1998 Jeep TJ AX15 issues

[ELT]

Hello,

I am having issues with my 1998 TJ's AX15 gearbox.

I was driving and when I went into fifth gear it didn't feel quite right, as if it wasn't fully engaged. When I downshifted to fourth I was unable to then go back into fifth gear, or any gear for that matter - whilst still in motion I managed to get into neutral and pull over.

I have dropped the gearbox and disassembled (pictures attached) and have been a able to now get into all gears apart from fifth gear. I understand there's a few common replacement parts such as the forks, synchros etc. however what I did find was that the reverse shift head that links the reverse and fifth shift rods (not sure what it's called) had some play in it (worn hole for the locking ball maybe?) which might potentially be impacting the ability to fully engage and disengage the fifth gear - not sure if this also explains being unable to shift into any gear when the issue first happened

It would be greatly appreciated to get some advice on this, this is the first time I've seen the inside of a gearbox but I'm going to give it a go.

 

[macleanflood]

Be careful of replacement shift forks. I had a shop rebuild mine. It went in and out five or six times.

On the first lap it wouldn't shift until first. There was a metal spur on the replacement fork that made contact with the case. Tech didn't see it.

When they took it apart I watched and pointed it out. We ground off the defect and it fixed that issue.

There were many more... including them giving me a broken case that hemorrhaged fluid.

I ended up purchasing one from Novak.

-Mac

 

[ELT]

Be careful of replacement shift forks. I had a shop rebuild mine. It went in and out five or six times.

On the first lap it wouldn't shift until first. There was a metal spur on the replacement fork that made contact with the case. Tech didn't see it.

When they took it apart I watched and pointed it out. We ground off the defect and it fixed that issue.

There were many more... including them giving me a broken case that hemorrhaged fluid.

I ended up purchasing one from Novak.

-Mac

Be careful of replacement shift forks. I had a shop rebuild mine. It went in and out five or six times.

On the first lap it wouldn't shift until first. There was a metal spur on the replacement fork that made contact with the case. Tech didn't see it.

When they took it apart I watched and pointed it out. We ground off the defect and it fixed that issue.

There were many more... including them giving me a broken case that hemorrhaged fluid.

I ended up purchasing one from Novak.

-Mac

Hi Mac,

Thank you for your reply and insight!

I managed to find the issue, a major crack on the fifth gear itself! This meant the synchroniser sleeve was unable to move back and forward.




I have purchased all of the major parts for fifth gear including the fork, so will keep what you said in mind during reassembly.

Many thanks,

Luke