED OR
ERRATIC (SHIFTS ALSO
HARSH AT TIMES)

NO REVERSE (D RANGES
OK)

HAS FIRST/REVERSE
ONLY (NO 1-2 OR 2-3
UPSHIFT)

MOVES IN 2ND OR 3RD
GEAR, ABRUPTLY
DOWNSHIFTS TO LOW

1. Fluid Level Low/High. 1. Correct fluid level and check for leaks if
low.

2. Throttle Linkage Misadjusted. 2. Adjust linkage as described in service
section.

3. Throttle Linkage Binding. 3. Check cable for binding. Check for return
to closed throttle at transmission.

4. Gearshift Linkage/Cable

Misadjusted.

5. Fluid Filter Clogged. 5. Replace filter. If filter and fluid contained

6. Governor Valve Sticking. 6. Inspect, clean or repair.

7. Governor Seal Rings Worn/

Damaged.

8. Clutch or Servo Failure. 8. Remove valve body and air test clutch,

9. Front Band Misadjusted. 9. Adjust band.

10. Pump Suction Passage Leak. 10. Check for excessive foam on dipstick

1. Gearshift Linkage/Cable

Misadjusted/Damaged.

2. Park Sprag Sticking. 2. Inspect and replace as necessary.

3. Rear Band Misadjusted/Worn. 3. Adjust band; replace.

4. Valve Body Malfunction. 4. Remove and service valve body. Replace

5. Rear Servo Malfunction. 5. Remove and disassemble transmission.

6. Front Clutch Burnt. 6. Remove and disassemble transmission.

1. Governor Valve, Shaft, Weights or

Body Damaged/Stuck.

2. Valve Body Malfunction. 2. Stuck 1-2 shift valve or governor plug.

3. Front Servo/Kickdown Band

Damaged/Burned.

1. Valve Body Malfunction. 1. Remove, clean and inspect. Look for

2. Governor Valve Sticking. 2. Remove, clean and inspect. Replace

4. Adjust linkage/cable as described in
service section.

clutch material or metal particles, an
overhaul may be necessary. Perform lube
flow test.

7. Inspect/replace.

and band servo operation. Disassemble
and repair transmission as needed.

after normal driving. Check for loose pump
bolts, defective gasket. Replace pump
assembly if needed.

1. Repair or replace linkage parts as
needed.

valve body if any valves or valve bores are
worn or damaged.

Replace worn/damaged servo parts as
necessary.

Replace worn, damaged clutch parts as
required.

1. Remove governor assembly and clean or
repair as necessary.

3. Repair/replace.

stuck 1-2 valve or governor plug.

faulty parts.

XJ TRANSMISSION AND TRANSFER CASE 21 - 87

DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

NO LOW GEAR (MOVES
IN 2ND OR 3RD GEAR
ONLY)

NO KICKDOWN OR
NORMAL DOWNSHIFT

STUCK IN LOW GEAR
(WILL NOT UPSHIFT)

CREEPS IN NEUTRAL 1. Gearshift Linkage Misadjusted. 1. Adjust linkage.

1. Governor Valve Sticking. 1. Remove governor, clean, inspect and
repair as required.

2. Valve Body Malfunction. 2. Remove, clean and inspect. Look for
sticking 1-2 shift valve, 2-3 shift valve,
governor plug or broken springs.

3. Front Servo Piston Cocked in

Bore.

4. Front Band Linkage Malfunction. 4. Inspect linkage and look for bind in

1. Throttle Linkage Misadjusted. 1. Adjust linkage.

2. Accelerator Pedal Travel

Restricted.

3. Governor/Valve Body Hydraulic

Pressures Too High or Too Low Due
to Sticking Governor, Valve Body
Malfunction or Incorrect Hydraulic
Control Pressure Adjustments.

4. Valve Body Malfunction. 4. Perform hydraulic pressure tests to

5. Valve Body Malfunction. 5. Sticking 1-2, 2-3 shift valves, or governor

1. Throttle Linkage Misadjusted/

Stuck.

2. Gearshift Linkage Misadjusted. 2. Adjust linkage and repair linkage if worn

3. Governor/Valve Body, Governor

Valve Stuck Closed; Loose Output
Shaft Support or Governor Housing
Bolts, Leaking Seal Rings or Valve
Body Problem (i.e., Stuck 1- 2 Shift
Valve/Gov. Plug).

4. Front Band Out of Adjustment . 4. Adjust Band.

5. Clutch or Servo Malfunction. 5. Air pressure check operation of clutches

2. Rear Clutch Dragging/Warped

Welded.

3. Valve Body Malfunction. 3. Perform hydraulic pressure test to

3. Inspect servo and repair as required.

linkage.

2. Floor mat under pedal, accelerator cable
worn or brackets bent.

3. Perform hydraulic pressure tests to
determine cause and repair as required.
Correct valve body pressure adjustments as
required.

determine cause and repair as required.
Correct valve body pressure adjustments as
required.

plugs.

1. Adjust linkage and repair linkage if worn
or damaged. Check for binding cable or
missing return spring.

or damaged.

3. Check line and governor pressures to
determine cause. Correct as required.

and bands. Repair faulty component.

2. Disassemble and repair.

determine cause and repair as required.

21 - 88 TRANSMISSION AND TRANSFER CASE XJ

DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

BUZZING NOISE 1. Fluid Level Low. 1. Add fluid and check for leaks.

2. Shift Cable Misassembled. 2. Route cable away from engine and bell
housing.

3. Valve Body Misassembled. 3. Remove, disassemble, inspect valve
body. Reassemble correctly if necessary.
Replace assembly if valves or springs are
damaged. Check for loose bolts or screws.

4. Pump Passages Leaking. 4. Check pump for porous casting, scores
on mating surfaces and excess rotor
clearance. Repair as required. Loose pump
bolts.

5. Cooling System Cooler Plugged. 5. Flow check cooler circuit. Repair as
needed.

6.Overrunning Clutch Damaged. 6. Replace clutch.

SLIPS IN REVERSE ONLY 1. Fluid Level Low. 1. Add fluid and check for leaks.

2. Gearshift Linkage Misadjusted. 2. Adjust linkage.

3. Rear Band Misadjusted. 3. Adjust band.

4. Rear Band Worn. 4. Replace as required.

5. Hydraulic Pressure Too Low. 5. Perform hydraulic pressure tests to
determine cause.

6. Rear Servo Leaking. 6. Air pressure check clutch-servo operation
and repair as required.

7. Band Linkage Binding. 7. Inspect and repair as required.

SLIPS IN FORWARD
DRIVE RANGES

SLIPS IN LOW GEAR 9D9
ONLY, BUT NOT IN 1
POSITION

1. Fluid Level Low. 1. Add fluid and check for leaks.

2. Fluid Foaming. 2. Check for high oil level, bad pump
gasket or seals, dirt between pump halves
and loose pump bolts. Replace pump if
necessary.

3. Throttle Linkage Misadjusted. 3. Adjust linkage.

4. Gearshift Linkage Misadjusted. 4. Adjust linkage.

5. Rear Clutch Worn. 5. Inspect and replace as needed.

6. Low Hydraulic Pressure Due to

Worn Pump, Incorrect Control
Pressure Adjustments, Valve Body
Warpage or Malfunction, Sticking
Governor, Leaking Seal Rings,
Clutch Seals Leaking, Servo Leaks,
Clogged Filter or Cooler Lines.

7. Rear Clutch Malfunction, Leaking

Seals or Worn Plates.

8. Overrunning Clutch Worn, Not

Holding (Slips in 1 Only).
Overrunning Clutch Faulty. Replace overrunning clutch.

6. Perform hydraulic and air pressure tests
to determine cause.

7. Air pressure check clutch-servo operation
and repair as required.

8. Replace Clutch.

XJ TRANSMISSION AND TRANSFER CASE 21 - 89

DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

GROWLING, GRATING OR
SCRAPING NOISES

DRAGS OR LOCKS UP 1. Fluid Level Low. 1. Check and adjust level.

WHINE/NOISE RELATED
TO ENGINE SPEED

TORQUE CONVERTER
LOCKS UP IN SECOND
AND/OR THIRD GEAR

HARSH 1-2 OR 2-3
SHIFTS

1. Drive Plate Broken. 1. Replace.

2. Torque Converter Bolts Hitting

Dust Shield.

3. Planetary Gear Set Broken/

Seized.

4. Overrunning Clutch Worn/Broken. 4. Inspect and check for debris in oil pan.

5. Oil Pump Components Scored/

Binding.

6. Output Shaft Bearing or Bushing

Damaged.

7. Clutch Operation Faulty. 7. Perform air pressure check and repair as

8. Front and Rear Bands

Misadjusted.

2. Clutch Dragging/Failed. 2. Air pressure check clutch operation and

3. Front or Rear Band Misadjusted. 3. Adjust bands.

4. Case Leaks Internally. 4. Check for leakage between passages in

5. Servo Band or Linkage

Malfunction.

6. Overrunning Clutch Worn. 6. Remove and inspect clutch. Repair as

7. Planetary Gears Broken. 7. Remove, inspect and repair as required

8. Converter Clutch Dragging. 8. Check for plugged cooler. Perform flow

1. Fluid Level Low. 1. Add fluid and check for leaks.

2. Shift Cable Incorrect Routing. 2. Check shift cable for correct routing.

Lockup Solenoid, Relay or Wiring
Shorted/Open.

Lockup Solenoid Malfunction. Remove valve body and replace solenoid

2. Dust shield bent. Replace or repair.

3. Check for debris in oil pan and repair as
required.

Repair as required.

5. Remove, inspect and repair as required.

6. Remove, inspect and repair as required.

required.

8. Adjust bands.

repair as required.

case.

5. Air pressure check servo operation and
repair as required.

required.

(look for debris in oil pan).

check. Inspect pump for excessive side
clearance. Replace pump as required.

Should not touch engine or bell housing.
Test solenoid, relay and wiring for

continuity, shorts or grounds. Replace
solenoid and relay if faulty. Repair wiring
and connectors as necessary.

assembly.

21 - 90 TRANSMISSION AND TRANSFER CASE XJ

DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

NO START IN PARK OR
NEUTRAL

NO REVERSE (OR SLIPS
IN REVERSE)

OIL LEAKS (ITEMS
LISTED REPRESENT
POSSIBLE LEAK POINTS
AND SHOULD ALL BE
CHECKED.

1. Gearshift Linkage/Cable

Misadjusted.

2. Neutral Switch Wire Open/Cut. 2. Check continuity with test lamp. Repair

3. Neutral Switch Faulty. 3. Refer to service section for test and

4. Neutral Switch Connect Faulty. 4. Connectors spread open. Repair.

5. Valve Body Manual Lever

Assembly Bent/Worn/Broken.

1. Direct Clutch Pack (front clutch)

Worn.

2. Rear Band Misadjusted. 2. Adjust band.

3. Front Clutch Malfunctioned/Burnt. 3. Air pressure test clutch operation.

1. Speedometer Adapter Leaks. 1. Replace both adapter seals.

2. Fluid Lines and Fittings Loose/

Leaks/Damaged.

3. Filler Tube (where tube enters

case) Leaks/Damaged.

4. Pressure Port Plug Loose

Loose/Damaged.

5. Pan Gasket Leaks. 5. Tighten pan screws to 150 inch pounds.

6. Valve Body Manual Lever Shaft

Seal Leaks/Worn.

7. Rear Bearing Access Plate Leaks. 7. Replace gasket. Tighten screws.

8. Gasket Damaged or Bolts are

Loose.

9. Adapter/Extension Gasket

Damaged Leaks/Damaged.

10. Neutral Switch Leaks/Damaged. 10. Replace switch and gasket.

11. Converter Housing Area Leaks. 11. Check for leaks at seal caused by worn

12. Pump Seal Leaks/Worn/

Damaged.

13. Torque Converter Weld

Leak/Cracked Hub.

14. Case Porosity Leaks. 14. Replace case.

1. Adjust linkage/cable.

as required.

replacement procedure.

5. Inspect lever assembly and replace if
damaged.

1. Disassemble unit and rebuild clutch
pack.

Remove and rebuild if necessary.

2. Tighten fittings. If leaks persist, replace
fittings and lines if necessary.

3. Replace O-ring seal. Inspect tube for
cracks in tube.

4. Tighten to correct torque. Replace plug
or reseal if leak persists.

If leaks persist, replace gasket. Do no over
tighten screws.

6. Replace shaft seal.

8. Replace bolts or gasket or tighten both.

9. Replace gasket.

seal or burr on converter hub (cutting seal),
worn bushing, missing oil return, oil in front
pump housing or hole plugged. Check for
leaks past O-ring seal on pump or past
pump-to-case bolts; pump housing porous,
oil coming out vent due to overfill or leak
past front band shaft access plug.

12. Replace seal.

13. Replace converter.

XJ TRANSMISSION AND TRANSFER CASE 21 - 91

SERVICE PROCEDURES

FLUID LEVEL CHECK

Transmission fluid level should be checked monthly
under normal operation. If the vehicle is used for
trailer towing or similar heavy load hauling, check
fluid level and condition weekly. Fluid level is
checked with the engine running at curb idle speed,
the transmission in NEUTRAL and the transmission
fluid at normal operating temperature.

FLUID LEVEL CHECK PROCEDURE

(1) Transmission fluid must be at normal operat­ing temperature for accurate fluid level check. Drive
vehicle if necessary to bring fluid temperature up to
normal hot operating temperature of 82°C (180°F).

(2) Position vehicle on level surface.

(3) Start and run engine at curb idle speed.

(4) Apply parking brakes.

(5) Shift transmission momentarily into all gear
ranges. Then shift transmission back to Neutral.

(6) Clean top of filler tube and dipstick to keep
dirt from entering tube.

(7) Remove dipstick (Fig. 13) and check fluid level
as follows:

(a) Correct acceptable level is in crosshatch area.
(b) Correct maximum level is to MAX arrow

mark.

(c) Incorrect level is at or below MIN line.
(d) If fluid is low, add only enough Mopart ATF

Plus 3 to restore correct level. Do not overfill.

REMOVAL

(1) Hoist and support vehicle on safety stands.
(2) Place a large diameter shallow drain pan

beneath the transmission pan.

(3) Remove bolts holding front and sides of pan to

transmission (Fig. 14).

(4) Loosen bolts holding rear of pan to transmis-

sion.

(5) Slowly separate front of pan away from trans-

mission allowing the fluid to drain into drain pan.

(6) Hold up pan and remove remaining bolts hold-

ing pan to transmission.

(7) While holding pan level, lower pan away from

transmission.

(8) Pour remaining fluid in pan into drain pan.
(9) Remove screws holding filter to valve body

(Fig. 15).

(10) Separate filter from valve body and pour fluid

in filter into drain pan.

(11) Dispose used trans fluid and filter properly.

CAUTION: Do not overfill the transmission. Overfill­ing may cause leakage out the pump vent which
can be mistaken for a pump seal leak. Overfilling
will also cause fluid aeration and foaming as the
excess fluid is picked up and churned by the gear
train. This will significantly reduce fluid life.

Fig. 13 Dipstick Fluid Level Marks—Typical

FLUID AND FILTER REPLACEMENT

Refer to the Maintenance Schedules in Group 0,
Lubrication and Maintenance, for proper service
intervals. The service fluid fill after a filter change is
approximately 3.8 liters (4.0 quarts).

Fig. 14 Transmission Pan

Fig. 15 Transmission Filter

21 - 92 TRANSMISSION AND TRANSFER CASE XJ

SERVICE PROCEDURES (Continued)

INSPECTION

Inspect bottom of pan and magnet for excessive
amounts of metal or fiber contamination. A light
coating of clutch or band material on the bottom of
the pan does not indicate a problem unless accompa­nied by slipping condition or shift lag. If fluid and
pan are contaminated with excessive amounts or
debris, refer to the diagnosis section of this group.

Check the adjustment of the front and rear bands,
adjust if necessary. Refer to Adjustment section of
this group for proper procedure.

CLEANING

(1) Using a suitable solvent, clean pan and mag­net.

(2) Using a suitable gasket scraper, clean gasket
material from gasket surface of transmission case
and the gasket flange around the pan.

INSTALLATION

(1) Place replacement filter in position on valve
body.

(2) Install screws to hold filter to valve body (Fig.

15). Tighten screws to 4 N·m (35 in. lbs.) torque.

(3) Place new gasket in position on pan. and
install pan on transmission.

(4) Place pan in position on transmission.

(5) Install screws to hold pan to transmission (Fig.

14). Tighten bolts to 17 N·m (150 in. lbs.) torque.

(6) Lower vehicle and fill transmission with
Mopart ATF Plus 3, type 7176 fluid.

TRANSMISSION FILL PROCEDURE

To avoid overfilling transmission after a fluid
change or overhaul, perform the following procedure:

(1) Remove dipstick and insert clean funnel in
transmission fill tube.

(2) Add following initial quantity of Mopart ATF
Plus 3 to transmission:

(a) If only fluid and filter were changed, add 3
pints (1-1/2 quarts) of ATF Plus 3 to transmis­sion.

(b) If transmission was completely overhauled,
torque converter was replaced or drained, and
cooler was flushed, add 12 pints (6 quarts) of ATF
Plus 3 to transmission.
(3) Apply parking brakes.
(4) Start and run engine at normal curb idle

speed.

(5) Apply service brakes, shift transmission

through all gear ranges then back to NEUTRAL, set
parking brake, and leave engine running at curb idle
speed.

(6) Remove funnel, insert dipstick and check fluid

level. If level is low, add fluid to bring level to
MIN mark on dipstick. Check to see if the oil level

is equal on both sides of the dipstick. If one side is
noticably higher than the other, the dipstick has
picked up some oil from the dipstick tube. Allow the
oil to drain down the dipstick tube and re-check.

(7) Drive vehicle until transmission fluid is at nor-

mal operating temperature.

(8) With the engine running at curb idle speed, the
gear selector in NEUTRAL, and the parking brake
applied, check the transmission fluid level.

CAUTION: Do not overfill transmission, fluid foam­ing and shifting problems can result.

(9) Add fluid to bring level up to MAX arrow
mark.

When fluid level is correct, shut engine off, release
park brake, remove funnel, and install dipstick in fill
tube.

CONVERTER DRAINBACK CHECK VALVE SERVICE

The converter drainback check valve is located in
the cooler outlet (pressure) line near the radiator
tank. The valve prevents fluid drainback when the
vehicle is parked for lengthy periods. The valve check
ball is spring loaded and has an opening pressure of
approximately 2 psi.

The valve is serviced as an assembly; it is not
repairable. Do not clean the valve if restricted, or
contaminated by sludge, or debris. If the valve fails,
or if a transmission malfunction occurs that gener­ates significant amounts of sludge and/or clutch par­ticles and metal shavings, the valve must be
replaced.

The valve must be removed whenever the cooler
and lines are reverse flushed. The valve can be flow
tested when necessary. The procedure is exactly the
same as for flow testing a cooler.

If the valve is restricted, installed backwards, or in
the wrong line, it will cause an overheating condition
and possible transmission failure.

CAUTION: The drainback valve is a one-way flow
device. It must be properly oriented in terms of flow
direction for the cooler to function properly. The
valve must be installed in the pressure line. Other­wise flow will be blocked and would cause an over­heating condition and eventual transmission failure.

OIL PUMP VOLUME CHECK

After the new or repaired transmission has been
installed, fill to the proper level with Mopart ATF
PLUS 3 (Type 7176) automatic transmission fluid.
The volume should be checked using the following
procedure:

XJ TRANSMISSION AND TRANSFER CASE 21 - 93

SERVICE PROCEDURES (Continued)

(1) Disconnect the From cooler line at the trans­mission and place a collecting container under the
disconnected line.

CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter­nal damage to the transmission may occur.

(2) Run the engine at curb idle speed , with the
shift selector in neutral.

(3) If fluid flow is intermittent or it takes more
than 20 seconds to collect one quart of ATF PLUS 3,
disconnect the To Cooler line at the transaxle.

(4) Refill the transaxle to proper level and recheck
pump volume.

(5) If flow is found to be within acceptable limits,
replace the cooler. Then fill transmission to the
proper level, using Mopart ATF PLUS 3 (Type 7176)
automatic transmission fluid.

(6) If fluid flow is still found to be inadequate,
check the line pressure using the Transaxle Hydrau­lic Pressure Test procedure.

FLUSHING COOLERS AND TUBES

When a transmission failure has contaminated the
fluid, the oil cooler(s) must be flushed. The torque
converter must also be replaced. This will insure that
metal particles or sludged oil are not later trans­ferred back into the reconditioned (or replaced) trans­mission.

The only recommended procedure for flushing cool­ers and lines is to use Tool 6906 Cooler Flusher.

WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1–1968. WEAR STANDARD INDUSTRIAL RUB­BER GLOVES.

KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI­BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.

KEEP THE AREA WELL VENTILATED.

DO NOT LET FLUSHING SOLVENT COME IN CON­TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM­INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.

COOLER FLUSH USING TOOL 6906

(1) Remove cover plate filler plug on Tool 6906.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen­erally used to clean automatic transmission compo-

nents. DO NOT use solvents containing acids, water,
gasoline, or any other corrosive liquids.

(2) Reinstall filler plug on Tool 6906.

(3) Verify pump power switch is turned OFF. Con­nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.

(4) Disconnect the cooler lines at the transmission.

NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.

NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis­sion cooler line and the cooler fitting. Failure to
remove the drainback valve will preventreverse
flushing the system.

(5) Connect the BLUE pressure line to the OUT­LET (From) cooler line.

(6) Connect the CLEAR return line to the INLET
(To) cooler line.

(7) Turn pump ON for two to three minutes to
flush cooler(s) and lines. Monitor pressure readings
and clear return lines. Pressure readings should sta­bilize below 20 psi. for vehicles equipped with a sin­gle cooler and 30 psi. for vehicles equipped with dual
coolers. If flow is intermittent or exceeds these pres­sures, replace cooler.

(8) Turn pump OFF.

(9) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.

(10) Turn pump ON for 30 seconds to purge flush­ing solution from cooler and lines. Turn pump OFF.

(11) Place CLEAR suction line into a one quart
container of Mopart ATF Plus 3, type 7176 automatic
transmission fluid.

(12) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans­mission cooler and lines. Turn pump OFF.

(13) Disconnect alligator clips from battery. Recon­nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.

ALUMINUM THREAD REPAIR

Damaged or worn threads in the aluminum trans­mission case and valve body can be repaired by the
use of Heli-Coils, or equivalent. This repair consists
of drilling out the worn-out damaged threads. Then
tap the hole with a special Heli-Coil tap, or equiva­lent, and installing a Heli-Coil insert, or equivalent,
into the hole. This brings the hole back to its original
thread size.

21 - 94 TRANSMISSION AND TRANSFER CASE XJ

SERVICE PROCEDURES (Continued)

Heli-Coil, or equivalent, tools and inserts are
readily available from most automotive parts suppli­ers.

REMOVAL AND INSTALLATION

TRANSMISSION

CAUTION: The transmission and torque converter
must be removed as an assembly to avoid compo­nent damage. The converter drive plate, pump
bushing, or oil seal can be damaged if the con­verter is left attached to the driveplate during
removal.

REMOVAL

(1) Disconnect battery negative cable.

(2) Disconnect and lower or remove necessary
exhaust components.

(3) Remove engine-to-transmission bending braces.

(4) Disconnect fluid cooler lines at transmission.

(5) Remove starter motor.

(6) Disconnect and remove crankshaft position sen­sor. Retain sensor attaching bolts.

CAUTION: The crankshaft position sensor can be
damaged during transmission removal (or installa­tion) if the sensor is still bolted to the engine block.
To avoid damage, remove the sensor before remov­ing the transmission.

Fig. 16 Crankshaft Position Sensor—2.5L Engine

(7) Remove torque converter access cover.

(8) If transmission is being removed for overhaul,
remove transmission oil pan, drain fluid and reinstall
pan.

(9) Remove skid plate for access, if necessary.

(10) Remove fill tube bracket bolts and pull tube
out of transmission. Retain fill tube seal. On4x4

Fig. 17 Crankshaft Position Sensor—4.0L Engine

models, it will also be necessary to remove bolt
attaching transfer case vent tube to converter hous­ing.

(11) Mark torque converter and drive plate for
assembly alignment. Note that bolt holes in crank­shaft flange, drive plate and torque converter all
have one offset hole.

(12) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.

(13) Mark propeller shaft and axle yokes for
assembly alignment. Then disconnect and remove
propeller shaft. On4x4models, remove both propel­ler shafts.

(14) Disconnect wires from park/neutral position
switch and vehicle speed sensor.

(15) Disconnect gearshift cable from transmission
manual valve lever.

(16) Disconnect throttle valve cable from transmis­sion bracket and throttle valve lever.

(17) On4x4models, disconnect shift rod from
transfer case shift lever or remove shift lever from
transfer case.

(18) Support rear of engine with safety stand or
jack.

(19) Raise transmission slightly with service jack
to relieve load on crossmember and supports.

(20) Remove bolts securing rear support and cush­ion to transmission and crossmember. Raise trans­mission slightly, slide exhaust hanger arm from
bracket and remove rear support.

XJ TRANSMISSION AND TRANSFER CASE 21 - 95

REMOVAL AND INSTALLATION (Continued)

(21) Remove bolts attaching crossmember to frame

and remove crossmember.

(22) Disconnect transfer case vent hose. Then dis-

connect vacuum switch harness.

(23) On4x4models, remove transfer case.
(24) Remove all converter housing bolts.
(25) Carefully work transmission and torque con-

verter assembly rearward off engine block dowels.

(26) Hold torque converter in place during trans-

mission removal.

(27) Lower transmission and remove assembly

from under the vehicle.

(28) To remove torque converter, carefully slide

torque converter out of the transmission.

INSTALLATION

(1) Check torque converter hub and hub drive
notches for sharp edges burrs, scratches, or nicks.
Polish the hub and notches with 320/400 grit paper
and crocus cloth if necessary. The hub must be
smooth to avoid damaging pump seal at installation.

(2) Lubricate converter drive hub and oil pump
seal lip with transmission fluid.

(3) Lubricate converter pilot hub with transmis­sion fluid.

(4) Align converter and oil pump.

(5) Carefully insert converter in oil pump. Then
rotate converter back and forth until fully seated in
pump gears.

(6) Check converter seating with steel scale and
straightedge (Fig. 18). Surface of converter lugs
should be 1/2 in. to rear of straightedge when con­verter is fully seated.

(7) Temporarily secure converter with C-clamp.

Fig. 18 Typical Method Of Checking Converter

Seating

(8) Position transmission on jack and secure it

with safety chains.

(9) Check condition of converter driveplate.

Replace the plate if cracked, distorted or damaged.

Also be sure transmission dowel pins are seated
in engine block and protrude far enough to
hold transmission in alignment.

(10) Raise transmission and align converter with

drive plate and converter housing with engine block.

(11) Move transmission forward. Then raise, lower
or tilt transmission to align converter housing with
engine block dowels.

(12) Rotate converter so alignment marks scribed
on converter are aligned with mark on driveplate.

(13) Carefully work transmission forward and over
engine block dowels until converter hub is seated in
crankshaft.

(14) Install and tighten bolts that attach transmis­sion converter housing to engine block (Fig. 19).

CAUTION: Be sure the converter housing is fully
seated on the engine block dowels before tighten­ing any bolts.

(15) Install torque converter attaching bolts.
Tighten bolts to following torque.

• 54 N·m (40 ft. lbs.) with 9.5 in. 3-lug converter

• 74 N·m (55 ft. lbs.) with 9.5 in. 4-lug converter

• 74 N·m (55 ft. lbs.) with 10.0 in. 4-lug converter

• 31 N·m (270 in. lbs.) with 10.75 in. 4-lug con-

verter

(16) Install crankshaft position sensor.

(17) Install transmission fill tube and seal. Install
new fill tube seal in transmission before installation.

(18) Connect transmission cooler lines to transmis­sion.

(19) Install transfer case onto transmission.

(20) Install rear crossmember and attach trans­mission rear support to crossmember.

(21) Remove engine support fixture.

(22) Remove transmission jack.

(23) Connect vehicle speed sensor wires.

(24) Connect wires to park/neutral position switch.

(25) Install crankshaft position sensor.

(26) Install converter housing access cover.

(27) Install exhaust pipes and support brackets, if
removed.

(28) Install starter motor and cooler line bracket.

(29) Install new plastic retainer grommet on any
shift linkage rod or lever that was disconnected.
Grommets should not be reused. Use pry tool to
remove rod from grommet and cut away old grom­met. Use pliers to snap new grommet into lever and
to snap rod into grommet at assembly.

(30) Connect gearshift and linkage and throttle
cable.

(31) Connect transfer case shift linkage.

21 - 96 TRANSMISSION AND TRANSFER CASE XJ

REMOVAL AND INSTALLATION (Continued)

Fig. 19 Transmission Attachment

(32) Adjust gearshift linkage and throttle valve

cable if necessary.

(33) Align and connect propeller shaft(s).
(34) Install skid plate, rear cushion and bracket, if

removed.

(35) Fill transfer case to bottom edge of fill plug

hole.

(36) Lower vehicle and fill transmission to correct

level with Mopart ATF Plus 3, type 7176 fluid.

TORQUE CONVERTER

REMOVAL

(1) Remove transmission and torque converter

from vehicle.

(2) Place a suitable drain pan under the converter

housing end of the transmission.

CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con­verter is removed creating an unstable condition.

The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.

(3) Pull the torque converter forward until the cen-

ter hub clears the oil pump seal.

(4) Separate the torque converter from the trans-

mission.

INSTALLATION

Check converter hub and drive notches for sharp
edges, burrs, scratches, or nicks. Polish the hub and
notches with 320/400 grit paper or crocus cloth if nec­essary. The hub must be smooth to avoid damaging
the pump seal at installation.

(1) Lubricate converter hub and oil pump seal lip
with transmission fluid.

(2) Place torque converter in position on transmis­sion.

CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.

(3) Align torque converter to oil pump seal open­ing.

(4) Insert torque converter hub into oil pump.

(5) While pushing torque converter inward, rotate
converter until converter is fully seated in the oil
pump gears.

XJ TRANSMISSION AND TRANSFER CASE 21 - 97

REMOVAL AND INSTALLATION (Continued)

(6) Check converter seating with a scale and
straightedge (Fig. 20). Surface of converter lugs
should be 1/2 in. to rear of straightedge when con­verter is fully seated.

(7) If necessary, temporarily secure converter with
C-clamp attached to the converter housing.

(8) Install the transmission in the vehicle.

(9) Fill the transmission with the recommended
fluid.

Fig. 21 Removing Extension Housing Yoke Seal

Fig. 20 Checking Torque Converter Seating

YOKE SEAL REPLACEMENT

REMOVAL

(1) Raise vehicle.

(2) Mark propeller shaft and axle yoke for align­ment reference.

(3) Disconnect and remove propeller shaft.

(4) Remove old seal with Seal Remover C-3985-B
(Fig. 21) from extension housing.

INSTALLATION

(1) Place seal in position on extension housing.

(2) Drive seal into extension housing with Seal
Installer C-3995-A or C-3972 (Fig. 22).

(3) Carefully guide propeller shaft slip yoke into
housing and onto output shaft splines. Align marks
made at removal and connect propeller shaft to rear
axle pinion yoke.

EXTENSION HOUSING BUSHING

REMOVAL

(1) Remove housing yoke seal.

(2) Insert Remover 6957 into extension housing.
Tighten tool to bushing and remove bushing (Fig.

23).

Fig. 22 Installing Extension Housing Yoke Seal

Fig. 23 Bushing Removal—Typical

INSTALLATION

(1) Align bushing oil hole with oil slot in extension

housing.

(2) Tap bushing into place with Installer 6951 and

Handle C-4171.

(3) Install new oil seal in housing using Seal

Installer C-3995–A (Fig. 24).

21 - 98 TRANSMISSION AND TRANSFER CASE XJ

REMOVAL AND INSTALLATION (Continued)

(1) Install new rear seal in extension housing. Use
Tool Handle C-4171 and Seal Installer C-3860-A to
install seal.

(2) Place extension housing gasket in position on
rear of transmission.

(3) Slide extension housing forward and over out­put shaft (Fig. 25).

(4) Guide park shaft into park sprag and push
extension housing forward until rod passes through
opening behind sprag. It may be necessary to use a
wire to hold sprag to the side for rod to pass through.

(5) Install bolts to hold extension housing to rear
of transmission.

(6) Install transfer case.

(7) Install propeller shafts.

(8) Install rear transmission mount and skid plate.

Fig. 24 Extension Housing Seal Installation

EXTENSION HOUSING

(9) Lower vehicle and verify transmission fluid
level. Add fluid as necessary.

REMOVAL

(1) Hoist and support vehicle on safety stands.
(2) Support transmission with a suitable lifting

device.

(3) Remove transmission skid plate. Refer to

Group 13, Frame and Bumpers, for proper procedure.

(4) Remove propeller shafts. Refer to Group 3, Dif-

ferential and Driveline, for proper procedure.

(5) Remove transfer case.
(6) Remove bolts holding extension housing to

transmission case (Fig. 25).

(7) Separate extension housing from transmission.
(8) Slide extension housing rearward and off out-

put shaft (Fig. 25).

Fig. 25 Extension Housing

INSTALLATION

Clear gasket material from sealing surfaces on
extension housing and rear of transmission. Replace
output shaft bearing, if necessary.

SPEEDOMETER ADAPTER

Rear axle gear ratio and tire size determine speed-

ometer pinion requirements.

REMOVAL

(1) Raise vehicle.
(2) Disconnect wires from vehicle speed sensor.
(3) Remove adapter clamp and screw (Fig. 26).
(4) Remove speed sensor and speedometer adapter

as assembly.

(5) Remove speed sensor retaining screw and

remove sensor from adapter.

(6) Remove speedometer pinion from adapter.
(7) Inspect sensor and adapter O-rings (Fig. 26).

Remove and discard O-rings if worn or damaged.

(8) Inspect terminal pins in speed sensor. Clean
pins with Mopart electrical spray cleaner if dirty or
oxidized. Replace sensor if faulty, or pins are loose,
severely corroded, or damaged.

INSTALLATION

(1) Thoroughly clean adapter flange and adapter
mounting surface in housing. Surfaces must be clean
for proper adapter alignment and speedometer oper­ation.

(2) Install new O-rings on speed sensor and speed­ometer adapter if necessary (Fig. 26).

(3) Lubricate sensor and adapter O-rings with
transmission fluid.

(4) Install vehicle speed sensor in speedometer
adapter. Tighten sensor attaching screw to 2-3 N·m
(15-27 in. lbs.) torque.

(5) Install speedometer pinion in adapter.

(6) Count number of teeth on speedometer pinion.
Do this before installing assembly in housing. Then
lubricate pinion teeth with transmission fluid.

XJ TRANSMISSION AND TRANSFER CASE 21 - 99

REMOVAL AND INSTALLATION (Continued)

Fig. 26 Speedometer Pinion Adapter Components

(7) Note index numbers on adapter body (Fig. 27).
These numbers will correspond to number of teeth on
pinion.

(8) Install speedometer assembly in housing.

(9) Rotate adapter until required range numbers
are at 6 o’clock position. Be sure range index num­bers correspond to number of teeth on pinion gear.

(10) Install speedometer adapter clamp and retain­ing screw. Tighten clamp screw to 10-12 N·m (90-110
in. lbs.) torque.

(11) Connect wires to vehicle speed sensor.

(12) Lower vehicle and top off transmission fluid
level, if necessary.

PARK/NEUTRAL POSITION SWITCH

REMOVAL

(1) Raise vehicle and position drain pan under

switch.

(2) Disconnect switch wires.
(3) Remove switch from case.

INSTALLATION

(1) Move shift lever to Park and Neutral positions.
Verify that switch operating lever fingers are cen­tered in switch opening in case (Fig. 28).

Fig. 27 Index Numbers On Speedometer Pinion

Adapter

Fig. 28 Park/Neutral Position Switch

(2) Install new seal on switch and install switch in
case. Tighten switch to 34 N·m (25 ft. lbs.) torque.

21 - 100 TRANSMISSION AND TRANSFER CASE XJ

REMOVAL AND INSTALLATION (Continued)

(3) Test continuity of new switch with 12V test

lamp.

(4) Connect switch wires and lower vehicle.
(5) Top off transmission fluid level.

GEARSHIFT CABLE

REMOVAL

(1) Shift transmission into Park.
(2) Remove shift lever bezel and necessary console

parts for access to shift lever assembly.

(3) Disconnect cable at shift lever and feed cable

through dash panel opening to underside of vehicle.

(4) Raise vehicle.

(5) Disengage cable eyelet at transmission shift
lever and pull cable adjuster out of mounting
bracket. Then remove old cable from vehicle.

INSTALLATION

(1) Route cable through hole in dash panel. Fully
seat cable grommet into dash panel.

(2) Place the auto transmission manual shift con­trol lever in “Park” detent (rearmost) position and
rotate prop shaft to ensure transmission is in park.

(3) Connect shift cable to shifter mechanism by
snapping cable retaining ears into shifter bracket
and press cable end fitting onto lever ball stud.

(4) Place the floor shifter lever in park position.
Ensure that the pawl is seated within the confines of
the adjustment gauge clip.

(5) Snap the cable into the transmission bracket so
the retaining ears are engaged and connect cable end
fitting onto the manual control lever ball stud.

(6) Lock shift cable into position by pushing
upward on the adjusting lock button.

(7) Remove and discard the shift cable adjustment
gauge clip from the park gate of the shifter.

BRAKE TRANSMISSION SHIFT INTERLOCK

REMOVAL

(1) Remove lower steering column cover. Refer to
Group 8E, Instrument Panel and Gauges, for proper
procedure.

(2) Remove lower steering column shroud. Refer to
Group 19, Steering, for proper procedure.

(3) Remove tie strap near the solenoid retaining
the brake transmission interlock cable to the steering
column.

(4) Disengage wire connector from solenoid.

(5) With the ignition removed or in the unlocked
position, disengage lock tab holding cable end to
steering column (Fig. 29).

(6) Pull cable end from steering column.

(7) Remove the floor console and related trim.
Refer to Group 23, Body, for proper procedure.

(8) Disconnect the cable eyelet from the bellcrank

(Fig. 30).

Fig. 29 Brake/Park Interlock Cable

(9) Disconnect and remove the cable from the shift

bracket.

INSTALLATION

(1) Route replacement cable behind instrument
panel and under floor console area to shift mecha­nism (Fig. 30).

(2) Insert cable end into opening in steering col­umn hub under ignition lock. Push cable inward
until lock tab engages.

(3) Connect the cable end eyelet onto shifter
bellcrank pin.

(4) Place gear selector in PARK.

(5) Push the spring-loaded cable adjuster forward
and snap cable into bracket.

(6) Adjust the brake transmission shifter interlock
cable. Refer to the Adjustment portion of this section
for proper procedures.

(7) Verify that the cable adjuster lock clamp is
pushed downward to the locked position.

(8) Test the park-lock cable operation.

(9) Install the floor console and related trim.

(10) Install tie strap to hold cable to base of steer­ing column.

(11) Install lower steering column shroud and igni­tion lock.

(12) Install lower steering column cover.

VALVE BODY

REMOVAL

(1) Raise vehicle.

(2) Remove oil pan and drain fluid.

(3) Loosen clamp bolts and remove throttle and
manual valve levers from manual lever shaft.

(4) Remove park/neutral position switch.

(5) Remove filter from valve body.