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Discussion Starter · #1 ·
I have a 91 YJ 4.0 all of the driveline is stock with the 5 speed manual. I just got the Jeep last week and I have had a few issues with shifting into 2nd & 4th especially when it's cold out.

For instance, this morning it was about 25 degrees out when I left for work. When ever I try to shift into 2nd the transmission would grind and pop back out to neutral. Shifting into third isn't a problem. Then when I shift into 4th it is similar to 2nd but not as bad. 4th just occasionally pops out to neutral but if I keep my hand on the shifter it stays in gear. Once the Jeep is warm (around 210 degrees) I only have the problem shifting into 2nd. 2nd will just start to grind if I shift slowly but if I shift quickly I can pop it into second with no problem.

Just wondering if anyone has ever encountered anything similar to this...
 

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Mine doesn't pop out but its hard to get into 2nd sometimes when its cold. I was told its just the transmission fluid being cold and once the it and the jeep warm up I don't have a problem.
 

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I had the exact issue with my 89......and it was the slave cylinder/throwout bearing. It was not fully disengaging the clutch when shifting.

Cannot guarantee you have same issue......but symptoms are same.
 

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Discussion Starter · #4 ·
I had the exact issue with my 89......and it was the slave cylinder/throwout bearing. It was not fully disengaging the clutch when shifting.

Cannot guarantee you have same issue......but symptoms are same.
Did you replace the bearing or have someone do it for you? I am just wondering how hard it is to replace.
 

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I have a 91 YJ 4.0 all of the driveline is stock with the 5 speed manual. I just got the Jeep last week and I have had a few issues with shifting into 2nd & 4th especially when it's cold out.

For instance, this morning it was about 25 degrees out when I left for work. When ever I try to shift into 2nd the transmission would grind and pop back out to neutral. Shifting into third isn't a problem. Then when I shift into 4th it is similar to 2nd but not as bad. 4th just occasionally pops out to neutral but if I keep my hand on the shifter it stays in gear. Once the Jeep is warm (around 210 degrees) I only have the problem shifting into 2nd. 2nd will just start to grind if I shift slowly but if I shift quickly I can pop it into second with no problem.

Just wondering if anyone has ever encountered anything similar to this...
thats not a cold issue, sounds like mechanical. I have a hard time getting it into gear when its cold sometimes if I dont let the jeep warm up but nothing like what you're talking about
 

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Do u have a BODY LIFT??..1" is fine but a 2" or 3" is not good for gearshifts! 2nd-4th and reverse can be abit notchy, and can be solved by cutting a small slit in the rubber boot (over ur gear stick!) where its catching the body.,or at worst it could be the synchromesh rings?
 

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Discussion Starter · #7 ·
Do u have a BODY LIFT??..1" is fine but a 2" or 3" is not good for gearshifts! 2nd-4th and reverse can be abit notchy, and can be solved by cutting a small slit in the rubber boot (over ur gear stick!) where its catching the body.,or at worst it could be the synchromesh rings?
Yeah, it has a 4" body lift on it. All three (2, 4, and reverse) seem to get stuck a little. 2nd is still the worst.
 

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you should try replacing your master cylinder and power bleeding the system to remove air and flush old fluid out .
i found this guy that sells them new for 40 dollars ( a 3rd of the factory ) and have used them for a long time.
they get weak after many years and you dont notice that it is not pushing the clutch in far enough to let you make smooth clean shifts.
Try it and you will see what I mean.

Jeep Clutch Master Cylinder 87-90 Wrangler NEW - eBay (item 120629069379 end time Dec-03-10 14:27:42 PST)

give me a call if you have any questions or issue's
 

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4 in body lift? wow... I would check the trans fluid also, seems like tons of people <for some reason> run a heavy gear oil instead of atf fluid and (aside from all around being hard on them in any weather) gear oil is almost a solid at 25 degrees...
 

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I once drove over a very steep burm and high centered my TJ. It forced the skid plate up about 1.5-2 inches. I could barely use second or fourth gears. When I got home, I jacked up the transfer case to remove the skid plate, and drove over the skid plate with a skid steer to flatten it out again. Worked great ever since. I would say it is your floor that is stopping you from using the gears. The stick is hitting the floor since the body lift is on there.
 

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Depends... Im pretty sure your slave is internal. It takes about 4 hours to do assuming you have decent automotive knowledge. Remove the drive shafts, exhaust, starter, unbolt the bell housing and drop the trans.
 

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My 89 has the AX15 and high mileage. I don't have much trouble with 4th, but until the transmission gets warmed up it fights shifting to 2nd with grinding and resisting at the shifter. Pretty sure the synchros are tired, but I found a trick that always works now - shift into second as soon as the Jeep is rolling and the clutch is all the way out. Probably 4-5 mph. Shifts smooth and already rolling fast enough it doesn't lug the motor.
 
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