YJ Wrangler Expedition project

[wjeeper]

All in all it worked out quite nicely except for losing fifth gear in the AX5 gearbox on the way home.

Same thing happened to me one day on the way to work. There is one snap ring on the main shaft (or counter shaft I cant remember) that breaks and the the gear slips back on the main shaft. It was a relatively cheap fix (so long as bits of that snap ring just settled down to the bottom of the transmission)

Wanna donate your old drivetrain to me?:elkgrin:

 

[96discoXD]

We'll see what happened. I'm going to do one of two things right now. I'm either going to just rebuild the AX5, checking prices now, or move forward with the V8 swap. If I rebuild the AX5 I'll find out in rather short order how bad the damage was, but I caught it relatively quickly and it still runs through 4th without any problem. I've only driven it about 15 miles that way and won't drive it more until I know the extent of the damage. I'll probably drain the fluid soon to check for chunks of the teeth/gears.
I'd sell you my old drivetrain if you want it...

 

[reece146]

You could upgrade the transmission to an AX15. That will live behind the V8 when you get around to it.

 

[96discoXD]

I thought about that, but I already have a rebuilt 700R4 and NP231C that will bolt right to a V8 sbc without requireing any adapters which allow me to avoid needing a $500 adapter from AA or Novak.

 

[wjeeper]

We'll see what happened. I'm going to do one of two things right now. I'm either going to just rebuild the AX5, checking prices now, or move forward with the V8 swap. If I rebuild the AX5 I'll find out in rather short order how bad the damage was, but I caught it relatively quickly and it still runs through 4th without any problem. I've only driven it about 15 miles that way and won't drive it more until I know the extent of the damage. I'll probably drain the fluid soon to check for chunks of the teeth/gears.
I'd sell you my old drivetrain if you want it...

Sounds exactly what happened to my AX5! This was a few years ago but the local dealership and paid $500-600 for it. However next time I know its an easy fix as long as you dont find lots of metal in the oil. Its seriously as easy as taking off the t-case, unbolting the rear case half and replace the $2 snap ring. Then go fishing with a magnet of try to flush the broken snap ring out of the drain with lots of oil.......or the next to free option is if the fifth gear and the gear on the countershaft are trashed just slip off 5th gear, throw it away and the transmission is a 4 speed

(stole this off of Jeepfourm BTW)

What you have is a VERY common AX-5 problem.
The snap ring that holds the 5th gear in place has fallen off.

The one that's suppose to be here...

Your snapring probably looks like this laying in the bottom of your tranny case...

The allows the 5th gear to slide back like this....

It's just a matter of removing the rear half of the AX-5 case, sliding the gear back into position and installing a new snapring. This can be done with the tranny in the Jeep.

There is also a modified snapring assembly that can be purchased that is suppose to fix it for good and not come off again.
It looks like this....

$22 up graded snap ring (dont care for the design much, I would rather chance a new snap-ring failing in the future than this "update") http://www.allstategear.com/AX5%205th%20GEAR%20SNAP%20RING%20RETAINER.htm

 

[96discoXD]

I have seen a collar assembly that can be put on the shaft to prevent the gear from moving if the snapring breaks again. I checked with the guy my dad uses for all his transmission work and he said a full rebuild will run $800 with them removing and re-installing the transmission, but if the main gear is chewed up and needs replacing it's going to jump to $1200. I'm not going to bother, I'll sell the AX5 as a core and move forward with the V8 conversion. In the end I'll have a lot more power and a vehicle that's more enjoyable to drive.

 

[mike94yj]

I had to rebuild my AX-15. It would not go into gear. It started being hard to shift and eventually it would not come out of gear. My syncros were wore out. they are bronze and do wear. The gear lube today contains less additives that can cause them to wear very fast.

 

[96discoXD]

I had to rebuild my AX-15. It would not go into gear. It started being hard to shift and eventually it would not come out of gear. My syncros were wore out. they are bronze and do wear. The gear lube today contains less additives that can cause them to wear very fast.

At least when you rebuild an AX15 you are reasonably assured that it will last a long time. I simply don't see the payoff in rebuilding an AX5 that was really inadequate when it was new anyway. I would look at doing an AX15 swap if I were going to keep the 4 cylinder engine, but I already have a rebuilt 700R4 and NP231C setup that will bolt up to a chevy small block without adapters, so I'm going to move in that direction. IIRC the AX5 actually just uses a 30 weight engine oil, not a specific gear lube.

 

[mike94yj]

I am pretty sure the the 30 weight oil has too high a sulfer content. I would check the specs before putting it in your tranny. Their are some good pruducts out their that would be much better.

 

[96discoXD]

I am pretty sure the the 30 weight oil has too high a sulfer content. I would check the specs before putting it in your tranny. Their are some good pruducts out their that would be much better.

I just remember someone pretty knowlegeable mentioning it. I have no plans to do anything with it anyway since I'll be pulling the entire drivetrain either in the next couple weeks or in the spring depending on how motivated I feel.:coffeedrink:

 

[mike94yj]

have you thought about an automatic?

 

[96discoXD]

I'm going to swap in a 700R4 automatic with the V8 swap.

 

[farrell]

I guess I'll keep my eyes open for a wrecked YJ with AC in the local boneyards, but they don't show up often and get picked clean to the bone very quickly when they do.
Since I'm home this morning I thought I would post some quick progress pics. I've modified a 40mm grenade ammo can to serve as a center console which will be lockable, and houses my CB to keep it secure and out of sight. I've also added a smaller 7.62 ammo can underhood on a modified jack mount to carry small spares and a small tool kit. I'll get some better pictures once I have it out of the garage.
Excuse the filthy garage, my son broke his arm and had surgery a few days ago so the jeep and the garage have been on the back burner.

what did you use to bolt down the ammo boxs on jack holder?

 

[96discoXD]

what did you use to bolt down the ammo boxs on jack holder?

If I recall they were just 5/16 or 3/8" stainless steel bolts with nylon locknuts that I had on hand. I did have to use spacers to make sure that the lid would clear the lip on the fender when opening the case.

 

[96discoXD]

Update: "Reality sets in"

After doing some real thinking about the direction I was taking my YJ in, I realized that I was going to end up with a very capable off road vehicle, but not a very good adventure/overland oriented vehicle which is what I wanted.

As such I just made a deposit on a really nice '04 WJ Grand Cherokee Laredo today. It has just 46K on the odometer and with the 4.0 liter engine it should last a long long time to come.

I'm looking at lift/wheel/tire options right now. My intent is to use this as a daily driver that will be capable of hauling lots of gear for hunting, camping and the occasional overland adventure.

I've decided to sell the Wrangler and a bunch of parts I have accumulated in anticipation of the V8 swap to pay for a good portion of the upgrades I will end up doing on the WJ.

I'll close this thread out with some pics of the new mistress when I bring her home, hopefully before Christmas.:coffeedrink: