93ZJ-Secc-21-Transmissions-and-Transfer-Cases.pdf

TRANSMISSION AND TRANSFER CASE 21 - 1

TRANSMISSION AND TRANSFER CASE

CONTENTS

page

AX 15 MANUAL TRANSMISSION ............ 1

AW-4 AUTOMATIC TRANSMISSION ......... 34

46RH AUTOMATIC TRANSMISSION ........ 151

NP231 TRANSFER CASE ............... . 271

NP242 TRANSFER CASE ............... . 292

NP249 TRANSFER CASE ............... . 319

SPECIFICATIONS ..................... . 345

AX 15 MANUAL TRANSMISSION

INDEX

page

General Information ....................... . 1

Transmission Assembly and Adjustment ....... . 19

Transmission Diagnosis .................... . 2

Transmission Disassembly and Overhaul ........ 5

Transmission Gear Ratios .................. . 2

Transmission Identification .................. . 1

Transmission Installation .................... 4

Transmission Lubricant .................... . 2

Transmission Removal ..................... . 3

Transmission Shift Pattern ................... 2

Transmission Switch and Plug Locations ........ 2

GENERAL INFORMATION

The AX 15 is a five speed, synchromesh, manual

transmission. Fifth gear is an overdrive range with a

ratio of 0.79:1. The shift mechanism is integral and

mounted in the shift tower portion of the adapter

housing (Fig. 1).

TRANSMISSION IDENTIFICATION

The AX 15 identification code numbers are on the

bottom surface of the transmission gear case (Fig. 2).

The first number represents year of manufacture.

For example, 3 would represent 1993. The second and

third numbers indicate month of manufacture.

Fig. 1 AX 15 Manual Transmission

21 - 2 AX 15 MANUAL TRANSMISSION

For example, 11 would represent November. The last

series of numbers is the transmission serial number.

Fig. 4 Fill Plug Location

Fig. 2 Transmission Identification Code Location

TRANSMISSION SHIFT PATTERN

The AX 15 shift pattern is shown in Figure 3. First

and second and third and fourth gear ranges are in

an H pattern. Fifth and reverse gear ranges are also

in line at the right of the H pattern (Fig. 3).

The AX 15 is equipped with a reverse lockout

mechanism. The shift lever must be moved through

the Neutral detent before making a shift to reverse.

Fig. 5 Drain Plug And Backup Light Switch Location

TRANSMISSION GEAR RATIOS

AX 15 transmission gear ratios are:

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

Fig. 3 AX 15 Shift Pattern

TRANSMISSION DIAGNOSIS

TRANSMISSION LUBRICANT

Recommended lubricant for AX 15 transmissions is

Mopar SAE 75W-90, API Grade GL-5 gear lubricant.

Correct lubricant refill or top-off level is to the

bottom edge of the fill plug hole.

Lubricant capacity is approximately 3.10 liters

(3.27 qts.).

LOW LUBRICANT LEVEL

A low transmission lubricant level is generally the

result of a leak, inadequate lubricant fill, or an incor-

rect lubricant level check.

Leaks can occur at the mating surfaces of the gear

case, intermediate plate and adapter 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 adapter housing will be

from the housing oil seals. Leaks at component mat-

TRANSMISSION SWITCH AND PLUG LOCATIONS

The fill plug is at the driver side of the gear case

(Fig. 4).

The drain plug and backup light switch are on the

passenger side of the gear case (Fig. 5).

AX 15 MANUAL TRANSMISSION

21 - 3

ing 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 are from the

front bearing retainer or retainer seal. Lubricant may

be seen dripping from the clutch housing after ex-

tended operation. If the leak is severe, it may also

contaminate the clutch disc causing slip, grab and

chatter.

Transmissions filled from air or electrically powered

lubricant containers can be underfilled. This gener-

ally happens when the container delivery mechanism

is improperly calibrated. Always check the lubricant

level after filling to avoid an under fill condition.

A correct lubricant level check can only be made

when the vehicle is level; use a drive-on hoist to

ensure this. Also allow the lubricant to settle for a

minute or so before checking. These recommendations

will ensure an accurate check and avoid an under-or-

overfill condition.

TRANSMISSION REMOVAL

(1) Shift transmission into Neutral.

(2) Raise vehicle on hoist.

(3) Remove skid plate.

(4) Mark front and rear propeller shafts for instal-

lation alignment (Fig. 1). Then remove shafts.

HARD SHIFTING

Hard shifting is usually the result of a low lubri-

cant level, improper or contaminated lubricants, com-

ponent damage, incorrect clutch adjustment, or by a

damaged clutch pressure plate or disc.

Substantial lubricant leaks can result in gear, shift

rail, synchro and bearing damage. If a leak goes

undetected for an extended period, the first indica-

tions of a problem are hard shifting and noise.

Incorrect or contaminated lubricants also contribute

to hard shifting. The consequence of using non-

recommended lubricants is noise, excessive wear, in-

ternal bind and hard shifting.

Improper clutch release is a frequent cause of hard

shifting. 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. 1 Marking Propeller Shaft And Axle Yoke

(5) Disconnect transfer case shift linkage from shift

lever, or range lever.

(6) Disconnect wire harness from distance sensor.

(7) Remove harness wires from clips on transmis-

sion case.

(8) Disconnect transmission and transfer case vent

hoses.

(9) Disconnect wires at transfer case electrical

switch.

(10) Support transmission with transmission jack.

Secure transmission on jack with safety chains.

(11) Support engine with jack positioned under

clutch housing or oil pan flange.

(12) Remove bolts/nuts attaching rear mount to

crossmember (Fig. 2).

(13) Remove rear crossmember.

(14) Remove transfer case attaching nuts and re-

move transfer case from transmission.

(15) Lower transmission enough to provide access

to shift lever.

(16) Reach up and around transmission case and

unseat shift lever dust boot from transmission shift

tower (Fig. 3). Move boot upward on shift lever for

access to lever retainer.

(17) Disengage transmission shift lever as follows:

(a) Reach up and around transmission case and

press shift lever retainer downward with your fin-

gers.

(b) Turn retainer counterclockwise to release it.

3). It is not necessary to remove shift lever

from floorpan boot. Simply leave lever in

place for later installation.

TRANSMISSION NOISE

Most manual transmissions make some noise dur-

ing normal operation. Rotating gears can generate a

mild whine that may only be audible at extreme

speeds.

Severe transmission noise is generally the result of

a lubricant problem, or internal component damage.

Insufficient, improper, or contaminated lubricant can

promote rapid wear of gears, synchros, shift rails,

forks and bearings. The overheating caused by a lu-

bricant problem, can also lead to gear breakage.

21 - 4 AX 15 MANUAL TRANSMISSION

(18) Disconnect and remove engine timing sensor.

Retain sensor attaching screws.

(19) Remove clutch slave cylinder from clutch hous-

ing. Move cylinder aside for working clearance and

access to other components.

(20) Remove bolts attaching clutch housing to en-

gine.

(21) Pull transmission rearward until clutch hous-

ing is clear of engine. Then remove transmission from

under vehicle.

TRANSMISSION INSTALLATION

(1) Mount transmission and clutch housing assem-

bly on transmission jack. Secure assembly with safety

chains.

(2) Lubricate pilot bearing and transmission input

shaft splines with Mopar high temperature grease.

(3) Align transmission input shaft and clutch disc

splines and seat clutch housing on engine.

(4) Install and tighten bolts that clutch housing to

engine. Tighten bolts to 61 N

Fig. 2 Transmission Rear Mounting

m (26 ft. lbs.) torque.

(8) Move adjustable support stand from under en-

gine and reposition it under transmission. Then re-

move transmission jack.

(9) Install rear crossmember. Tighten crossmember-

to-frame bolts to 41 N

m (30 ft. lbs.) torque. Tighten

transmission-to-rear support bolts/nuts to 45 N

m (33

ft. lbs.) torque.

(10) Install slave cylinder in clutch housing.

Tighten cylinder attaching nuts securely.

(11) Connect or install engine timing sensor, if re-

moved.

(12) Connect transfer case electrical switch wires.

(13) Connect transfer case shift rod to range lever.

(14) Connect transmission and transfer case vent

hoses.

(15) Connect backup light switch wires.

(16) Connect distance sensor and sensor wires.

(17) Align and install front/rear propeller shafts.

Tighten shaft U-joint clamp bolts to 19 N

m (170 in.

lbs.) torque.

(18) Install skid plate if removed. Tighten bolts to

42 N

m (31 ft. lbs.) torque. Tighten stud nuts to 17

m (150 in. lbs.) torque.

(19) Top off transmission and transfer lubricant

levels.

(20) Lower vehicle.

Fig. 3 Shift Lever Attachment

m (45 ft. lbs.) torque.

(5) Lower transmission for access to transmission

shift tower.

(6) Reach up and around transmission and insert

shift lever in shift tower. Press lever retainer down-

ward and turn it clockwise to lock it in place. Then

install lever dust boot on shift tower.

(7) Align transfer case and transmission shafts and

install transfer case. Tighten transfer attaching nuts

to 35 N

AX 15 MANUAL TRANSMISSION

21 - 5

TRANSMISSION DISASSEMBLY AND OVERHAUL

ADAPTER HOUSING REMOVAL

(1) Remove release bearing, release lever and re-

lease fork from clutch housing. Then remove clutch

housing from transmission.

(2) Remove backup light switch. Then remove drain

plug (Fig. 1) and drain transmission lubricant into

pan.

Fig. 3 Shift Tower Gasket Removal/Installation

Fig. 1 Drain Plug And Backup Light Switch Location

(3) Remove shift tower bolts and remove tower

from adapter or extension housing (Fig. 2).

(4) Remove gasket from shift tower (Fig. 3).

Fig. 4 Shift Arm Retainer Bolt Removal/Installation

Fig. 2 Shift Tower Removal/Installation

(5) Remove shift arm retainer bolt (Fig. 4).

(6) Loosen and remove restrictor pins (Fig. 5).

(7) Remove shift arm shaft plug (Fig. 6).

(8) Remove shift arm shaft with large magnet (Fig.

7).

(9) Remove shift arm (Fig. 8).

(10) Remove plug for reverse shift head lock ball.

Plug is at right side of adapter housing near backup

light switch (Fig. 9).

Fig. 5 Removing/Installing Restrictor Pins

(11) Remove lock ball spring with pencil magnet

(Fig. 10).

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