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Unread 06-23-2006, 08:56 PM   #1
lah2420
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1995 YJ Wrangler 
 
Join Date: Mar 2006
Location: , Arkansas
Posts: 853
It's Alive!!! The tranny works!!!

After 9 weeks of frustration, I finally have a running Jeep again. It may only run once before something breaks, but it's running. Swapping in an AX15 was fairly easy. Finding out why the AX15 kept locking into 5th gear wasn't easy. Shift rails don't have to be bent very much to throw everything out of tolerance. I guess a good thing is that I know the inner workings of a manual transmission very well now. I also know how long it takes to order and wait on parts deliveries.

Biggest lesson learned----just because you don't believe something is the problem is no reason not to check it anyway.

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Unread 06-23-2006, 10:03 PM   #2
dbikers
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Oh yeah? What was the tallied total (parts only)? Am curious as i fear that one day i too will have to do the same thing in my '89.....
I've heard numbers all ove the place (although they typically are in the $1800~$2000 ballpark...
thanks in advance.

john
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STUPID HURTS.......OUCH!@#$
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Unread 06-24-2006, 01:29 AM   #3
jipjip
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Quote:
Originally Posted by dbikers
Oh yeah? What was the tallied total (parts only)? Am curious as i fear that one day i too will have to do the same thing in my '89.....
I've heard numbers all ove the place (although they typically are in the $1800~$2000 ballpark...
thanks in advance.

john

i hope that's installed!!!! an ax15 can be found at a j/y fairly cheap....if your spending that kind of money, might as well go w/ a stronger unit (NV4550)
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95 yj sahara green w/ spice hard and soft top, bikini top,full steel doors, and 2 piece bestop soft doors,tnt customs front tube fenders w/ 6" flare,warn gas tank skid, skidrow oil pan skid,4.0HO,rear 31 spline 8.8 w/ disc brakes,4.10's and lsd,front HP d30 w/ 4.10's and aussie front locker,ax15,np231j w/ jb conversions ss sye, tom woods custom cv d/s,RE 4.5xd,35" toyo open country m/t's, 1" daystar body lift, warn 9.5ti
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Unread 06-24-2006, 06:30 AM   #4
dbikers
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Well, that's just it...when reading some posts regarding the BA10 and the conversion the posts read "be ready to spend $2000", so that was why the question. I was hoping that the parts would be less than half of that, i'll do the rest myself ...so back to my question....how much just for parts??

Thanks
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Unread 06-24-2006, 07:38 AM   #5
lah2420
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Join Date: Mar 2006
Location: , Arkansas
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Transmission $150.
NP231 $100.
External Slave and master $120
New seals and shift fork pads for tcase $90
Seals, syncros, and bearings for transmission $350. This would have been cheaper if I had just bought a rebuild kit instead of replacing parts as I found them bad.
5th counter gear $120. Do NOT remove this gear with a 2 jaw puller the way the book shows. It breaks teeth on the gear.
New 5th gear syncro, keys, and springs because the new gear is the post '92 version $35.
New 5th gear shift sleeve $40. Part of my trial and error.
New 5th gear shift rail $30.
Cheap transmission jack from Harbor Freight $60. WELL worth the money since it cost $40 a day to rent one. Easier on the back too.

I could have save about $200 in parts if I had believed the shift rail was slightly bent when my little pea brain told me to check it and I refused.

I also could have saved about $100 if I had bought a total rebuild kit instead of trying to do it piece by piece.

But that's just the way I seem to do things. Those costs are all approximate because it would make me mad at myself to pull the receipts and see what all I wasted again. Overall, if I were you, I would watch for a cheap used tranny and tcase, rebuild them, and install them yourself. This was the first one I had ever seen the inside of. I'm not afraid of a manual transmission any more.
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Unread 06-24-2006, 01:39 PM   #6
jipjip
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but if your just doing a swap from the ba10 to the ax15, then you won't have to rebuild it unless you know there's a problem. to just do the swap, all you need is the tranny and t-case. all the rest bolts right up.
oh and a different d/s too.
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95 yj sahara green w/ spice hard and soft top, bikini top,full steel doors, and 2 piece bestop soft doors,tnt customs front tube fenders w/ 6" flare,warn gas tank skid, skidrow oil pan skid,4.0HO,rear 31 spline 8.8 w/ disc brakes,4.10's and lsd,front HP d30 w/ 4.10's and aussie front locker,ax15,np231j w/ jb conversions ss sye, tom woods custom cv d/s,RE 4.5xd,35" toyo open country m/t's, 1" daystar body lift, warn 9.5ti
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Unread 06-24-2006, 07:19 PM   #7
Chuck2543
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I actually just finished a rebuild on my AX5. Nice little project, transmissions are. Parts actually took longer than the labor. Those transmission rebuild kits are great, paid about $140 for mine, and got all the synchros, bearings, and seals. Total cost of project including clutch and some new tools ~ $400. Once you crack a transmission open, and get it back together successfully, you're not as afraid of that little box anymore.
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[CENTER][SIZE="1"]1990 Jeep Wrangler YJ
2.5L "four-banger"
4" suspension lift
33" BFG A/T
Reman NP231
Custom Fab Front and rear bumpers.[/SIZE][/CENTER]
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Unread 06-24-2006, 07:30 PM   #8
lah2420
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1995 YJ Wrangler 
 
Join Date: Mar 2006
Location: , Arkansas
Posts: 853
Quote:
Originally Posted by Chuck2543
I actually just finished a rebuild on my AX5. Nice little project, transmissions are. Parts actually took longer than the labor. Those transmission rebuild kits are great, paid about $140 for mine, and got all the synchros, bearings, and seals. Total cost of project including clutch and some new tools ~ $400. Once you crack a transmission open, and get it back together successfully, you're not as afraid of that little box anymore.
Mine would have been cheaper but for 2 things. First, if the counter 5th gear teeth hadn't gotten broken by using a 2 jaw puller like the manual said---the gear on the end of the countershaft has bolt holes to use a bolt style puller---I could have saved $120. Then, if I had checked the straightness of the shift rail before buying a shift sleeve and more syncros I could have saved another hundred. Also, I bought syncros and seals before cracking the case open and finding worn bearings. a kit would have been smarter. Like you said, after that there's nothing to be afraid of in that little box any more.

And jipjp, if you meant drive shaft by the D/S, the original fits fine. the BA and the AX15 are exactly the same length.
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Unread 06-24-2006, 08:09 PM   #9
Chuck2543
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Posts: 160
Quote:
Originally Posted by lah2420
Mine would have been cheaper but for 2 things. First, if the counter 5th gear teeth hadn't gotten broken by using a 2 jaw puller like the manual said---the gear on the end of the countershaft has bolt holes to use a bolt style puller---I could have saved $120. Then, if I had checked the straightness of the shift rail before buying a shift sleeve and more syncros I could have saved another hundred. Also, I bought syncros and seals before cracking the case open and finding worn bearings. a kit would have been smarter. Like you said, after that there's nothing to be afraid of in that little box any more.

And jipjp, if you meant drive shaft by the D/S, the original fits fine. the BA and the AX15 are exactly the same length.

I had actually made 2 trips to autozone trying to find a puller that would fit right on 5th gear. I finally broke down and bought a 7 ton puller from sears. Came off real easy, with no damage. The trick is to make sure the pulling arms put the pressure on the inside of the gear, not the teeth. I was lucky and caught that before i put too much pressure in it.
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[CENTER][SIZE="1"]1990 Jeep Wrangler YJ
2.5L "four-banger"
4" suspension lift
33" BFG A/T
Reman NP231
Custom Fab Front and rear bumpers.[/SIZE][/CENTER]
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