Possible to Repair Synchros?

Thanks Earle. I might get the manual. The Haynes sure doesn't go into enough detail for me to dare to start taking gears out... I have even found as much detail in the 4X4 Jeep catalouge I get quarterly...lol. Thanks.

I kinda doubt you are feeling chain slip in 4x4. The only times I have heard of that happening was seconds before a big bang happened when the t-case exploded. I guess it is possible though....

I would be more inclined to think linkage adjustment. I also would be checking the tranny and engine mounts for slop, that can be one cause of linkage out of adjustment.

Mike

I had to change the chains on both my YJ and XJ within about a few months of each other and it really isnt that tough. I did them both from underneath so I could leave the case in.

John > >

Hey John, thanks. That is what my brother said he used to be able to do on the older jeeps. (cj's) I am waiting for a little warmer weather, to give her a try....I don't use her much in winter, just sits in my garage (unheated...lol) I have got to get some manuals like Will said. Sure would help on the tranny & Transfer case. I may just look around for a used tranny, after checking the mounts & linkage. Someone also mentioned the little vacumn unit for the 4WD doesn't always work right on the yj's.(think there is one on the side of the tranny?) I know I had trouble once with the vacumn unit on the front axel....I think my Dakota has a similar set up. Don't have to lock in to shift to 4wd?

The AX5 is classified as a "light duty" transmission, and in my opinion you would be taking your chances with a used one, unless you took it apart and gave it a complete inspection. The weak links appear to be the fifth gear, and the synchros. Every once in a while someone posts here that they managed to shatter fifth gear, or the shaft that it sits on, trying to pass someone else, this in a four cylinder Jeep! Before replacing or rebuilding the transmission, I would make absolutely sure that it doesn't have any water in it, fill it to capacity with the correct fluid, and test drive it one more time.

I like to replace the "small parts kit", whatever is in it, and seals, when taking apart a transmission or transfer case. This gives you some peace of mind, which may be illusory, but I don't mind that. If you rebuild the transfer case in place, you are not going to replace the front seal. This would bother me. There is a vacuum switch on top of the transfer case too, that sometimes gives problems. There is a cable kit to eliminate the vacuum deal, that you might like. This gives you the curious option of low range two wheel drive.

Earle

You must have more flexible hands and arms than I do - it took me long enough to split the case on the bench that I didn't regret dropping the tc (not the tranny, just the tc). Pop the linkage loose, 6 mount bolts and 2 drive shafts and it's out. I would be worried about buggering the case trying to split it in place.

He says that it zips shifting up. I don't think double clutching will help with that.

Earle Hort> Double clutching is good, much better than tearing transmissions apart in