89 jeep wrangler

Leo,

You can buy a complete 2.5 very cheap, a lot of people upgrade to the I6 or v8's from the 2.5 and want to sell them. I would probably tear down and go through a used one. You can get a brand new one on eBay for around $1200USD. The trans is the AX5. Always replace the slave when you replace the clutch on the AX5 of that vintage..

HTH

Carl

Keeping firmly in mind Novak are known LIARS, and full-of-shit Pollacks, this seems true:

The Novak Guide to the Aisin-Warner AX5 Transmission

The Jeep AX-4 & AX-5 TransmissionThe Aisin Warner AX5 transmission was a standard shift, five-speed transmission introduced in the 1984 XJ Cherokee Jeep, and found in the 1984 to 2006 Jeep XJ, YJ & TJ models. It is a light-duty transmission found behind the AMC 150 (2.5L) I4 engine. It was also found behind the GM 2.8L 60 degree V6 (early XJ only).

The AX5 is prevalent, but sadly it's strength is minimal, making it a questionable off-road transmission. Failures behind even stock engines are not uncommon. We do not make any conversions components available to retain the AX5 with six or eight cylinder engines.

Note that there is an AX4 transmission in early XJ models, which is essentially the AX5, minus its overdriven fifth gear.

Features The AX5 is a split-case, top shifting, overdrive transmission with the shifter being located in the rear section of the transmission. The AX5 is fully synchronized in all gears. All gears are helically cut.

Identification The AX5 transmission case is 16-1/2" long. It features a cast aluminum case with a cast-iron mid-plate. The case is ribbed and features the shifter in the rear quarter of the assembly. In the vein of newer transmissions, the AX5 uses dowel pins for bellhousing alignment.

The Jeep AX5 has a 21 spline output shaft for connecting to the transfer case input shaft. The AX5 was used with an internal slave/throwout assembly up through the 1994 model year. In 1995, a more conventional slave cylinder and cross-arm were used. The input shaft is a 14 spline and its stickout length is 7-1/2".

The AX5 looks similar to the AX15 and are they are occasionally confused in identification as well as interchange.

Transfer Case Compatibility The Jeep AX5 was factory-married to the Jeep Jeep New Process (aka New Venture) Model 231 transfer case.

Because of the weaknesses of this transmission, we do not make adapter assemblies to join it to other transfer cases.

Engine Compatibility and Adaptability AMC / Mopar Jeep As the AX5 was married to the Jeep engines mentioned above, it is OEM compatible with them.

Individuals, hoping to replace their AX5 occasionally assume the AX15 will replace it directly. The bellhousing patterns and spline counts between these similar appearing transmissions are deceivingly close, but not compatible.

The current, best all-around strategy for replacing the AX5 is to replace it and 2.5L with an engine and transmission whose strengths are better matched for the duties of a Jeep, as discussed below.

GM Because of the transmission's weak service record behind even stock Jeep powerplants, we do not offer any conversion to V6 or V8 power. This is essentially a small car transmission in a truck. The customer's efforts and funds are best spent converting to a stronger transmission during the engine upgrade. This is not a difficult thing at all and these details are discussed in the following articles:

Playing to the gas again?

A good used factory engine would be the way to go, particularly if the AX5 came with it.

I did express doubts about Novak, but he has a point: behind the 4, for girly driving, it's probably OK.

You have the AX5. Don't listen to Ludwig. He is the group idiot. The stock transmission is fine for use with the stock engine, especially since there is hardly anything else that will fit without a lot of trouble. Do replace the clutch, slave cylinder and master cylinder when you have the engine out, and clean the inside of the bell housing real well before assembly.

Do you have a hole in the block from a connecting rod coming loose, or from freeze damage? Sometimes freeze damage can be repaired, if you can find someone expert in brazing cast iron. Otherwise, do you have engine rebuilders with a real good reputation locally? Find a core somewhere, and have the local guys rebuild it for you. Save on shipping, and have someone local you can complain to if it comes to that. Sometimes the recycling yards will install a used engine with a 30-day warranty, but you take your chances going that route.

If you want to upgrade your power train, the Jeep Conversion Manual sold by Advance Adapters is a good educational resource.

Earle

---snippy---

You "express doubts" about people the same way I do, with one minor difference. When I go after someone, they deserve it. I am pretty sure you are not worth my trouble though.

Earle