Jeep Wrangler Forum - View Single Post

ryobi · 09-17-2007, 12:16 PM

Ok,

When I bought my YJ (1994, 2.5 liter, 5 spd man.) it had 154,00 miles on it and the clutch has never been changed. The master and slave cylinder has been replaced before. the gear oil level in the tranny was replaced since I became the owner 1500 miles ago.

Putting the vehicle into gear was very difficult. It took considerable force to make the shifter enter 1st gear. It was the same for 2nd gear. It was a little easier to put it into reverse but there was usually some grinding noises (high pitched). Putting it into 3rd, 4th, or 5th was no problem. This is all while I was sitting still, completely stopped with the engine running.

So, I got into the habit of putting it into 1st gear while the engine was stopped (no problem doing that) then starting the vehicle and then driving off.

Shifting while driving is no problem. As long as I am down shifting and still rolling a little bit the tranny slips right into gear. Now, if I completely stop and then try put it into 1st gear it again becomes extremely difficult.

I checked with the previous owners and they said that it had been like that for so long that they got into the habit of putting it into 3rd and then quickly shifting into 1st. This works MOST of the time.

Then my stepdad noticed something. He noticed that if I started the engine while in gear and clutch pedal depressed the vehicle bagan to roll. I had experienced this before but attributed it to the fact that I was on unlevel ground. So, Iwent and found a parking lot and I puttered around at about 3 MPH in 1st gear with the clutch pedal pushed down.

So, I went out and got a new clutch,pressure plate, throwout bearing, and pilot bearing. Since I am dropping the transmission to change the clutch out I need to know; Do I need to go ahead and have the transmission rebuilt? Money is, of course, an issue. Does this indicate I need to have the transmission completely rebuilt or do I just need synchronizers or something else? Is this something I can do myself? The diagrams don't look TOO difficult. I can see where possessing a jig or something to hold everything aligned while putting the case back together might be needed. Has anyone done this before?

I would like to bulletproof this process as much as possible. I am having considerable trouble getting the tranny out. So, far I have removed the transfer case and unbolted the transmission completely. The transmission shows no signs of leaving willingly, although I have removed all eight of the bolts that attach it to the engine. I know that I have to pull the tranny backwards somewhat to get it to drop out, but how much? Since the exhaust is in the way I am removing the tail pipe completely to give myself some room to work.

Plus, what is this rear crossmember bar? The manual states that after dropping the skid plate you jack the tranny up slightly and remove the rear crossmember bar/brace to drop transfer case. Well, when I dropped the skid plate the transfer case and tranny tried to follow it down because nothing was holding them up BUT the skid plate. Is that normal?

While I've got this all of this undone I have found a hole in my exhaust system and the it is, of course, welded. I am planning on replacing this with new pipes as cheaply as possble I am thinking a generic cat. converter with a cherry bomb muffler. Any suggestions.

Thank You all in advance for your assistance.

09-17-2007, 12:16 PM	#1
ryobi Newb Join Date: Aug 2007 Posts: 12	Clutch? Transmission? Some advice needed Ok, When I bought my YJ (1994, 2.5 liter, 5 spd man.) it had 154,00 miles on it and the clutch has never been changed. The master and slave cylinder has been replaced before. the gear oil level in the tranny was replaced since I became the owner 1500 miles ago. Putting the vehicle into gear was very difficult. It took considerable force to make the shifter enter 1st gear. It was the same for 2nd gear. It was a little easier to put it into reverse but there was usually some grinding noises (high pitched). Putting it into 3rd, 4th, or 5th was no problem. This is all while I was sitting still, completely stopped with the engine running. So, I got into the habit of putting it into 1st gear while the engine was stopped (no problem doing that) then starting the vehicle and then driving off. Shifting while driving is no problem. As long as I am down shifting and still rolling a little bit the tranny slips right into gear. Now, if I completely stop and then try put it into 1st gear it again becomes extremely difficult. I checked with the previous owners and they said that it had been like that for so long that they got into the habit of putting it into 3rd and then quickly shifting into 1st. This works MOST of the time. Then my stepdad noticed something. He noticed that if I started the engine while in gear and clutch pedal depressed the vehicle bagan to roll. I had experienced this before but attributed it to the fact that I was on unlevel ground. So, Iwent and found a parking lot and I puttered around at about 3 MPH in 1st gear with the clutch pedal pushed down. So, I went out and got a new clutch,pressure plate, throwout bearing, and pilot bearing. Since I am dropping the transmission to change the clutch out I need to know; Do I need to go ahead and have the transmission rebuilt? Money is, of course, an issue. Does this indicate I need to have the transmission completely rebuilt or do I just need synchronizers or something else? Is this something I can do myself? The diagrams don't look TOO difficult. I can see where possessing a jig or something to hold everything aligned while putting the case back together might be needed. Has anyone done this before? I would like to bulletproof this process as much as possible. I am having considerable trouble getting the tranny out. So, far I have removed the transfer case and unbolted the transmission completely. The transmission shows no signs of leaving willingly, although I have removed all eight of the bolts that attach it to the engine. I know that I have to pull the tranny backwards somewhat to get it to drop out, but how much? Since the exhaust is in the way I am removing the tail pipe completely to give myself some room to work. Plus, what is this rear crossmember bar? The manual states that after dropping the skid plate you jack the tranny up slightly and remove the rear crossmember bar/brace to drop transfer case. Well, when I dropped the skid plate the transfer case and tranny tried to follow it down because nothing was holding them up BUT the skid plate. Is that normal? While I've got this all of this undone I have found a hole in my exhaust system and the it is, of course, welded. I am planning on replacing this with new pipes as cheaply as possble I am thinking a generic cat. converter with a cherry bomb muffler. Any suggestions. Thank You all in advance for your assistance.