I have a question for you regarding the AX-5 2nd gear and hub. There is no snap ring on the AX-5 hub like there is on the AX-15. But I pressed on 2nd gear last night and could not get the hub to budge off the splines. Is there something that I'm missing?
I wanted to say Thanks!
I followed your directions, and have everything back together except for putting the cases on. Not taking the shifting arms out saves time! I read these steps 6 times then was able to do it all from memory, I only printed off the pictures of the parts breakdown so I could make sure I had all parts in the right order.
First I just wanted to say let you know how much this thread helped with my rebuild. Secondly I would like to add some points as I just completed my rebuild and found some easier/different ways to do things.
-When lowering the transmission while still attached to the engine, you may lower the transmission down alot further than 3". I had mine down about 8" which makes access to the top two torx bolts much easier.
-Once the torx bolts are removed, my recommendation is to just reinstall regular bolts in the top two locations on the bell housing. This makes for an easier removal in the future.
-The most helpfull thing that I found out during the process of this rebuild was that once the bearings are removed from the shafts using a press, they DO NOT need to be pressed back on. The easiest way to reinstall any of the bearings or gears that you have to press off is to simply heat them with a torch. Heat the inner ring of the bearing, making sure not to heat to much of the outside directly, as many of the bearings have not metal pieces. When the bearing is good and hot simply put on some gloves and slide the bearing in place. You want to let mother nature work for you.
Hope this helps someone, as I just finished my tranny rebuild this weekend.
Hey there, a few months back i bought a 95 yj and was driving along one day in second gear when i heard a loud clunk and from that moment on the shifter was stuck in neutral position, wouldnt even grind when i tryed to put it into gear.
Luckily i had a 93 yj sitting in the backyard with same motor and trans. It took me two days to do the swap and once i had her in place, the thing ran beautifully. Now(three months later), me and my buddy decided we should take the old one apart and see what went wrong.
I am very excited to see what you have posted here, and i will be documenting mine as well.
Do you have any ideas to what may have gone wrong inside this thing?
Max, thanks for this thread. Mine is looking at a rebuild in the near future and this will help greatly. 1st and 2nd do fine shifting, but I grind when shifting to 3rd and 4th and on the rare cases 5th unless I hold in on the clutch for afew secs. looks like i still need to get a couple tools. I liked how you told the sizes of the wrenches and such. thanks again
91 YJ "Tonka" 4.0/ax15, stock/stock axles,
99 WJ 4.0 work in progress
also, havent really used any lube other than petro jelly on the rails and balls/pins. the only oil i used was pen synchromesh on the needle bearings. could this be why its not shifting? it shifts just fine with the case off though..
After I zipped mine back up after doing the rebuild I was having the same problem when I was trying to test shift it on the bench...or at least I thought I was having a problem. I thought the same thing as you--maybe a detent ball in the wrong place or something. I was about to open it all up again, when I decided to think on it for a while. After a couple of hours my brain clicked. I was trying to move the shift rails incorrectly. There was nothing wrong with the transmission. I was sticking a socket extension in where the shifter goes and trying to simulate the motion that I normally use when shifting with the shifter. Don't know if I can explain it in words, but I was trying to tilt the socket extension like a lever but I needed to push/slide it straight forward or backward (no bending my wrist). Then it worked--because that's the way it is supposed to work Maybe you are smarter than I was, but that was my problem. Also it takes considerable force to shift it when using something short (like a socket extension).