Manual transmission problems on 99 TJ 4-cylinder

[joshwellborn]

Just got a 99 2.5 TJ with 160,000 miles. I'm pretty sure the previous owner was pretty hard on it. Baja BF Goodrich tires, lots of mud, small lift, winch, previous owner is a younger driver.
It's hard to get it into any gear. Reverse and First in particular. When I think I'm in reverse, I often discover I am not when I release the clutch while accelerating. Same thing with First gear--as I release the clutch and attempt to accelerate, I discover it is still in neutral.
Also, it wants to grind going into second, unless I slam it pretty hard into second.
I've never replaced a clutch, (or removed a transmission for that matter), but I'm feeling up to it!
Should I first just try a fluid flush (never done that either). Should I try an additive in the transmission fluid before I rip the thing apart?

 

[P man]

Hi and welcome to the forum.

Definitely start with a fluid check and change making sure to use the correct fluid. Check to make sure the clutch master resevoir is full and the fluid isn't black. The ax5 is a decent transmission under normal use but they can fail under hard use/higher miles. Don't waste money on additives

 

[macleanflood]

I spent a lot of time and money trying to get a localish shop to me to rebuild my AX15 and ended up pulling and reinstalling my transmission 7 times.

If you do a replacement I'd order a AX15...they still make them...from Novak or Advanced Adapters for just under $2k shipped. The AX15 is a direct bolt in.

Transmission, transfer case...drive lines and skid plate are easy to pull. I did it many times on my gravel driveway. Don't be scared.

-Mac

 

[P man]

I spent a lot of time and money trying to get a localish shop to me to rebuild my AX15 and ended up pulling and reinstalling my transmission 7 times.

If you do a replacement I'd order a AX15...they still make them...from Novak or Advanced Adapters for just under $2k shipped. The AX15 is a direct bolt in.

Transmission, transfer case...drive lines and skid plate are easy to pull. I did it many times on my gravel driveway. Don't be scared.

-Mac

He has a 2.5 so not a direct swap but definitely doable

 

[macleanflood]

He has a 2.5 so not a direct swap but definitely doable

Right! The spline count to the transfer case is different...and you could fix that with a SYE since it includes a new shaft...I think. Or get a used 231.

-Mac

 

[P man]

Right! The spline count to the transfer case is different...and you could fix that with a SYE since it includes a new shaft...I think. Or get a used 231.

-Mac

The bellhousing is different as well and an SYE would only change the output correct? The input gear normally isn't changed for an SYE. I am an ax15 fanboi but the ax5 isn't a bad transmission and serves most people well

 

[joshwellborn]

Thanks everyone! I'm assuming I have AX5 transmission... How can I check for sure?

 

[P man]

Thanks everyone! I'm assuming I have AX5 transmission... How can I check for sure?

There is a plate in the middle of the transmission..try to stick a magent to it. Let us know if it sticks or not.

I'm 83 percent sure you have an ax5

 

[Blackjack]

Your symptoms would lead me to blame the clutch more than anything but you will certainly not hurt doing a fluid change either.

 

[kmbarreiros]

To the OP,
I also have never removed a drivetrain but this is how my jeep sits right now:

I was able to do this pretty much myself with basic tools. The only help I got was when I was pulling the actual tranny out, since I was using a regular floor jack a piece of wood and some ratchet straps I got my brother in law to help me guide it out.
The hardest part of the whole ordeal was the starter bolts mine where stripped. But you don't actually need to remove the starter to get the tranny out.
I had to get it out because I replaced the rear main seal, and oil pan seal.
I now need to get a new clutch friction disc, and then make a decision on my AX-5. Mine is not grinding but rather whining, I think it has a bad bearing.

 

[kmbarreiros]

These were the steps I did....understand I have a garage and this is not my daily driver so I knew going into this it is going to sit for a while..I set a goal of getting it back to working order for spring of 23' with the minimalist of cost. I started this in early Oct 22'.
Parked it , remove the front drivers seat, then shifter knob, shifter leather cover, and shifter itself.
Underneath I removed center skid, exhaust, front and rear drive shafts.
Next I removed the transfer case shifter linkage.
I then removed the tranny and transfer case as one piece.
Once out I pulled the transfer case apart from the tranny.
Then clutch pressure plate, clutch friction disc, flywheel, and bell housing shield/cover.

 

[SkylinesSuck]

Your symptoms would lead me to blame the clutch more than anything but you will certainly not hurt doing a fluid change either.

Agreed.

 

[JSpike]

Welcome to forum. Nice looking TJ too !
By your symptoms it sounds like clutch master cylinder or slave to me not the trans. When I get any vehicle used I change all the fluids !
Look at that clutch master cylinder fluid level first.
Good luck.

 

[RussTJ]

I have a '97 2.5 with a 5 speed. A few years back I was having a few problems with the Jeep. It's a third vehicle for us and I'd put off some repairs that I needed to do. I noticed that on top of everything else it was starting to shift into gear with difficulty. I had a bad alternator and I found that after replacing the alternator and battery my shifting problems had disappeared. I can't say if this is part of your issue but I wanted to mention it. I can't mechanically describe how this would effect the shifting but I do know that insufficient power will cause problems.

 

[joshwellborn]

There is a plate in the middle of the transmission..try to stick a magent to it. Let us know if it sticks or not.

I'm 83 percent sure you have an ax5

Is that the right plate? Just above the skid plate. Magnet DOES stick to it.

 

[joshwellborn]

I removed what I believe to be the Fill Plug first. I wanted to see if anything came out—if I understand correctly, the fill plug should not overflow, since the fill plug also serves as the “fill line.”
It overspilled for quite a while. Here is a pic. As you can see, the fluid looks like brown/tan house paint. The second photo is of the fluid coming from the drain plug.

 

[TJ4Jim]

Well it appears there has been water intrusion into your trans as the milky color seems to confirm that. If your contemplating replacing the clutch now would be a good time to pull the trans and give it a flush. Otherwise refill the trans with clean lube then run her a bit and change the fluid again.

 

[joshwellborn]

Well it appears there has been water intrusion into your trans as the milky color seems to confirm that. If your contemplating replacing the clutch now would be a good time to pull the trans and give it a flush. Otherwise refill the trans with clean lube then run her a bit and change the fluid again.

Sounds good!
Do I need to do the transfer case before I flush the trans? I’d do it now, but I don’t have the right size Allen wrench.

 

[TJ4Jim]

Sounds good!
Do I need to do the transfer case before I flush the trans? I’d do it now, but I don’t have the right size Allen wrench.

View attachment 384443

No reason to as they do not share lubricant. Fyi my preferred (and many others) trans fluid for the AX-5 is Redline that is not usually available locally but Amazon carries it. I would use inexpensive stuff for the initial flush.

 

[joshwellborn]

No reason to as they do not share lubricant. Fyi my preferred (and many others) trans fluid for the AX-5 is Redline that is not usually available locally but Amazon carries it. I would use inexpensive stuff for the initial flush.

But do you think water is in the transfer case also? I assume someone drove this Jeep through deep water.