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Fastolds 11-05-2008 09:49 PM

2.5 manual trans problems
Hello- and thank you for letting me join your community. I have just untaken a little project for a friend of mine. He recently acquired a 94 Wrangler with a 2.5 and a manual trans, 4wd. When he road tested it, there was a weird noise, most noticeably in 3rd gear. Kinda hard to describe, but it would be like a rattling noise. Since he bought it, his wife has had problems shifting it into gear. He was telling me that he would press the clutch down, shift the trans into neutral, and then let off the clutch. When he did that, the engine would stall out, like it was in gear. I haven't looked at it too much, but i'm wondering if there is a problem with the clutch or something inside the trans itself.

Could someone help me get pointed in the right direction?

Thanks a bunch...
Adam Friday

jpdocdave 11-05-2008 10:30 PM

syncros and random gears deciding to move off their shaft are common probs in that trans.

Fastolds 11-05-2008 10:46 PM

Are these transmissions worth rebuilding? Or should i start looking for a decent replacement?

syncros is what we were originally thinking when we road tested it. He got this thing cheap, so he has a little lee-way when it comes to fixing it. It needs a front u joint on the left front wheel, and the wipers don't work... Other than those 3 things, it ain't bad.

Is there a way to figure out if it is actually something inside the trans?


jpdocdave 11-06-2008 08:22 AM

tear it down is the only way to find out. i've heard people with a lot of stories about their rebuilt trans lasting a few months to a year, and others were fine, it depends on who's doing it, but that trans is weak, especially if you get bigger tires.

Fastolds 11-06-2008 05:01 PM

yeah, the truck has 31" tires on it, but i honestly think it wasn't used for much. I got a price on a used/reman one. It's from a junkyard, but they said it was "remanufactured" and comes with a 3 month warranty. It costs $650 after the core return. Any ideas on where i can find one that'll work in this thing?


RobSwan 11-06-2008 05:43 PM

I recently rebuilt my AX-5 in a 90 Wrangler, 4cyl. 4WD. I bought the bearings and synchros off of E-Bay for around $150.00. The one thing I would suggest is buying a Jeep Shop manual, which covers the AX-5 disassembly and re-assembly quite well. Another thing I would suggest is to take pics of the disassembly in different stages for reference later in the assembly process. And pay close attention to the numberous balls, springs, and detent pins located in the shift rods and cast-iron middle assemby. There are several places to get the parts here on the net. It just depends on how much time and effort you want to put into it. Good Luck!!!

Fastolds 11-06-2008 06:45 PM

can you give me an idea where you can get those parts for a rebuild?


Fastolds 11-07-2008 12:39 PM

would an ax5 trans out of a 2000 tj fit into a 94 yj that currently has an ax5 in it? found one locally, but i don't know for sure.


RobSwan 11-08-2008 05:58 AM

I got the synchros and bearing kit off of E-Bay, just type in "AX-5 transmission" in your search bar, and the rebuild kits should come up...The EBay vendor that I bought from was " acerl" , you might try to search by seller. Several 4x4 vendors sell the seperate gears and other small parts if you need them.
As far as the 2000 TJ trans fitting, I know that the later transmissions had a different front bearing retaining plate, but I was told you can use the one off of your old transmission and replace it. Check the bellhousings between your trans. and the newer one you found. I found that the openings for the inlet and bleeder tubes from the clutch slave cylinder (internal) are different from a 90 to a 93 model, but are interchangeable. Hope this helps...and good luck..

Fastolds 11-08-2008 10:41 PM

thanks for all the replys/help. I ripped the ax5 out of the yj tonight and tore it down. the cage on the input shaft bearing was gone, and it caused carnage on several of the gears, including the one right behind that bearing. I think i am going to discuss with the owner of the truck about getting a different one, but i still don't know. I assume the rebuild kits only come with syncros and bearings, so i would still need to get the gears that are chewed up, and hope that there isn't anything that i'm missing visually.

I found an ax5 on ebay through a company called "The Wrangler Barn" in Oregon. They advertise a used one for $500 shipped. The local one I thought i had a lead on is gone, and other local places offer used ones for 750-1000.

Can anyone offer any opinions on the Wrangler barn and where do you usually draw the line with rebuilding these things?


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