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53flattie 11-19-2012 05:13 PM

AX5 - 5th Gear Problem
1 Attachment(s)
'93 YJ, didn't have 5th gear when I bought it. I found the "AX5 5th Gear" sticky and followed it. Everything went great with disassembly - thanks so much to the author.

The problem is, my retainer isn't broken, but the gear is. I have 2 questions - can the 5th gear be pulled off the shaft without further disassembly? And if so, how in the hell do you get that split ring off? Everything spins freely, so I can't get any leverage...

Attachment 510585

Opihi59 11-19-2012 05:52 PM

Technique to remove the snap ring is 2 screwdrivers of equal length, whack on top of the screwdrivers with a large hammer. Gotta have 2 same length screwdrivers, and gotta hit them bot simultaneously. Snap ring with come off and then ricochet into a place where you will never find it again.

53flattie 11-19-2012 06:02 PM

Thanks Opihi - I am familiar with that method and will certainly give it a try. Lol.

I considered wedging something between the gears, to keep them from spinning. But I was afraid I might break a tooth...

Will the 5th gear come off the main shaft?

sxi4evr 11-19-2012 06:06 PM

dang i bet thats a tough job to do with the trans still under the jeep

Opihi59 11-19-2012 06:34 PM


Originally Posted by sxi4evr (Post 14481083)
dang i bet thats a tough job to do with the trans still under the jeep

Generally not that hard to do under the Jeep--remember the snap ring has broken off and you can then clamp on the retaining collar upgrade. Unless of course you have gears to replace but then it's only a bit annoying.


Originally Posted by 53flattie (Post 14481064)
Will the 5th gear come off the main shaft?

It should, what generally happens is that the ring breaks, then the gear slips back and just "spins" on the shaft. Unless the other 5th gear (countershaft) is trashed, you should be able to slip on a new mainshaft 5th gear, the retaining collar upgrade, or new snapring, and have 5th gear again. Don't even think about using that old snap ring over again.....

53flattie 11-19-2012 08:27 PM

I ordered a new snap ring and collar last week. Unfortunately, I didn't know that the gear was shot until I finished the disassembly tonight. Looks like I'll be placing another order tomorrow.

Thanks for the information.

And for anyone else thinking of tackling the job with the trans still in the Jeep - it's really not bad at all.

Opihi59 11-19-2012 09:38 PM

If you can't find the parts you need, PM MeanMax and he'll tell you where to get the gears you need, from one of his sources. I see that your mainshaft 5th gear is chewed up, how about the 5th gear counter shaft that mates with it? It is also possible you could find parts close by in salvage yards, or at a tranny shop with a graveyard out back.

Somehow I thought you were from Clover? I have family in Easley and in Anderson, graduated from HS there quite a few years back, was up in Easley last August. I know my way all around there from many bike tours up into Oconee and beyond from Anderson.

ROTTEN 11-19-2012 09:53 PM

Just curious. Before 5th went did it feel kinda rumbly when it was in that gear. Kinda like vibrations but the faster you went it smoothed out?

53flattie 11-20-2012 03:58 PM

Rotten - it actually didn't do anything but click when I put it in 5th gear. Now I know that it was probably the counter gear spinning against the broken main shaft gear.

53flattie 11-20-2012 04:02 PM

Opihi - I live within a half mile of the new Easley High School, right on Hwy 8. Very small world!
How did you get to Hawaii, from Easley, SC??

The counter gear is fine, surprisingly. Not sure why the main gear would have failed like it did. It's not like there are extreme torque loads on 5th gear...

I was able to source a new gear at my local 4x4 shop (via Omix Ada) for $86. I just wish I wouldn't have ordered that $40 retainer...

Opihi59 11-20-2012 04:25 PM

I'd still go with the retainer, if we're talking about the snap ring replacement collar featured in MeanMax's writeup from the FAQ. You'll be kicking yourself if you don't do it and in a year you're back under there fixing that item. It's a good investment as AX5 is notorious for dropping that snapring. Just think how much you saved doing all this work yourself.

53flattie 11-22-2012 04:29 PM

1 Attachment(s)
Double screwdriver trick worked the first try. Thanks for the tip!

Now for reassembly...

Opihi59 11-22-2012 04:32 PM

It looks like you're on your way to success on this. :thumbsup:

Happy Turkey day, it's early yet here in the Sandwich Isles and we haven't eaten yet. But just think, you have an endless supply of Duke's Mayonnaise, and I have to have it mailed in.......

53flattie 11-22-2012 05:06 PM

One last thing... I've seen one reference to using 80W in the transmission, and another saying 10W30. Can you confirm which is correct?

UltimatE 11-22-2012 05:48 PM

10w30 without a doubt.

The time now is 02:51 PM.

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