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Jeep Pops Out of Gear

This bulletin applies to 2007-2010 Jeep Nitro and Wrangler models. The manual transmission may intermittently pop out of gear when accelerating.

Verify that the shift boot is not interfering with the engagement of first gear. If the transmission pops out of gear in first, third and fifth gear, then the shift boot would be the most likely cause for the complaint. If the shift boot is not the cause, it will be necessary to replace the first gear and 1-2 synchronizer assembly.

PARTS NEEDED

P/N                                                               ITEM

68085902AA (NAFTA/Latin America only)…Kit, first gear and 1-2 synchronizer assembly

68080512AB (International only)…………….Kit, first gear  and 1-2 synchronizer assembly

04874464……………………………………....Qty 2, manual trans. Lubricant

04318083……………………………………....Gasket maker

SPECIAL TOOLS

9633……….NSG370 manual transmission build fixture

9636……….Mainshaft/bearing remover

9648……….Mainshaft build fixture

8228……….1-2 synchronizer hub installer

W-262……..Reverse gear synchronizer hub installer

                     Standard 3-jaw gear puller

                     Bearing heater/hot plate

1. Remove the transmission from the vehicle.

2. Disassemble the transmission.

3. Install the new first gear and 1-2 synchronizer assembly onto the mainshaft. Note: When installing the synchronizer sleeve, make sure that the side of the sleeve with the groove faces toward second gear. The selective snap rings are made available in case the mainshaft snap ring is damaged during shaft disassembly. Upon reassembly, select the thickest snap ring that will fit properly in the snap ring groove.

4. Reassemble the transmission using the new front countershaft seal and output shaft seal from the kit.

5. Install the transmission to the vehicle.

6. Fill the transmission with 3.17 pints of Mopar Manual Transmission Lubricant.

Refer to DealerCONNECT > TechCONNECT for detailed service procedures.

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