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Old 12-13-2011, 05:33 PM   #1
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Need serious help!!! Please understand

Hello all,
This is my first post so i apologize for the lengthy note. I recently inherited a 1992 yj from my father who recently passed on. He and I had a vast fondness of jeeps as i grew up. I really really want to keep it, it runs great but it needs some work. I'm kind of short on cash and this is my daily driver now so i would like to keep it cost effective and do some of the work on my own. Its a 92 yj 4cyl 2.5L 5 speed pretty much stock except for a 2 inch lift.

My first issue is: I have a slight ticking coming from somewhere by the valve cover (i think). (I have a video of the noise that i will post soon). I also don't seem to have 5th gear. Its going into every other gear just fine, When i try to shift into 5th it just free revs. I also have a clutch problem. I'm not sure if its the clutch it self or the slave. eg. I,m at a traffic light and im in first, if i hold down the pedal long enough it will start engaging even with my foot to the floor.
The most major problem im concerned with is i recently noticed a crack on the chassis. Anyone know how this could be fixed?
Please any help would be greatly appreciated

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Old 12-13-2011, 06:00 PM   #2
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check and make sure you dont have a exhaust leak at the maniflod, that can make a ticking sound.but yes it could be a lifter or rocker. as for the cluch, that could be the slave cylinder or the master. if your not leaking fluid it may be hard to tell which one is bad. you can get a new slave and master package already filled with fluid and bled for about 170 from the dealer. and its simple to put on. the last one i got i got off ebay and won it for .99 cents with 5.00 shipping and lasted over 2 years

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Old 12-13-2011, 06:06 PM   #3
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first issue. sticking or worn lifter, maybe injector, flat cam. you may not have a 5th gear, meaning the gear in the tranny is broke. have to take it apart. clutch master cylinder. check for leakage on the firewall. crack frame, replace is the best. weld on some plates will get you by.
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Old 12-13-2011, 06:31 PM   #4
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Old 12-13-2011, 06:34 PM   #5
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Would the slave be an easy DIY install? Also is there any way to diagnose either lifters or injectors?
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Old 12-13-2011, 07:13 PM   #6
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For your clutch problem, it sounds like you're bleeding off pressure somewhere, so something is leaking. A '92 will have an internal slave cylinder, so the only way to actually get to it is to drop the trans. Normally though, if it is leaking, you will have brake fluid dripping from your bellhousing, so you can just check for that. Check the line from the slave to the master for leaks as well, and check the master cylinder at the firewall in the engine bay and inside the cab. If you can't find any external leaks, and you're not loosing any fluid, then the master has an internal leak allowing fluid to leak back into the reservoir and needs to be replaced.
As for your lack of fifth gear, the ax5 transmission has a snap ring that holds fifth gear on the mainshaft that is known to break. Sometimes all that happens is that the gear slides back on the shaft out of engagement with no damage to anything else and sometimes it chews up some stuff when it goes. There is a company that makes a repair kit to replace the snap ring and has a collar that clamps around the shaft behind it as a reinforcement, but I can't think of the name of it offhand. Google ax5 fifth gear repair, and you should be able to find out.
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Old 12-13-2011, 09:01 PM   #7
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Old 12-14-2011, 12:01 AM   #8
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That damn ax5... That shit should have been a recall. lol..

I don't have fifth either. Most of us just deal, so I've noticed.
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Old 12-14-2011, 05:50 PM   #9
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haha yeah it's running just fine on 4. would like to have something there in fifth instead of just free rev lol oh well guess I'm driving a 4 speed.
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Old 12-14-2011, 11:37 PM   #10
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Originally Posted by AceYJ View Post
haha yeah it's running just fine on 4. would like to have something there in fifth instead of just free rev lol oh well guess I'm driving a 4 speed.
I can do about 55 comfortably. Any higher than that and I'm looking for 5th because of RPMs.

Most of my driving is around town so it isn't a big deal. I don't know if I can do a long highway trip (over an hour).
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Old 12-15-2011, 01:24 PM   #11
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Originally Posted by SiLlY

I can do about 55 comfortably. Any higher than that and I'm looking for 5th because of RPMs.

Most of my driving is around town so it isn't a big deal. I don't know if I can do a long highway trip (over an hour).
Well I drive it to work everyday and I have to take the highway for about half hour, I do about 65-70 mph holding about 3 grand on the tach. It feels fine.
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Old 12-15-2011, 01:46 PM   #12
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Where is the crack? i can see it in the picture but where on frame? sounds like the slave cyl. i am really glad i have the ax15 tranny.
on the picture it looks like something was torched off.????
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Old 12-15-2011, 04:25 PM   #13
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The crack can be repaired with some plat steel...
5th gear in the ax5 is known to go out, most of the time its a clip. It can be replaced or a locking collar installed. There is a write on here somewhere that is pretty detailed on how to repair it, it entails removing the tailshaft....don't have to remove the trans.
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Old 12-15-2011, 06:21 PM   #14
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Originally Posted by BPJOOP93
Where is the crack? i can see it in the picture but where on frame? sounds like the slave cyl. i am really glad i have the ax15 tranny.
on the picture it looks like something was torched off.????
Its mid frame right under passanger door
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Old 12-15-2011, 06:37 PM   #15
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The crack can be repaired with some plat steel...
5th gear in the ax5 is known to go out, most of the time its a clip. It can be replaced or a locking collar installed. There is a write on here somewhere that is pretty detailed on how to repair it, it entails removing the tailshaft....don't have to remove the trans.
About the ax-5:

Yeah, it's all over the net. Can't believe it isn't or wasn't a recall. 5th gear is no biggie though. Several reason why I haven't done it.

1. Winter is coming and only other vehicle is a Harley. Can't risk it.
2. If I am going to mess with the drive train.. it'll be to put another trans in it.. or an already fully rebuilt ax-5. (My synchros are bad too)
3. 5th isn't really needed unless I'm driving for hours on the highway. That's just personal opinion though. It can probably do it just fine.

Don't get me wrong.. Would love to have it. It just hasn't hit the priority scale yet.
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Old 12-15-2011, 08:19 PM   #16
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where are you located? if you are close to scranton pa i can help you out with the cracked frame and weld it.
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Old 12-15-2011, 08:46 PM   #17
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where are you located? if you are close to scranton pa i can help you out with the cracked frame and weld it.
That's awesome of you! Kudos!

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