[Mean Max]

This is a write-up on how to install the clip & collar kit on an AX-5 that has lost 5th gear. However, the AX-5 pictured here had much more severe issues & required a full rebuild, but being as I had intended on making this write-up I'll go through the procedure for the benefit of anyone who may need to perform it.

My friend & fellow JF member YJake lost 5th gear on his AX-5 recently. We assumed that he just lost the clip & the gear slid back on the shaft, thus losing it's engagement and resulting in a loss of 5th gear. So he bought the clip & collar kit and we started the repair, with the AX-5 still installed in the Jeep.

First pull the skid plate off, drain the fluids from the transmission & tranfer cases, remove both driveshafts & unbolt the transfer case.

Remove the shifter, transfer case shifter, and the shifter tower from the gearbox.

Remove the bolt from the shifter arm that attaches it to the pivot/slide shaft.

Remove the 2 spring loaded shift detent assemblies.

Remove the allen plug at the rear of the transmission case. This will allow you access to remove the pivot/slide shaft. After removing the pivot/slide shaft you can pull the shifter arm up & remove it from the transmission case.

Now you're ready to remove the rear case cover. There are 7 bolts and 1 nut around the perimeter of the case holding it on.

Okay, so this is a picture of a 2WD AX-5 output shaft from a disassembled gearbox, but it shows the 5th gear shift fork & syncronizer (large diameter gearset at the bottom) and the actual 5th gear (small gear on output shaft) and the clip that is supposed to retain it on the output shaft. The clip on the small gear (5th gear) is the clip that frequently falls off.

When the clip falls off, the small 5th gear will slide back on the shaft & lose contact with the larger counter shaft gear that drives it. This is why 5th gear feels like neutral under those conditions. If there has been no damage to the gears, the 5th gear can be tapped back into place on the shaft & a new clip installed. Installing the aluminum 2 piece collar (shown loosely attached here) will prevent a repeat performance.

As you can see here, this was not an option for us.

Reverse the disassembly order to reassemble & refill the transmission with 10W-30 motor oil and ATF in the transfer case.

Hope this helps!

Max

[YJake]

That picture of my ground away gears will haunt me in my sleep for days to come

[turtlerace]

Originally Posted by YJake

That picture of my ground away gears will haunt me in my sleep for days to come

We were just kidding with the 'grind 'em til you find 'em' comments.

[Mean Max]

Originally Posted by YJake

That picture of my ground away gears will haunt me in my sleep for days to come

Originally Posted by turtlerace

We were just kidding with the 'grind 'em til you find 'em' comments.

How's this for carnage?

Max

[Opihi59]

Very nice Max !! Post up the source for that 2-piece collar, I know you've done it before, I seem to recall Consolidated Transmissions or something ladat. With this writeup, everyone who owns a wrench should be able to tear the rear of their case off and fix that broken snap-ring/add in the 2-piece collar upgrade without having to pull the whole tranny.

Unless of course, they find gear soup in the rear case half like you did.

[rustywrangler]

Is it a similar setup on the AX-15 or totally different???

[leroyz71]

Thanks for the write up!

[Opihi59]

Originally Posted by rustywrangler

Is it a similar setup on the AX-15 or totally different???

There is a snap-ring on the AX 15 which serves the same purpose, but for some reason, it is not prone to breaking like the one on the AX 5. I'm really not sure why, since they look the same to me. Having now said this, I am hoping I don't upset the Karma and have mine implode in the next week or so even though I only have about 18 months on the rebuild I did on it.

Anyone else have any input on this?

[Mean Max]

Originally Posted by Opihi59

Very nice Max !! Post up the source for that 2-piece collar, I know you've done it before, I seem to recall Consolidated Transmissions or something ladat. With this writeup, everyone who owns a wrench should be able to tear the rear of their case off and fix that broken snap-ring/add in the 2-piece collar upgrade without having to pull the whole tranny.

Unless of course, they find gear soup in the rear case half like you did.
Great memory! The info will be listed below!

Originally Posted by rustywrangler

Is it a similar setup on the AX-15 or totally different???
Similar yes, but I can't say if the collar will fit the diameter of the AX-15 output shaft. I have an extra collar, so when I tear down the AX-15 I will check it out & report back in this thread.

Originally Posted by Opihi59

There is a snap-ring on the AX 15 which serves the same purpose, but for some reason, it is not prone to breaking like the one on the AX 5. I'm really not sure why, since they look the same to me. Having now said this, I am hoping I don't upset the Karma and have mine implode in the next week or so even though I only have about 18 months on the rebuild I did on it.

Anyone else have any input on this?
That's exactly what I have found. It is very common on the AX-5, but the similarly equipped AX-15 doesn't seem to be as prone (if ever?) to having this failure.

Okay guys, here is the info on sourcing the locking collar & clip.

The collar part number is:
AX5SRK and costs $34.50

The snap ring (1 required) is:
83500592 and costs $4.00

The replacement gear set (5th gear & counter gear) is:
G525 and costs $109.35

These parts can be sourced from:
Consolidated Transmissions
2850 W Airport Blvd
Sanford, FL 32771-1610
(407) 321-2055
(800) 578-8726

Ask to speak to Brandon, his family owns & operates Consolidated Transmissions and he will gladly assist you in getting the right parts to get you going!

Max

[YJake]

Well done Max!

I'm sure you just saved people thousands of dollars in transmission work at a shop with this thread!

To whoever does this repair, enjoy it!

Some of us lost a lot of sleep in the process of making this write up

[Mean Max]

Originally Posted by YJake

Well done Max!

I'm sure you just saved people thousands of dollars in transmission work at a shop with this thread!

To whoever does this repair, enjoy it!

Some of us lost a lot of sleep in the process of making this write up

Thanks Jake!

It was a busy weekend, but many lessons were learned & friendships were strengthened. It all makes for a good day!

Max

[UltimatE]

Originally Posted by Mean Max

How's this for carnage?

Max

Ooohh OOohhh can I play?

[turtlerace]

Originally Posted by UltimatE

Ooohh OOohhh can I play?

That's not carnage, that is a unintentional access port.

[Floppy]

Max, thank you for posting this! When I have some free time I'm probably going to do this on mine. 5th gear is probably useless for me with the new tires but I'd like to fix it anyway.

[Matt The Hammer]

Last time my AX had 5th gear... Bill Clinton was in office.

Hope it's still ok.

Problably lonely.

Overdrive here I come! Thanks again Max. I'll post pictures of my 5th gear adventure.