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lonerider6 05-22-2008 06:44 PM

Shifting Problem
I am sure that this is a common problem and someone knows the answer. This is my first jeep, a 1995 YJ, 138k miles, 2.5l 5speed. While stopped and motor running it is almost impossible to shift into any gear, while moving and shifting between gears no problem. In my many years of shadetree mechanic experience I diagnosed the problem as a bad clutch master and or slave cylinder. I replaced both of them, finally got them bled down. I have about 1 inch freeplay at the top of the clutch pedal and the pedal "feels" firm. I hear the clutch fork squeaking in the bellhousing as I press the pedal down. Problem is that I still have the same problem, shifts OK while moving, almost impossible while stopped. Any help would be appreciated before I take the tranny, transfer case and bellhousing off for a new clutch. Thanks, Al

jpdocdave 05-22-2008 07:23 PM

if it isn't the clutch, synchros are a common problem in that trans. but not likely in all gears at the same time.

sounds like clutch to me

Coyote_94YJ 05-22-2008 07:33 PM

Have you checked the tranny fluid?

lonerider6 05-23-2008 06:47 AM

I have not but will do so today. No sign of any leaks but with 138k it could probably use replacement. Any suggestions on type of lube. I use synthetic in my 95 Dodge 5spd turbo diesel and thought I might drain down the trans and refill with that. However that sometimes brings on seal leaks as I found when I refilled the rear of the Dodge with synthetic. Thanks for the replies. I kind of thought that the clutch could be a problem with that mileage. I did get over 150k out of my Dodge clutch and it was still in good shape when replaced. However I was the only one driving the Dodge and have driven manuals for many many years. We shall see how it works out. Al

jpdocdave 05-23-2008 07:22 AM

rear seal leaks w/ fluid---i gotta bring this up. i see all the time, and used to do this myself. you are filling your rear end, and jam as much fluid in as possible and plug it. then you get axle seal leaks. i used to think more fluid the better, but no. make sure you let it come back out till its at the bottom of the fill

not sayin you overfilled or anything, but many do, and i used to. sorry, had to bring that up

lifted jeeps w/ modified pinion angles a little different though

jgwalt 05-25-2008 09:41 PM

i had a similar problem with my 94. external slave cyl correct? i pulled the transmission to replace the clutch, which looked o.k., but there is a little clip on mine that holds the clutch fork to the transmission on the opposite side than the slave cyl. it was broken on one side, and i believe that may have caused my whole problem. lol if you end up pulling the tranny be sure and pre-spray the 6 grade 8 bolts on the belly pan, because i stripped the heads off 3, just with a breaker bar and my foot. talk about a headache....oh and you dont have to take the bellhousing or t-case off...just pull the trans together with the tcase.

lonerider6 06-01-2008 03:51 PM

So I spent my birthday pulling the transmission and transfer case out. I found that all of the pieces of the clutch assembly were worn, not disintegrated or broken, just worn. So I replaced the pressure plate, disc, release bearing, and pilot bearing. The smartest thing I believe I did however was pull the flywheel and have it surfaced. Put everything back together and as long as the jeep was up on the lift, and I was underneath and dirty, I drained and refilled both differentials, the transmission and transfer case with the correct lubes. Buttoned everything back up and the transmission now shifts the way it should. Thanks to all for the responses and suggestions. Al

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