Jeep CJ/Scrambler 1971-1986 Repair Guide

T-150 3-Speed Transmission Overhaul

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The Tremec T-150 transmission is used in varied vehicle applications, with or without transfer cases. The gear selection is controlled by either a top shift housing or by a remote control shift lever assembly. Although some of the gears and case applications are not interchangeable, the gear arrangement is basically the same.

DISASSEMBLY



See Figures 1 and 2

  1. Remove the bolts securing the transfer case to the transmission. Remove the transfer case.
  2.  
  3. Remove the transfer case drive gear locknut, flat washer, and drive gear. Remove the large fiber washer from the rear bearing adapter. Move the second-third clutch sleeve forward and the first-reverse sleeve to the rear before removing the locknut.
  4.  
  5. Remove the transmission oil plug and drive the countershaft out of the case with a suitable size drift. Do not lose the countershaft access plug when removing the countershaft. With the countershaft removed the countershaft gear will lie at the bottom of the case, leave it there until the mainshaft is removed.
  6.  
  7. Punch alignment marks in the front bearing cap and the transmission case for assembly reference.
  8.  
  9. Remove the front bearing cap and gasket.
  10.  
  11. Remove the large lock ring from the front bearing.
  12.  
  13. Remove the clutch shaft, front bearing, and the second-third synchronizer assembly. A special tool is required for this operation.
  14.  
  15. Remove the rear bearing and adapter assembly with a brass drift and hammer. Drive the adapter out the rear of the case with light blows from the hammer.
  16.  
  17. Remove the mainshaft assembly. Tilt the spline end of the shaft downward and lift the front end up and out of the case.
  18.  
  19. Remove the countershaft tool and arbor as an assembly. Remove the countershaft thrust washers, countershaft roll pin, and any pilot roller bearings that may have fallen into the case.
  20.  
  21. Remove the reverse idler shaft. Insert a brass drift through the clutch shaft bore in the front of the case and tap the shaft until the end with the roll pin clears the counter bore in the rear of the case. Remove the shaft.
  22.  
  23. Remove the reverse idler gear and thrust washers from the case.
  24.  
  25. Remove the retaining snapring from the front of the mainshaft. Remove the second-third synchronizer assembly and second gear. Mark the hub and sleeve for reference during assembly.
  26.  

Observe the position of the insert springs and the inserts during removal for correct assembly.

  1. Remove the insert springs from the second-third synchronizer, remove the three inserts, and separate the sleeve from the synchronizer hub retaining snapring.
  2.  
  3. Remove the snapring and the tabbed thrust washer from the mainshaft and remove the first gear blocking ring.
  4.  
  5. Remove the first-reverse synchronizer hub snapring.
  6.  

Observe the position of the insert springs and the inserts during removal for correct assembly.

  1. Remove the first-reverse sleeve, insert spring and the three insert from the hub. Remove the spacer from the rear of the mainshaft.
  2.  


CAUTION
Do not attempt to remove the press fit hub by hammering. Hammer blows will damage the hub and mainshaft.

  1. Remove the front bearing retaining snapring and any remaining roller bearings from the clutch shaft.
  2.  
  3. Press the front bearing off the clutch shaft with an arbor press.
  4.  


CAUTION
Do not attempt to remove the bearing by hammering. Hammer blows will damage the bearing and the clutch shaft.

  1. Clamp the rear bearing adapter in a soft-jawed vise. Do not over-tighten.
  2.  
  3. Remove the rear bearing retaining snapring. Remove the bearing adapter from the vise.
  4.  
  5. Press the rear bearing out of the adapter with an arbor press.
  6.  
  7. Thoroughly wash all parts in clean solvent and dry with compressed air. Do not dry the bearings with compressed air, use a clean shop cloth. Clean the needle and clutch shaft bearings by placing them in a shallow parts cleaning tray and covering them with solvent. Allow the bearings to air dry on a clean shop cloth. Check the case for the following: Cracks in the bores, bosses, or bolt holes. Stripped threads in bolt holes. Nicks, burrs, rough surfaces in the shaft bores or on the gasket surfaces.
  8.  
  9. Check the gear and synchronizer assemblies for the following: Broken, chipped, or worn gear teeth. Damaged splines on the synchronizer hubs or sleeves. Bent or damaged inserts. Damaged needle bearings or bearing bores in the countershaft gear. Broken or worn teeth or excessive wear of the blocking rings. Wear of galling of the countershaft, clutch shaft, or reverse idler shaft. Worn thrust washers. Nicked, broken, or worn mainshaft or clutch shaft splines. Bent, distorted, or weak snaprings. Worn bushings in the reverse idler gear. Replace the gear if the bushings are worn. Rough, galled, or broken front or rear bearings.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the T-150 transmission control assembly



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the T-150 transmission

ASSEMBLY



  1. Lubricate the reverse idler shaft bore and bushings with transmission oil.
  2.  
  3. Coat the transmission case reverse idler gear thrust washer surfaces with petroleum jelly and install the thrust washers in the case.
  4.  

Make sure the locating tangs on the thrust washers are aligned in the slots in the case.

  1. Install the reverse idler gear. Align the gear bore, thrust washers, and case bore. Install the reverse idler shaft from the rear of the transmission case. Be sure to align and seat the roll pin in the shaft into the counter bore in the rear of the case.
  2.  
  3. Measure the reverse idler gear end-play by inserting a feeler gauge between the thrust washer and the gear. End-play should be 0.004-0.018 in. (0.10-0.46mm). If end play exceeds 0.018 in. (0.46mm), remove the reverse idler gear and replace the thrust washers.
  4.  
  5. Coat the needle bearing bores in the countershaft gear with petroleum jelly. Insert the arbor tool in the bore of the gear and install the (25) needle bearings and the retainer washers at each end of the countershaft gear.
  6.  
  7. Coat the countershaft gear thrust washer surface with petroleum jelly and position the thrust washers in the case.
  8.  

Make sure the locating tangs on the thrust washers are aligned in the slots in the case.

  1. Insert the countershaft into the bore at the rear of the case just far enough to hold the thrust washer in place.
  2.  
  3. Install the countershaft gear in the case. Do not install the roll pin at this time. Align the gear bore, thrust washers, the bores in the case, and install the countershaft.
  4.  

Do not remove the arbor tool completely.

  1. Measure the countershaft gear end-play by inserting a feeler gauge between the washer and the countershaft gear. End-play should be 0.004-0.018 in. (0.10-0.46mm). If the end-play exceeds 0.018 in. (0.46mm), remove the gear and replace the thrust washer.
  2.  
  3. When the correct countershaft gear end-play has been obtained, install the countershaft arbor and remove the countershaft. Allow the countershaft gear to remain at the bottom of the case, leave the countershaft in the case enough to hold the thrust washer in place.
  4.  
  5. Coat the splines and machined surfaces on the mainshaft with transmission oil. Install the first-reverse synchronizer on the output shaft splines by hand. The end of the hub with the slots should face the front of the shaft. Use an arbor press to complete the hub installation. Install the retaining snapring in the groove farthest to the rear.
  6.  


CAUTION
Do not attempt to drive the hub on the shaft with a hammer.

  1. Coat the splines of the first-reverse hub with transmission oil and install the first reverse sleeve and gear halfway onto the hub, with the gear end of the sleeve facing the rear of the shaft. Align the marks made during disassembly.
  2.  
  3. Install the insert spring in the first-reverse hub. Make sure the spring bottoms in the hub and covers all three insert slots. Position the three "T'' shaped inserts in the hub with the small ends in the hub slots and the large ends inside the hub. Push the inserts fully into the hub so they seat on the insert spring, slide the first-reverse sleeve and gear over the inserts until the inserts engage in the sleeve.
  4.  
  5. Coat the bore and the blocking ring surface of first gear with transmission oil and place blocking ring on the tapered surface of the gear.
  6.  
  7. Install the first gear on the output shaft. Rotate the gear until the notches in the blocking ring engage the inserts in the first-reverse synchronizer assembly. Install the tanged thrust washer, sharp end facing out, and retaining snapring on the mainshaft.
  8.  
  9. Coat the bore and blocking ring surface of the second gear with transmission oil. Place the second gear blocking ring on the tapered surface of second gear.
  10.  
  11. Install the second gear on the output shaft with the tapered surface of the gear facing the front of the mainshaft.
  12.  
  13. Install one insert spring into the second-third synchronizer hub. Be sure that the spring covers all three insert slots in the hub. Align the second-third sleeve with the hub using the marks made during disassembly. Start the sleeve onto the hub.
  14.  
  15. Place the three inserts into the hub slots and on top of the insert spring. Push the sleeve fully onto the hub to engage the inserts in the sleeve. Install the remaining insert spring in the exact position as the first spring. The ends of both springs must cover the same slot in the hub and not be staggered.
  16.  

The inserts have a small lip on each end. When they are correctly installed, this lip will fit over the insert spring.

  1. Install the second-third synchronizer assembly on the mainshaft. Rotate the second gear until the notches in the blocking ring engage the inserts in the second-third synchronizer assembly.
  2.  
  3. Install the retaining snapring on the mainshaft and measure the end-play between the snapring and the second-third synchronizer hub. The end-play should be 0.0040-0.014 in. (0.10-0.36mm) If the end-play exceeds the limit, replace the thrust washer and all the snaprings on the mainshaft assembly. Install the spacer on the rear of the mainshaft.
  4.  
  5. Install the mainshaft assembly in the case. Be sure that the first-reverse sleeve and gear is in the neutral (centered) position.
  6.  
  7. Press the rear bearing into the rear bearing adapter with an arbor press. Install the rear bearing retaining ring and the bearing adapter lockring.
  8.  
  9. Support the mainshaft assembly and install the rear bearing and adapter assembly in the case. Use a soft faced hammer to seat the adapter in the case.
  10.  
  11. Install the large fiber washer in the rear bearing adapter. Install the transfer drive gear, flat washer, and locknut. Tighten the locknut to 150 ft. lbs. torque.
  12.  
  13. Press the front bearing onto the clutch shaft. Install the bearing retaining snapring on the clutch shaft and the lockring into its groove.
  14.  
  15. Coat the bore of the clutch shaft assembly with petroleum jelly and install the (15) roller bearings in the clutch shaft bore.
  16.  


CAUTION
Do not use chassis grease or a similar heavy grease in the clutch shaft bore. Heavy grease will plug the lubricant holes in the shaft and prevent proper lubrication of the roller bearings.

  1. Coat the blocking ring surface of the clutch shaft with transmission oil. Position the blocking ring on the clutch shaft.
  2.  
  3. Support the mainshaft assembly and insert the clutch shaft through the front bearing bore in the case. Seat the mainshaft pilot in the clutch shaft roller bearings. Tap the bearings into place with a soft faced hammer.
  4.  
  5. Apply a thin film of sealer to the front bearing cap gasket and position the gasket on the case. Be sure the cutout in the gasket is aligned with the oil return hole in the case.
  6.  
  7. Remove the front bearing cap oil seal with a suitable tool. Install a new seal with a suitable driver.
  8.  
  9. Install the front bearing cap and tighten the bolts to 33 ft. lbs. Be sure that the marks on the cap and the transmission case are aligned and the oil return slot in the cap lines up with the oil return hole in the case.
  10.  
  11. Make a wire loop about 18-20 in. (457-508mm) long and pass the wire under the countershaft gear assembly. The wire loop should raise and support the countershaft gear assembly when it is pulled upward.
  12.  
  13. Raise the countershaft gear with the wire. Align the bore in the countershaft gear with the front thrust washer and the countershaft. Start the countershaft into the gear with a soft faced hammer.
  14.  
  15. Align the roll pin hole in the countershaft with the roll pin holes in the case and complete the installation of the countershaft. Install the countershaft access plug in the rear of the case and seat with a soft faced hammer.
  16.  
  17. Install the countershaft roll pin in the case. Use a magnet or needle nose pliers to insert and start the pin in the case. Use a 1 / 2 in. punch to seat the pin. Install the transmission filler plug.
  18.  
  19. Shift the synchronizer sleeves through all gear ranges and check their operation. If the clutch shaft and mainshaft appear to bind in the neutral position, check for blocking rings sticking on the first or second gear tapers.
  20.  
  21. Install the transfer case on the transmission. Tighten the attaching bolts to 30 ft. lbs.
  22.  

Shift Control Housing
  1. Remove the back-up light switch and the transmission controlled spark switch (TCS) if so equipped.
  2.  
  3. Remove the shift control housing cap, gasket, spring retainer, and the shift lever spring as an assembly.
  4.  
  5. Invert the housing and mount in a soft-jawed vise.
  6.  
  7. Move the second-third shift rail to the rear of the housing, rotate the shift fork toward the first-reverse rail until the roll pin is accessible. Drive the roll pin out of the fork and rail with a pin punch. Remove the shift fork and the roll pin.
  8.  

The roll pin hole in the shift fork is offset. Mark the position of the shift fork for assembly reference.

  1. Remove the second-third shift rail using a brass drift or hammer. Catch the shift rail plug as the rail drives it out of the housing. Cover the shift and poppet ball holes in the cover to prevent the poppet ball from flying out. Mark the location of the shift rail for assembly reference.
  2.  
  3. Rotate the first-reverse shift fork away from the notch in the housing until the roll pin is accessible. Drive the roll pin out of the fork and rail using a pin punch. Remove the shift fork and roll pin.
  4.  

The roll pin hole in the shift fork is offset. Mark the position of the shift fork for assembly reference.

  1. Remove the first-reverse shift rail using a brass drift or hammer. Catch the shift rail plug as the rail drives it out of the housing. Cover the shift and poppet ball holes in the cover to prevent the poppet ball from flying out. Mark the location of the shift rail for assembly reference.
  2.  
  3. Remove the poppet balls, springs, and the interlock plunger from the housing.
  4.  
  5. Install the poppet springs and the detent plug in the housing.
  6.  
  7. Insert the first-reverse shift rail into the housing, and install the shift fork on the shift rail.
  8.  
  9. Install the poppet ball on the top of the spring in the first-reverse rail.
  10.  
  11. Using a punch or wooden dowel, push the poppet ball and spring downward into the housing bore and install the first-reverse shift rail.
  12.  
  13. Align the roll pin holes in the first-reverse shift fork and install the roll pin. Move the shift rail to the neutral (center) detent.
  14.  
  15. Insert the second-third shift rail into the housing and install the poppet ball on top of the spring in the shift rail bore.
  16.  
  17. Using a punch or wooden dowel, push the poppet ball and spring downward into the housing bore and install the second-third shift rail.
  18.  
  19. Align the roll pin holes in the second-third shift rail and the shift fork and install the roll pin. Move the shift rail to the neutral (center) position.
  20.  
  21. Install the shift rail plugs in the housing, and remove the shift control cover from the vise.
  22.  
  23. Install the shift lever, shift lever spring, spring retainer, gasket, and the shift control housing cap as an assembly. Tighten the cap securely.
  24.  
  25. Install the back-up light switch and the TCS switch if so equipped.
  26.  

 
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