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TRANSMISSION AND TRANSFER CASE
21 - 1
TRANSMISSION AND TRANSFER CASE
CONTENTS
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page
AX15 MANUAL TRANSMISSION . . . . . . . . . . . . . 1
NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . . . 7
AX15 MANUAL TRANSMISSION
INDEX
page
GENERAL INFORMATION
AX 15 MANUAL TRANSMISSION . . . . . . . . .
TRANSMISSION ASSEMBLY INFORMATION
TRANSMISSION GEAR RATIOS . . . . . . . . . .
TRANSMISSION IDENTIFICATION . . . . . . . .
TRANSMISSION LUBRICANT . . . . . . . . . . . .
TRANSMISSION SHIFT PATTERN . . . . . . . .
TRANSMISSION SWITCH AND PLUG
LOCATIONS . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
HARD SHIFTING . . . . . . . . . .
LOW LUBRICANT LEVEL . . . .
TRANSMISSION NOISE . . . . .
REMOVAL AND INSTALLATION
TRANSMISSION . . . . . . . . . . .
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . .
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1
3
3
2
2
2
............... 3
............... 3
............... 3
............... 3
............... 6
.... 2
ratio of 0.79:1. The shift mechanism is integral and
mounted in the shift tower portion of the adapter
housing (Fig. 1).
GENERAL INFORMATION
AX 15 MANUAL TRANSMISSION
The AX 15 is a 5–speed, synchromesh, manual
transmission. Fifth gear is an overdrive range with a
Fig. 1 AX 15 Manual Transmission
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TRANSMISSION AND TRANSFER CASE
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GENERAL INFORMATION (Continued)
TRANSMISSION IDENTIFICATION
The AX 15 identification code numbers are on the
bottom surface of the transmission gear case (Fig. 2).
The first number is year of manufacture. The sec-
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.
Approximate dry fill lubricant capacity is:
•
3.10 liters (3.27 qts.) in 4–wheel drive models
TRANSMISSION SWITCH AND PLUG
LOCATIONS
The fill plug is at the driver side of the gear case
(Fig. 4).
Fig. 2 Identification Code Number Location
ond and third numbers indicate month of manufac-
ture. The next series of numbers is the transmission
serial number.
TRANSMISSION SHIFT PATTERN
The AX 15 shift pattern is shown in (Fig. 3). First
and second and third and fourth gear ranges are in
line for improved shifting. Fifth and reverse gear
ranges are also in line at the extreme right of the
pattern (Fig. 3).
Fig. 4 Fill Plug Location
The drain plug and backup light switch are on the
passenger side of the gear case (Fig. 5).
Fig. 5 Drain Plug/Backup Light Switch Location
Fig. 3 AX 15 Shift Pattern
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.
TRANSMISSION LUBRICANT
Recommended lubricant for AX 15 transmissions is
Mopar 75W–90, API Grade GL–3 gear lubricant, or
equivalent.
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GENERAL INFORMATION (Continued)
TRANSMISSION AND TRANSFER CASE
21 - 3
TRANSMISSION GEAR RATIOS
AX 15 gear ratios are:
First gear . .
Second gear
Third gear .
Fourth gear
Fifth gear . .
Reverse . . . .
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3.83:1
2.33:1
1.44:1
1.00:1
0.79:1
4.22:1
TRANSMISSION ASSEMBLY INFORMATION
Lubricate the transmission components with gear
lubricant during assembly. Use petroleum jelly to
lubricate seal lips and/or hold parts in place during
installation.
DIAGNOSIS AND TESTING
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 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 hous-
ing will be from the housing oil seals. Leaks at com-
ponent mating surfaces will usually 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 caus-
ing slip, grab and chatter.
Transmissions filled from air or electrically pow-
ered lubricant containers can be under filled. This
generally happens when the container delivery mech-
anism is improperly calibrated. Always check the
lubricant level after filling to avoid an under fill con-
dition.
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 recommenda-
tions will ensure an accurate check and avoid an
under–or–over fill condition.
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 usually hard shifting and
noise.
Incorrect or contaminated lubricants can also con-
tribute to hard shifting. The consequence of using
non–recommended lubricants is noise, excessive
wear, internal 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.
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, obviously audible transmission noise is
generally the result of a lubricant problem. Insuffi-
cient, improper, or contaminated lubricant can pro-
mote 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. Disconnect the battery negative cable.
2. Remove the shifter boot and shifter.
3. Raise the vehicle on a hoist.
4. Drain the transmission fluid (Fig. 6).
5. Support the engine and transmission with an
adjustable jack stand.
6. Remove exhaust pipe and heat shield.
7. Mark the front and rear propeller shafts for
installation alignment (Fig. 7).
8. Remove the front propeller shaft.
9. Remove the rear propeller shaft.
10. Remove the transmission skid plate.
11. Disconnect the transfer case linkage and vehi-
cle speed sensor electrical connector and vent tube
hose (Fig. 8).
12. Reposition the adjustable jackstand under the
engine.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants, compo-
nent damage, incorrect clutch adjustment, or by a
damaged clutch pressure plate or disc.
21 - 4
TRANSMISSION AND TRANSFER CASE
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REMOVAL AND INSTALLATION (Continued)
Fig. 6 Drain Plug and Backup Light Switch Location
Fig. 8 Vehicle Speed Sensor
Fig. 7 Marking Propeller Shaft and Axle Yoke
13. Place a transmission jack under the transmis-
sion and secure the transmission with safety chains.
14. Remove the rear transmission mount.
15. Remove the rear crossmember.
16. Remove the transfer case assembly. Refer to
Transfer Case removal later in this Group.
17. Lower the engine and transmission no more
than 7.6 cm.
18. Remove the two (2) upper and two (2) mid
clutch housing to engine bolts.
19. Remove the engine speed sensor (crankshaft
position sensor) (Fig. 9).
20. Remove the clutch slave cylinder from the
clutch housing.
21. Remove the lower transmission bolts.
22. Remove the transmission assembly from the
vehicle.
Fig. 9 Engine Speed Sensor
2. Install the transmission to the vehicle (Fig. 10).
3. Install the two (2) lower transmission bolts.
Tighten the bolts to 74.6 N·m.
4. Install the clutch slave cylinder to the clutch
housing.
5. Install the engine speed sensor (crankshaft posi-
tion sensor) to the vehicle (Fig. 9).
6. Install the two (2) upper clutch housing to
engine bolts. Tighten the bolts to 36.6 N·m.
7. Install the two (2) mid clutch housing to engine
bolts. Tighten the bolts to 58.3 N·m.
8. Raise the engine and transmission with the
adjustable jackstand.
9. Install the transfer case assembly. Refer to
Transfer Case installation later in this Group.
10. Install the rear crossmember.
INSTALLATION
1. Mount the transmission on a transmission jack
and secure the transmission with safety chains.
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REMOVAL AND INSTALLATION (Continued)
TRANSMISSION AND TRANSFER CASE
21 - 5
Fig. 10 Transmission to Engine Mounting
13. Install the transmission skid plate.
14. Align and install the front and rear propeller
shafts.
15. Install the exhaust pipe and heat shield.
16. Remove the transmission jack.
17. Fill the transmission with the proper fluid
(Fig. 12).
Fig. 11 Clutch Housing to Transmission
11. Install the rear transmission mount.
12. Connect the transfer case linkage and vehicle
speed sensor electrical connector and vent tube (Fig.
8).
Fig. 12 Fill Plug Location
18. Remove the adjustable jackstand from under
the engine.

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