Jeep Wrangler Forum banner

1 - 18 of 18 Posts

·
Registered
Joined
·
17 Posts
Discussion Starter #1
Hey everyone,
I've been referencing these forums for years and this evening I started a acct due to my latest project on my Jeep.
I would work on my Jeep here and there. For several years, since my Jeep purchase in 2023, I've been wanting to swap my 3" body lift for a 2.5" suspension lift. Living at a place with a 1 vehicle garage, I decided to have a shop do the lift for me, mostly do to limited space and the certainty that I would run into some ceased bolts. After being put off by the shop for several months, I decided to do this install myself, of which went well. With the money I saved by doing this myself, I was able to "do a little more and a little more" building mechanical confidence. My current project is what I consider a "big one" so I thought I would share.
When I installed my lift, I noticed a slight drive train vibration which could have been fixed with a transfer case drop. Why would I decrease clearance when I just made clearance? With this in mind, I decided to drop my transfer case and install the SYE kit, of which was successful (from what I can tell). At this point, like Forrest Gump, I thought "hell, why stop here?". I then dropped my worn out AX5 and ordered the ax5 to ax15 retrofit kit with new transmission from Advanced Adapters. I currently have the proper parts swapped from the ax5 to ax15 to satisfy my 2.5L. I'm currently waiting on a clutch alignment tool and clutch fork retained clip via web order. I thought while I was waiting on these parts to arrive would make a great opportunity to share and document this project. Stay tuned!
 

·
Super Moderator
Joined
·
10,652 Posts
Welcome to the Forum Mr. Peepers,

That's the first time I've seen a boot jack used as a transfer case support.

Good for you. It seems like you're doing the right thing by doing the work yourself.
It's a fun and satisfying experience. Once you learn something, it makes it easier to learn something else. Plus you get to buy more tools.

If you have any questions, it's best to post them in the YJ tech forum here.

Look for a post by Got it at last. In his signature you'll find a link to several service manuals. Those manuals really help. I have my own loaded on my desktop and I can print the pages related to the work I'm doing and carry them out to my shop for easy reference.

Good Luck, L.M.
 
  • Like
Reactions: Gotlift

·
Registered
Joined
·
17 Posts
Discussion Starter #4
Today’s update:
Waiting on some parts to arrive. While inspecting several components in the bell housing, I pulled out the pivot ball stud and inspected it. It was obviously worn in a certain spot, so I ordered another. I also ordered a retaining clip for the clutch fork/pivot stud assembly. Also, after further research I learned to “NEVER TURN A JEEP FLYWHEEL AND REUSE”. After further reading, I decided to play it safe and order an OE Flywheel, new. Looks like I’ll be a week out before I start installing the trans. The goal for Monday is to install the new output shaft into the transfer case.
 

·
Registered
Joined
·
4,218 Posts
Looks like you are taking the right approach to getting things done right.

Now that we are on the subject of getting things right.... Either you are a time traveler or something isn't quite right in your first post. :) You should be able to edit that.
 

·
Super Moderator
Joined
·
10,652 Posts
His other car is a Delorean.

Good Luck, L.M.
 
  • Like
Reactions: daddyjeep

·
Registered
Joined
·
17 Posts
Discussion Starter #8
Installed the new input shaft in the np231 transfer case. This input shaft came with the Advanced Adapters ax5 to ax15 retro fit kit. Also, I should get the pivot ball stud and retained clip to put back in my clutch fork assembly today. The goal of today in to install the new flywheel, bushing clutch and pressure plate. I may possibly attempt to install the transmission today if all other plans go well.
 

Attachments

·
Registered
Joined
·
17 Posts
Discussion Starter #9
I had my first setback today when installing the clutch disk and centerforce high perfromance pressure plate. Neither the pressure plate or flywheel came with any alighment pins. I lined up the pressure plate in the orientation of which the bolts seemed to go. Upon torqing the bolts to 40 ft/lbs (of which I read on the net) the forks seemed to compress quite a bit. Before reaching 40 ft.lbs, one of the bolts snapped off into the new flywheel. I will be taking the flywheel to the machine shop Monday to get the broken bolt out of the new flywheel. I'll also get all new bolts rather than using the original. Also, I will be extra careful when finding the proper orientation next time. Not a good day, time for a beer!
 

·
Registered
Joined
·
17 Posts
Discussion Starter #10
Today wasn't a total bust. I got the ball pivot stud replaces, new throwout bearing installed in the fork and after an hour of gruesome configuration installed the retaining clip on the left side of the fork
 

Attachments

·
Registered
Joined
·
17 Posts
Discussion Starter #11
Today was a good day. I dropped the flywheel off at the shop, played 18 holes of golf, picked up the flywheel and off I went. I got a lot done today, the pictures speak for themselves. 1 more hard day wrenchin and I'll be back on the road.
 

Attachments

·
Registered
Joined
·
17 Posts
Discussion Starter #13
Today's update:

Today's goal was to be out cruising in the jeep minus the front drive shaft (still on order) but, that didn't happen.

Once again, set back by having to order parts online. Although I installed the new transfer case shifter bracket and linkage (provided by the Advanced Adapters ax5 to ax15 kit) I ran into a snag when reinstalling the stock ax5 transmission mount. To put bluntly, the ax5 transmission bracket mounts to the ax5 via 2 bolt holes while the ax15 calls for 4 bolts from the mount to the ax15. After calling Advanced Adapters, they reminded me that the instructions to modify and drill the stock mounts were included with the instructions provided. This appeared to be physically impossible due to the lack of surface area of the stock ax5 transmission mount and needing to drill the 4 holes. After calling Advanced Adapters again, the tech guy just seemed to get frustrated with my questions. I just got to a point where I said "I just want a stock ax15 mount, this modification wont work for me, what part do you recommend?". With no help to him, I found a conversion bracket from the 2 bolt ax5 mount to the ax15 4 bolt mount on the Advanced Adapters website. OK! So, I ordered that, we'll see if that works. When I ordered the conversion bracket, the cheapest shipping option was $28. WTF! I wrote in the notes for the order "Really? $28 for shipping of a 5lb package?". About an hour later, I received a call about this concern and they were able to find another solution. $16 shipping through Fedex. That's better!. So now, I'm sippin a beer and waiting for parts. My new front drive shaft will arrive and be here prior to the transmission mount bracket. Hopefully (fingers crossed) I will be on the road by this time next week.
 

Attachments

·
Registered
Joined
·
17 Posts
Discussion Starter #14
UPDATE:
After another setback of having to order the proper rear yoke to accommodate the rear driveshaft provided by the SYE kit, I took Mr. Peepers on his maiden voyage (since build). It drives and shifts great with no vibrations. However, as part of the kit, I replaced the pilot bearing with a pilot bushing. After driving for approx. 20 minutes, I hear a slight noise from where I believe to be the pilot bushing. If I were to describe it, it would sound like a "cricket noise". Is this normal as the input from the transmission seats into the new bushing? Also, I stripped the pivot bolt from my np231 shifter to shifter bracket. If anyone could give me some insight to this, I'd greatly appreciate it!
 

·
Super Moderator
Joined
·
10,652 Posts
Why is that?

An OE flywheel is slightly concave. If a machine shop turns a flywheel, they will most probably turn it flat. Then the clutch disc won't ride true on the flywheel and will likely be difficult to shift.
I don't know if a machine shop can turn a flywheel concave, even if they knew it was originally that way.

Good Luck, L.M.
 

·
Registered
Joined
·
101 Posts
Things you don’t know until you know I guess. Well, mine is turned and installed so we’ll see how it goes.
 
1 - 18 of 18 Posts
Top