T-5 Problem - JeepForum.com
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post #1 of 3 Old 02-08-2002, 11:40 PM Thread Starter
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Join Date: Dec 2001
Location: Russellville, KY
Posts: 7
Post T-5 Problem

I was test-driving my ’86 CJ7 during timing adjustments after installing a Howell FI kit.
I was in first gear starting to accelerate from a stop and heard a loud “pop” and the jeep would not go. The engine was running and you could hear noise coming from the transmission and t-case area. Not a loud noise just a small and fast clicking/rubbing sound.
With the engine running and in first gear the drive shaft is not turning.
After turning the shafts by hand in several different arrangements it appears that 1st and 2nd gear does not connect. I dropped the transmission out and started disassembly. I have not removed any gears yet, however, looking in from the top of the tranny with the top cover removed I cannot see any damaged parts.
Does anyone have any advice?

86 CJ7 w/ a 258.
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post #2 of 3 Old 02-09-2002, 03:07 PM
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Location: Mount Joy, Pa
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Did you check the clutch? I had one that the rivets sheared between the hub and the friction area. Does it attempt to move in gears 3-5? If no gears work, then you probably have an input problem, ie clutch or shaft. Was there any "sparklies" in the fluid when you drained it? That is usually a give away to internal damage. Good luck, Steve.

One Way Up Racing
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post #3 of 3 Old 02-09-2002, 07:42 PM Thread Starter
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Join Date: Dec 2001
Location: Russellville, KY
Posts: 7

Steve, Yeah I checked the clutch. I put a new clutch and pressure plate in it in December and first suspected it for this failure. However it checked O.K.

I found the problem. I went ahead and started disassembling the main shaft assembly.
By turning the input shaft and holding the output shaft from turning in 1st and 2nd, but couldn’t hold the output shaft from turning in 3rd, 4th and 5th I figured I had striped something in the 1st and 2nd gear synchronizer assembly, however, I could not see any damage. After fully disassembling the main shaft it was obvious the external splines on the main shaft and the internal splines on the 1st and 2nd gear synchronizer hub were stripped. Oh well, time to let go of a few more frog skins.

Thanks for your suggestions.

86 CJ7 w/ a 258.
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