1999 TJ manual transmission won't go into gear - JeepForum.com
 
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post #1 of 7 Old 08-20-2017, 11:31 AM Thread Starter
blackhelmet34
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1999 TJ manual transmission won't go into gear

Just bought my first TJ cheap off of a buddy. It needs some work but is just for riding around on the weekends. He told me it has been making some noise in the rear-end for about a month and that CarMax said it probably just needed rear diff serviced. He just put a new clutch in it about 2 weeks ago and said it still needed to be broken in. Those were the only two problems he was aware of.

I noticed the gears grind a few times when shifting but that pretty much stopped when I slowed down my shifts. The rear end made a grinding noise, seemed worse at low speed and when turning (one wheel moving faster than the other). I pulled the rear diff drain plug and it drained a decent amount of milky brown gear oil. Then pulled the diff cover and didn't find any big chunks of metal or anything that looked too bad. I didn't really know what else to look for so I just sprayed the inside with brake cleaner to get all the old gear oil out and then put the cover back on with gasket maker and filled it up with Mobil 1 75w90 gear oil until it ran out the drain plug (1.4 qts). Grinding sound is still present, but I drove it up the road about a mile. When I went to turn around, it was hard to get out of gear, then would not go back into gear for anything. Tried with/without clutch and with/without engine running with no luck. I found a lot of threads on this forum about throwout bearing but all those people can shift without engine running. Also ruled out the shift boot as it won't go into 1/3/5 not just 2/4/R. I don't think this is related to the rear diff service but am not sure. Transmission also has milky brown fluid run out when opening the fill plug. I was planning on running Redline MT-90 but had to special order it in. I obviously don't want to do that if it needs major transmission work now though. Any ideas? Thanks!

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post #2 of 7 Old 08-20-2017, 08:09 PM
mukluk
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The milky brown fluid means the Jeep has been in decently deep water and the fluids weren't changed afterward. That, coupled with the shifting difficulty and noise from the rear end makes me believe corrosion has set in sufficiently that a rebuild of both is likely warranted.

2000 TJ SE
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post #3 of 7 Old 08-22-2017, 08:48 AM Thread Starter
blackhelmet34
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Quote:
Originally Posted by mukluk View Post
The milky brown fluid means the Jeep has been in decently deep water and the fluids weren't changed afterward. That, coupled with the shifting difficulty and noise from the rear end makes me believe corrosion has set in sufficiently that a rebuild of both is likely warranted.
Thanks for the reply - I was afraid that might be the case. If that is the problem, is it normal to not be able to shift the transfer case into neutral also?
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post #4 of 7 Old 08-22-2017, 09:01 AM
JimSmith
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Hope you got that Jeep ridiculously cheap, if your trans, t-case and both diffs need to be rebuilt it's gonna be pricey. When you drained the rear diff was there rust on the carrier and/or spider gears?

I would consider the person that sold you that mess no longer a buddy....

'98 Chili Pepper 2.5, AX5, 33x12.5x15, 5.13, D30 Aussie, Super 35
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post #5 of 7 Old 08-22-2017, 12:20 PM
mukluk
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Quote:
Originally Posted by blackhelmet34 View Post
Thanks for the reply - I was afraid that might be the case. If that is the problem, is it normal to not be able to shift the transfer case into neutral also?
Not normal. With the transmission and axles showing water contamination in their lube, it wouldn't be much of a surprise to find the transfer case also got water in it. Can you at least get the transfer case to shift into 4HI/4LO?

2000 TJ SE
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post #6 of 7 Old 08-22-2017, 01:11 PM Thread Starter
blackhelmet34
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Quote:
Originally Posted by JimSmith View Post
Hope you got that Jeep ridiculously cheap, if your trans, t-case and both diffs need to be rebuilt it's gonna be pricey. When you drained the rear diff was there rust on the carrier and/or spider gears?

I would consider the person that sold you that mess no longer a buddy....
No rust whatsoever. Also didn't seem to be any metal chunks or shavings in the drained fluid. I don't know exactly what i am looking for in there but everything really looked good - no chunks missing from gears or cracks or anything.

After some messing with it I was able to get the t-case to shift fine through 2 high, 4 high, neutral and 4 low.
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post #7 of 7 Old 08-22-2017, 01:13 PM Thread Starter
blackhelmet34
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Quote:
Originally Posted by mukluk View Post
Not normal. With the transmission and axles showing water contamination in their lube, it wouldn't be much of a surprise to find the transfer case also got water in it. Can you at least get the transfer case to shift into 4HI/4LO?
I was finally able to get the transfer case to shift. Seems like it hadn't been in 4x4 much but it is shifting fine now.
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