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Unread 06-26-2013, 07:31 PM   #1
darren2569
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2002 TJ Wrangler 
 
Join Date: Aug 2008
Location: Akron, Ohio
Posts: 145
AX-15 rebuild issues

So, I just rebuild the AX15 for my wifes TJ. I got it all back together but it seems to be stuck in gear. The shifter is in the neutral position but it is definitely in gear. With some effort I got th e shifter into 5th at which point I cant turn either shaft. Move the shifter back to neutral and I can turn it but its in gear.

I know I put all the detent balls and plugs back in but I noticed looking at the FSM it looks like the 1-2 and 3-4 plugs are different sizes but theres no mention of them being different. I also dont remember them looking any different but then I didnt compare them either.

Anyone know if the plugs are different or do I have another issue? It did shift into each gear just fine before i put the case back together but i was also just moving the shift forks by hand.

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Unread 06-26-2013, 09:36 PM   #2
JeepnBlake
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2004 TJ Wrangler 
 
Join Date: Jan 2008
Location: Lincoln Nebraska
Posts: 3,082
The detent balls are all the same, that's not your issue.

The issue you may be having is the synchros there are 3 different types, 2 are smaller and the other 3 are all about the same size. The problem is that 2 of the larger ones are the same, but one is different (5th gear) it goes on the outside of the main case. If you get it mixed up with the others it will cause your transmission to lock into a gear and act similarly to what you're describing.

You might also have the shift forks out of place, or you might have one of the shift rings turned around, can't remember off the top of my head if they're symmetrical front to back or if they're directional.
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Unread 06-27-2013, 04:59 AM   #3
darren2569
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Location: Akron, Ohio
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I was very careful to match the old and new syncro rings to make sure I got the right ones in the right places. The one shift ring I know is the right way round but the other I wasnt sure but it didnt look like it mattered. Looks like I'm tearing it apart again. At least I know what to look at. Thanks
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Unread 06-27-2013, 06:02 AM   #4
doublins
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1998 TJ Wrangler 
 
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Did you put the dowel that guides the shift mechanism in backwards? The one that slides in from the rear and is retained by the hex plug?

When I rebuilt my AX-15 I remember having this issue at first, and I had installed that dowel backwards on reassembly. I flipped it and all was well.
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Unread 06-30-2013, 09:35 PM   #5
darren2569
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Location: Akron, Ohio
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Well, Seems i didnt seat the one bearing all the way on the shaft which was causing it to bind up when it was all back together

Explains the extra clip I found on the bench. Now its all back together it shifts great
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