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Home >> Jeep >> 1987 >> Comanche Laredo, 2.1 B >> Repair and Diagnosis >> Transmission >> Manual Trans >> Overhaul - BA 10/5 5-Speed >> Transmission Reassembly

Transmission Reassembly

  1. Install retaining plate (if equipped) with machined surface toward bearing. Install reverse driven gear on mainshaft with teeth chamfer facing rearward. Install new nut and stake in position.
  2. Install speedometer worm gear, position undercut towards gears. Install necessary adjusting shims from prior readings obtained. Install new spring washer and snap ring. Apply pressure from press lightly upon input shaft to compress spring washer and seat snap ring.
  3. Ensure snap ring is fully seated. Install detent ball and spring into lock-out channel. Ensure locating dowels are in place. Engage 3rd-4th synchronizer, noting position of indexing marks made previously. Install needle bearing into input shaft.
  4. Assemble input and main shafts together. Place synchros in neutral. With teeth of main, input and countershaft assemblies meshed and while holding assembly together in this manner, install assembly into transmission case. See Fig 1.
  5. Ensure shift forks engage with synchronizer sleeves. Apply a thin coat of sealer to mating faces of case halves. Install countershaft bearing retainer (if equipped).
    Fig 1: Installing Shafts Into Transmission Case
    G95D55700Courtesy of PEUGEOT MOTOR OF AMERICA, INC.
  6. Ensure positioning dowels are in place. With countergear and mainshaft installed, assemble 2 halves of transmission case together. Install countershaft gear locking nut. Hold mainshaft stationary.
  7. Engage 4th gear and tighten nut to specification. Stake nut in place using Vise-Grips. Place 3rd-4th shift fork back in neutral. Install new prelubricated input shaft oil seal (if equipped). Using a seal protector, install clutch housing with small amount of sealant on rear face of clutch housing.
  8. Tighten case half bolts. Rotate input shaft to seat bearings. Tighten retainer plate bolts. Loosen 4 bearing bolts and tap case half while turning input shaft. Tighten bearing bolts.
  9. Position transmission to rest on clutch housing. Place 5th-reverse shift shaft in 5th gear position. Coat intermediate housing mating surfaces with sealant. Install housing, making sure that locating dowels are in place and selector fingers are engaged in fork shaft gate.
  10. Install 5th-reverse intermediate shaft and synchronizer. Position synchronizer so mark made during disassembly is visible (if new, so circular groove on face points toward reverse).
  11. Install 5th-reverse synchronizer sleeve and fork, aligning reference marks made during disassembly. Install Retainer (.0314-AE) on case housing and install new roll pin in 5th-reverse shift fork. Remove retainer and place assembly in neutral.
  12. Install 5th drive gear with needle bearing. Install spacer and snap ring (if equipped). Install snap ring in mainshaft groove. Lubricate machined surface of mainshaft and press 5th driven gear and speedometer drive onto mainshaft using Bushing (.0310AB) and Installers (.0310P and .0314).
    NOTE: Check all gears for proper meshing and operation.
  13. Install new snap ring to retain 5th driven gear and speedometer drive gear. Remove extension housing. Remove bearing with race (shim, if equipped) and oil seal.
  14. Install extension housing without its bearing. Install Dial Indicator (.0314-FZ) against rear face of housing. Place measuring plunger against shoulder of shaft (not spacer). Zero dial indicator. Remove extension housing.
  15. On 1st version models, install correct shims to adjust mainshaft bearing preload as predetermined. See 1st Version Mainshaft Bearing Preload. Install bearing using press and Adapter (.0314-U). For 2nd version models, install bearings using Press Block (0314-R) and install new snap ring.
  16. Clamp Gauge Block (.0314-K) in vise. Position extension housing with inner bearing race installed, against gauge block. With gauge block previously zeroed from step 14), install dial indicator over housing and record measurement of indicator.
  17. Subtract required free play of .002" (.05 mm) from recorded measurement and round off to the nearest .002" (.05 mm). Result is required shim thickness to adjust 5th-reverse intermediate shaft bearing free play.
    NOTE: Shims are available in increments of .002" (.05 mm) between .004-.008" (1.0-2.0 mm).
  18. Install spacer and predetermined adjusting shim. Apply sealant to extension housing mating surfaces. Make sure that centering dowels are installed and protrude approximately .002" (.05 mm). Install extension housing, ensuring that selector fingers engage with selector fork shaft.
  19. Tighten extension housing bolts to specification while tapping housing with soft mallet just above the intermediate shaft. Install inspection plate with new gasket and retaining bolts or screws. Install new output shaft oil seal.
  20. Install lock-out plunger spring on outside of case. Install speedometer gear with prelubricated "O" rings. Lubricate release bearing guide. Install release bearing and lock it to release fork.
TORQUE SPECIFICATIONS

Application Ft. Lbs. (N.m)
Back-Up Light Switch 20 (27)
Case Half (Nos. 4 & 6 Bearing Bolts) 11 (15)
Clutch Housing Mounting Bolts 20 (27)
Extension Housing Mounting Bolts 11 (15)
Intermediate Housing Mounting Nuts 13 (18)
Mainshaft Lock Nut 40 (54)
Reverse Lock-Out Plunger Lever 11 (15)
Countershaft Lock Nut 18 (24)
INCH Lbs. (N.m.) 
Case Half Bolts 87 (9.8)
Retainer Plate 87 (9.8)
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