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Old 10-09-2007, 08:13 PM
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Join Date: Oct 2007
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BuddyG is on a distinguished road
AX-5 Leaking From Weird Spot

I was hoping someone could identify the missing sleeve in the picture below and provide an intellegent name so that I can find a replacement. My AX-5 (1993 YJ 2.5L) is leaking gear oil. I thought it was coming from the input shaft, but when I dropped the transmission, I realized it was coming from one of the holes. The picture shows the front of the transmission with the clutch housing removed. All the other holes have some sort of seal or sleeve in them except for the leaky hole. It only has a post, plug or shaft of some sort. It'll all make sense someday after my first rebuild, perhaps. Hopefully, that's a year or more away.

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Old 10-10-2007, 09:26 AM   #2
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ryobi is on a distinguished road

I just got through wrestling with my 1994 AX5 this last weekend.

No oil should be exiting the tranny from that end. The bell housing/clutch housing is not a "wet" area.

Based on your pictures I wonder if a piece of a gear or something didn't bind inside the housing and crack a hole in it at that location.

I would suggest several options. 1; new tranny housing (expensive) 2; some rtv to plug the hole (RTV doesn't adhere to oily surfaces none-too-well) 3; a bit of JB weld to plug the hole (best possible solution barring any binding issues)

Since the gear oil is splashed around inside the tranny without benefit of any pressurizing device (ie; oil pump) the ability to withstand pressure is not going to be a problem. A good two part epoxy could also work, provided it does not succumb to the acidity of the gear oil.

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Old 10-10-2007, 07:43 PM
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The only real difference between that hole and the others is that little collar in the other two visible holes. There isn't one in the leaking hole. In any case, I opted to cut a small piece of gasket material to cover the hole. The clutch housing keeps the gasket tight against the tranny and more leaks. Seems to be working well. It's only a short-term fix and the benefit of having oil in the tranny makes up for it. Thanks for the input, I feel better about my fix now.
As for JB Weld, that was the first thing I thought of last night when I saw where the leak was coming from. I love that stuff almost as much as my Jeep.
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