AX 15 Swap on 95 4.0L 5 spd

[xtensenfamily]

I'm swapping my transmission on my 95 YJ 4.0L 5 spd. My syncros are bad so 3 and 4 grind and I can't downshift. I found a used one that I got for $50, which the guy swears was working fine (no grinding, syncros seemed fine) before he totaled the jeep and is now just parting it out. I figured I might as well try it for $50 plus another $60 for some MT90. If it doesn't work, I'll call it good practice to replace with a rebuilt.

My question is, what is the best manual to guide me through this? Chilton, Hayes, etc.? I'm pretty handy but have never swapped out a transmission. Guidance and suggestions would be much appreciated.

 

[jps4jeep]

either of those should get you through the swap, but if you can turn a wrench, you can swap a manual trans.

here is a quick cliff notes version. Support the drive train with a jack and a piece of wood under the rear-most part of the oil pan.

remove drive shafts

Drop skid plate

remove t-case shifter linkage, speedo wire and vent line

Remove t-case.

Remove trans/t case boot in the vehicle

Remove trans shifter

Disconnect the slave cylinder and vent

remove trans and bell housing. swap bell housing to new trans, repeat in opposite order.


remember t-case and trans need to slide out before dropping them from under the vehicle. you might want a trans jack, if your a fairly strong guy, just use you muscle, either the trans or t-case weigh more than 50 lbs a piece. you might want to drain the fluids prior, but if you can pull everything off fairly level, really not needed, should only leak a little. Oh you might need a clutch allignment tool if you fubar the splines when pulling the trans, most parts stores wil have them, or just cut the input shaft off a just trans and use that.

 

[Ggg]

Personally I would not invest the extra money on MT90 until after you have verified the $50 trans works properly. This is a really good time to r/r the clutch too if it needs it.

 

[xtensenfamily]

either of those should get you through the swap, but if you can turn a wrench, you can swap a manual trans.

here is a quick cliff notes version. Support the drive train with a jack and a piece of wood under the rear-most part of the oil pan.

remove drive shafts

Drop skid plate

remove t-case shifter linkage, speedo wire and vent line

Remove t-case.

Remove trans/t case boot in the vehicle

Remove trans shifter

Disconnect the slave cylinder and vent

remove trans and bell housing. swap bell housing to new trans, repeat in opposite order.


remember t-case and trans need to slide out before dropping them from under the vehicle. you might want a trans jack, if your a fairly strong guy, just use you muscle, either the trans or t-case weigh more than 50 lbs a piece. you might want to drain the fluids prior, but if you can pull everything off fairly level, really not needed, should only leak a little. Oh you might need a clutch allignment tool if you fubar the splines when pulling the trans, most parts stores wil have them, or just cut the input shaft off a just trans and use that.

Great, thanks. I'll probably tackle this tomorrow, so I will be back!

 

[xtensenfamily]

Personally I would not invest the extra money on MT90 until after you have verified the $50 trans works properly. This is a really good time to r/r the clutch too if it needs it.

Good point, thanks.