Jeep Wrangler/YJ 1987-1995 Repair Guide

Transmission

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REMOVAL & INSTALLATION



AX 5 Transmission
1987-89 WITH 2.5L ENGINE

CAUTION
The clutch driven disc contains asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid.

  1. Raise the outer gearshift lever boot and remove the upper part of the console.
  2.  
  3. Remove the lower part of the console.
  4.  
  5. Remove the inner boot.
  6.  
  7. Remove the gearshift lever and stub shaft by pressing down on the stub shaft retainer and rotating the retainer counterclockwise to release it from the lugs in the shift tower. Then, lift the retainer, stub shaft and shift lever up and out of the tower Don't remove the shift lever from the stub shaft.
  8.  
  9. Raise and support the vehicle on jackstands.
  10.  
  11. Drain the transmission and transfer case.
  12.  
  13. Matchmark the rear driveshaft and yoke for installation alignment.
  14.  
  15. Unbolt and remove the rear driveshaft.
  16.  
  17. Position a floor jack under the transmission and take up the weight slightly.
  18.  
  19. Unbolt and remove the rear crossmember.
  20.  
  21. Disconnect the hydraulic line from the clutch slave cylinder. Disconnect the speedometer cable.
  22.  
  23. Disconnect the back-up light switch.
  24.  
  25. Disconnect the transfer case vent hose at the case.
  26.  
  27. Disconnect all linkage and hoses from the transfer case and transmission.
  28.  
  29. Matchmark the front driveshaft and yoke.
  30.  
  31. Remove the front driveshaft.
  32.  
  33. Chain the transmission to the jack.
  34.  
  35. Unbolt the transmission from the engine and lower the jack while pulling back.
  36.  

To install:
  1. Install the transmission to the engine. Torque the transmission-to-transfer case adapter nut to 26 ft. lbs. (35 Nm).
  2.  
  3. Install the front driveshaft. Torque the U-joint flange-to-transfer case nut to 35 ft. lbs. (47 Nm).
  4.  
  5. Connect all linkage and hoses at the transfer case and transmission.
  6.  
  7. Connect the transfer case vent hose at the case.
  8.  
  9. Connect the back-up light switch.
  10.  
  11. Connect the hydraulic line from the clutch slave cylinder.
  12.  
  13. Connect the speedometer cable.
  14.  
  15. Install the rear crossmember. Torque the rear crossmember-to-side sill fasteners to 30 ft. lbs. (41 Nm) and the rear support isolator-to-transmission bolts to 33 ft. lbs. (45 Nm).
  16.  
  17. Install the rear driveshaft. Torque the U-joint flange-to-transfer case nut to 35 ft. lbs. (47 Nm).
  18.  
  19. Fill the transmission and transfer case.
  20.  
  21. Lower the vehicle.
  22.  
  23. Install the gearshift lever and stub shaft by pressing down on the stub shaft retainer and rotating the retainer clockwise.
  24.  
  25. Install the inner boot.
  26.  
  27. Install the lower part of the console.
  28.  
  29. Raise the outer gearshift lever boot and install the upper part of the console.
  30.  

BA 10/5 Transmission
1987-89 WITH 4.2L ENGINE

CAUTION
The clutch driven disc contains asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid.

  1. Remove the shift lever knob.
  2.  
  3. Remove the shift lever outer boots and the transmission tower dust boot.
  4.  
  5. Remove the shift lever stub shaft retaining plate (snapring on some models) and remove the shift lever and stub shaft as an assembly.
  6.  
  7. Raise and support the vehicle on jackstands.
  8.  
  9. Drain the transmission and transfer case.
  10.  
  11. Matchmark the rear driveshaft and yoke for installation alignment.
  12.  
  13. Unbolt and remove the rear driveshaft.
  14.  
  15. Position a floor jack under the transmission and take up the weight slightly.
  16.  
  17. Unbolt and remove the rear crossmember.
  18.  
  19. Disconnect the hydraulic line from the clutch slave cylinder. Disconnect the speedometer cable.
  20.  
  21. Disconnect the back-up light switch.
  22.  
  23. Disconnect the transfer case vent hose at the case.
  24.  
  25. Disconnect all linkage and hoses from the transfer case and transmission.
  26.  
  27. Matchmark the front driveshaft and yoke.
  28.  
  29. Remove the front driveshaft.
  30.  
  31. Chain the transmission to the jack.
  32.  
  33. Unbolt the transmission from the engine and lower the jack while pulling back.
  34.  

To install:
  1. Slide the transmission and transfer case assembly into place, engaging the clutch assembly. Torque the transmission-to-transfer case adapter nut to 26 ft. lbs. (35 Nm) and the transmission case-to-engine fastener to 28 ft. lbs. (38 Nm).
  2.  
  3. Install the front driveshaft. Torque the U-joint strap bolts to 15 ft. lbs. (20 Nm).
  4.  
  5. Connect all linkage and hoses at the transfer case and transmission.
  6.  
  7. Connect the transfer case vent hose at the case.
  8.  
  9. Connect the back-up light switch.
  10.  
  11. Connect the hydraulic line to the clutch slave cylinder.
  12.  
  13. Connect the speedometer cable.
  14.  
  15. Install the rear crossmember. Torque the rear crossmember-to-side sill bolts to 30 ft. lbs. (41 Nm) and the rear support isolator-to-transmission bolts to 33 ft. lbs. (45 Nm).
  16.  
  17. Position a floor jack under the transmission and take up the weight slightly.
  18.  
  19. Install the rear driveshaft. Torque the U-joint strap bolts to 15 ft. lbs. (20 Nm).
  20.  
  21. Matchmark the rear driveshaft and yoke for installation alignment.
  22.  
  23. Drain the transmission and transfer case.
  24.  
  25. Raise and support the vehicle on jackstands.
  26.  
  27. Install the shift lever stub shaft retaining plate (snapring on some models) and install the shift lever and stub shaft as an assembly.
  28.  
  29. Install the shift lever outer boots and the transmission tower dust boot.
  30.  
  31. Install the shift lever knob.
  32.  

AX 4/5 and AX 15 Transmissions
1990-95 MODELS

See Figures 1 and 2



Click image to see an enlarged view

Fig. Fig. 1: Lower the transmission no more than 3 in. (76mm) to gain access to the shift lever base-AX 4/5/15 transmission



Click image to see an enlarged view

Fig. Fig. 2: Shift lever removal/installation-AX 4/5/15 transmission

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the skid plate.
  6.  
  7. Drain the transmission and transfer case.
  8.  
  9. Matchmark the front and rear driveshaft and yoke for installation alignment.
  10.  
  11. Unbolt and remove the driveshafts.
  12.  
  13. Disconnect the transfer case shift linkage from the shift lever or range lever.
  14.  
  15. Disconnect the electrical connectors and vent hose from the transmission and differential.
  16.  
  17. Position a jack under the transmission and take up the weight slightly.
  18.  
  19. Unbolt and remove the rear crossmember.
  20.  
  21. Remove the transfer case from the transmission.
  22.  
  23. Lower the transmission enough to provide access to the shift lever.
  24.  
  25. Reach up and around the transmission case and unseat the shift lever dust boot from the transmission shift tower. Reposition the boot to access the lever retainer.
  26.  
  27. Press the shift lever retainer downward and turn it clockwise to release it.
  28.  
  29. Lift the lever and retainer out of the shift tower.
  30.  

It is not necessary to remove the shift lever from the floor pan boot. Leave the lever in place for installation.

  1. If equipped, remove the engine timing sensor.
  2.  
  3. If equipped, disconnect the speedometer cable from the transmission.
  4.  
  5. Disconnect the slave cylinder from the transmission and position it aside.
  6.  
  7. Secure the transmission to the jack.
  8.  
  9. Unbolt the transmission from the engine and lower the jack while pulling back.
  10.  

To install:
  1. Lubricate the pilot bearing and transmission input splines with high temperature grease.
  2.  
  3. Align the transmission input shaft and clutch disc splines and install the transmission. Torque the bolts to 45 ft. lbs. (61 Nm).
  4.  
  5. Reach up around the transmission and insert the shift lever in the shift tower. Press the lever retainer downward and turn it clockwise to lock it in place. Install the dust lever on the dust boot.
  6.  
  7. Install the transfer case and torque the bolts to 26 ft. lbs. (35 Nm).
  8.  
  9. Install the crossmember. Torque the bolts to 26-33 ft. lbs. (37-45 Nm).
  10.  
  11. Install the slave cylinder to the transmission housing.
  12.  
  13. If equipped, install the engine timing sensor.
  14.  
  15. If equipped, connect the speedometer cable.
  16.  
  17. Connect the electrical connectors and vent hose to the transmission and transfer case.
  18.  
  19. Connect the transfer case shift rod to the lever.
  20.  
  21. Install the driveshafts using new strap bolts. Torque the strap bolt nuts to 14 ft. lbs. (19 Nm) and the flange-to-transfer case bolts to 35 ft. lbs. (47 Nm).
  22.  
  23. Fill the transmission and transfer case.
  24.  
  25. Lower the vehicle.
  26.  
  27. Connect the negative battery cable.
  28.  

 
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