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Old 05-23-2013, 01:33 AM   #1
Join Date: May 2013
Location: Adelaide
Posts: 6
Help needed! hard gear change, error codes and clicking sounds...

G'day lads,

I'm really new into this jeep experience, I just bought a 2004 Wrangler Sahara with 7speed manual trans (yeap, 7 = 6+Reverse) the issues that I have with it:
  1. when I shift from 1st to 2nd gear, with the clutch depressed all the way down, I can hear a really loung grinding noise, like in big old trucks, and it shifts really hard. similar thing but a little better it happens when shifting from 2nd to 3rd... all good when I'm downshifting... any diagnostics? advices on what to check?
  2. a couple of days ago I got 3 error codes: P0133, P0153 and P0688. I've removed the battery overnight, and in the morning no CEL, no error codes...after 2 days, CEL camed back with only 2 codes this time: P0153 and! The O2 sensors - all of them, were replaced with OEM in last december... I will do a electrical cleaning and circuit checking during the weekend, maybe will fix something or at least I'll find out wtf is wrong...any suggestions?
  3. after driving a while - engine @running temp, when I'm sitting nicely at traffic lights, I can hear every minute (yes, the lights around Adelaide are like forever red :-( most of the time) a click sound like a relay does, and then I hear a sound like a fan is starting and then stops in a 5-10 secs...after a minute again... the sound is coming from behind/beneeth passenger side dasboard... anyone else experienced somthing like this? any ideas?
anyway, so far I've managed to replace the wheels with some 20' with new street tires, the front rotors and brake pads, rear drums and shoes...

I plan in the near future to replace the clutch if needed, adjust the steering box (it has a free play of about 1'), also some or all the bushings, and maybe Ujoints... The Jeep is in pristine condition, and i intend to keep it like has only 98000Km with no rust...

any input will be greatly appreciated! Cheers!

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Old 05-23-2013, 10:17 AM   #2
Bigkidneys's Avatar
Join Date: Dec 2012
Location: Perdido Key, FL
Posts: 235
Sounds like a throwout bearing or Pilot bearing with the clutch. I was having similar issues with noises and hard shifting and grinding and not even a month into it my slave cylinder went out so I had to replace it all. I got a LUK clutch kit here stateside for $115 US and a new slave cylinder for $60. When we pulled the tranny the throwout bearing was dry as crap and loud when trying to spin it so that was part of the problem. The pilot bearing was literally disintegrated as well. Truth be told, do yourself a favor and have it all replaced and not just a bearing. The PO of my Jeep just replaced the throwout bearing 15,000 miles ago instead of doing everything like he should have.
No idea about the codes. For question #3, when this happens do you have your air or heat on?

2001 Jeep Wrangler Sahara Edition
4" Zone Suspension Lift Goodyear MTR 35s
Black Rock 909 D Rims
I6 4.0L 5 speed 3.73 gears
And more mods to come
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Old 05-23-2013, 08:52 PM   #3
Join Date: May 2013
Location: Adelaide
Posts: 6
ufff...about the clutch we're on the same page...if some replacement is required, definetly will change question thou...which one is pilot bearing? I know the throw-out, but the pilot doesn't ring any bell

at question 3, the sound can be heard only when I'm on heat and set for legs and windscreen...if I set on any other level, it's gone (I just went out to check after reading your post...)
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