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HOMESERVICE MANUALSJEEP1986CHEROKEE BASE, 4D UTILITY, 2.5 H, 4WD, STANDARD, AX4REPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONMANUAL TRANSOVERHAUL - AISIN AX4 & AX5 4 & 5-SPEEDCOMPONENT DISASSEMBLY & REASSEMBLYSHIFT RAILS & COMPONENTSDISASSEMBLY
1986 Jeep Cherokee Base, 4D Utility, 2.5 H, 4WD, Standard, AX4

Shift Rails & Components: Disassembly

1986 Jeep Cherokee Base, 4D Utility, 2.5 H, 4WD, Standard, AX4SECTION Disassembly
  1. Install 2 clutch housing bolts, washers and suitable nuts in intermediate plate. See Figure . Increase or decrease number of washers used so that bolt tip and outer surface of nut are aligned.
  2. Clamp bolts in jaws of vise. Ensure machined surfaces of intermediate plate are protected from damage to sealing surfaces. Remove detent screw plugs. Using a Torx bit and pencil magnet, remove detent balls and springs from side and bottom of intermediate plate.
    NOTE: Detent balls in intermediate housing will usually fall out when plugs or shift rails are removed. Ensure detent balls, springs and interlock pins are not lost. Use a pencil magnet to remove parts that do not come out easily.
  3. Using a hammer and punch, drive out 5 shift fork pins and remove 2 "C" rings from the shift rails. Pull shift rail No. 4 from intermediate plate and catch detent balls and pin. Remove shift rail No. 4 and 5-R shift fork. See Fig 1 .
  4. Remove shift rail No. 5 from intermediate plate with reverse shift head attached. Remove shift rail No. 3 from intermediate plate, catching interlock pins. Remove shift rail No. 1 from intermediate plate.
  5. Remove shift rail No. 2 along with 1-2 and 3-4 shift forks. Remove reverse idler gear and shaft. Remove reverse shift arm from reverse shift fork.
Fig 1: Exploded View of Shift Rails & Forks
G92C13989
RENDER: 1.0x

NO RELATED

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  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
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