Jeep UNIVERSAL CJ-2A - Check; Install; Replace

K
TRANSMISSION- TRANSFER CASE
nuts and washers from the control levers and re-
move levers. Push the shafts into the case to re -
move them and then remove the sleeve, poppet
ba ll and spring. Check the oil seals carefully for
oil
leakage and replace if necessary. If it is evident
that a minimum clearance of .001" to .0 07" can-
not be obtained between the end of the interlock
sleeve and shift levers, even though the longest
sleeve has been installed, remove the original
interlock pin from the shift lever poppet spring.
Replace the original interlock pin with a transfer
case intermediate gear needle bearing roller, Part
No. 809294, which has been ground to a length of
. 780" [19,8 mm.]. The installation of this mod ifi ed
roller should ensure positive engagement of the
ball at each end of the interlock sleeve in the
respective detents of the shifting levers as the
transmission is shifted through the gear pattern.
Assemble the transmission to where shift action
can be checked. If it is apparent that the im-
provised pin · is too long and is causing a bind
when shifting is attempted, reduce its length a
little at a time from the . 780" dimension until a
smooth shift action with a positive ball and detent
e ngagement is obtained. Install this improvised
pin only when the l ongest interlock sleeve does not
provide the desired minimum clearance.
Re assemble in reverse order. When assembling the
interlock sleeve be sure that th e shift lever popp et
spring works freely inside the interlock and that
th e interlock pin, or the modified roller substituted
for the pin, is not omitted from inside the spring.
If the notched surfaces of the shifting levers are
dirty or rough they should be thoroughly cleaned
and smoothed. If notched surfaces are scored or
damaged, the lever or levers should be replaced.
Note: Each time an interlock sleeve or shift lever
is replaced, check the clearance between the
interlock sleeve and the shift lever .
To reassemble the transm is sion proceed as follows:
a. Position the reverse idler gear in the case and
install the shaft using care that the slot at the shaft
end is correctly aligned to receive the lock plate .
b. To assemble the countershaft gear , it is neces-
sary to use Tool W-166, Fig. 187. Pl ace the mandril
through the gear set and insert the long spacer
positioning it at the center of the gear set. Place a
set of twenty rollers at each end of the spac er fol·
lowed by a spacing washer at each end . A small
amount of grease will hold the spacing washer
in position . Place the assembled countersha ft gear
set in the bottom of the case with the large gear
toward the front.
c. Install the rear main shaft bearing on the main
shaft with the closed side of the bearing toward
the front or low end of the shaft . Replace the bear-
ing snap ring and main shaft snap ring.
d. Pass the front end of the main shaft through
the rear bearing opening and assemble the low and
reverse sliding gear on the shaft wi th the shifting
fork groove toward the rear.
e. Assemble the second speed gear on the shaft
with the teeth w hich engage in the clutch sleeve
toward the front of the case .
172
f. Next, assemble the synchronizer unit. The as-
sembly sequence of the synchronizer is s how n in
Fig. 189. First install the two springs in the high
and in termediate clutch hub. Th ese springs must
be installed with the spring tension opposed . Place
the right lipped end of a spring in a slot of the
hub and place the spring in the hub. Turn the hub
around and make exactly the same installation
wi th the other spring starting with the same slot .
Fi g. 191. Install the three synchronized shifting
plates in the three slots in the hub with the smooth
side of the plates out . Hold the plates in position
and slip the second and direct speed clutch sleeve
over the hub. Install the two blocking rings one
one
each side of the hub.
g. Install the shifting fork and shoe.
h. Place some heavy grease in the main shaft
pilot and position the thirteen needle type roller
bearings.
i. Install the main drive gea r. If the bearing has
been removed, note that the closed side is assembled
toward the inside of the case.
j . Enter the main shaft bearing in the case and
assemble the shaft in position.
k. Install the front bearing retainer.
I. Turn the transmission case over to allow the
gears to mesh and start the countershaft through
the case at the rear with the lock plate slot toward
the rear and in alignment with the slot in the idler
gear shaft.
m . Place the two rear thrust washers ov er the
end of the shaft and align the countershaft gears
with the shaft. Press the shaft through the gears
placing the front thrust washer in position with the
tongue of the washer in the slot in the case .
n. Install the lock plate. Tap both shafts forward
to put a bind on the plate to hold it in position.
o. Install rear bearing snap ring and rear main-
shaft bearing on shaft .
p. Attach rear bearing retainer and gasket to the
transmission case. Tighten cap screws evenly and
securely.
q. In stall speedometer drive gear on shaft with
the shoulder of gear toward the front. Ch ec k
the oil seal which is installed next and replace with
new one if necessary.
r. Install the companion coupling flange with the
flat washer, lock washer and nut.
s. Check the complete transmission for operation.
t. Install transmission case cover.
K-11 . OPTIONAL 4-SPEED TRANSMISSION
• Mod els CJ - 5. Cj -6
A four - speed transmission with a cane-type shift
is optional on 'J eep' Mod els CJ-5 and Cj-6. This
transmiss ion provides four speeds forward and one
reverse with synchromesh engagement in second,
third, and fourth speed.
For quick identification, the optional 4- speed
transmission is 11 Ys" long whereas the standard
3-speed transmission is 8" long. However the in-
structions for removal and installation of the two
transmissions are the same. Use the procedur e