1991 YJ AX-5 clutch/tranny issues? (tires, tuning, mileage, purchase)

[Magnatomicflux]

Folks,

I just picked up a 91 YJ and it seems to be having a chattering issue with the manual AX-5. It shifts thru all the gears just fine, it isn't a problem getting into gear at all.

Now, I bought it like this, because the YJ is structurally sound. Solid frame, solid body, solid little 2.5 4 banger (which, in the next year or so may throw my 4.0 with the AX-15 in). Lift kit, "brand new" BFG 32" A/T tires, nice American Racing wheels....all for 1500 bucks. I hauled the sob 3 1/2 home on a trailer.

The issue arises IN thrid gear. It's chattering, but I can't tell if it is coming from the bellhousing or the tranny itself. It also does it in 4th. The sound is like a metallic baseball card in the spokes. I haven't checked the tranny fluid yet, but I'm wondering if low fluid could cause this to happen in select gears, and not all gears?

Same question goes towards a bad component in the clutch assembly. The clutch doesn't start to grab until its about 3/4 up from the floor. My current YJ with the AX-15 grabs about 2 or 3 inches from the floor. So, I'm wondering if it is bend fingers on the pressure plate causing the chattering. If so, wouldn't it affect ALL gears? Or, is it not allowing certain gears to completely mesh because the fingers in the pressure plate are weak?

OR...am I most likely looking at new gears/syncros?


I appreciate the help.

[ukrkoz]

Personally, I think you looking at 2 things:
1. CHANGE gear oil to a quality one and see what happens. Quality one as in - Amsoil. Can't beat it.
2. Personally, I think, your clutch plate and pressure plate are worn out, requiring longer release throw to lower pressure plate enough to purchase on the clutch plate. Unless it's a brand new both, of course, but then you may want to look into flushing clutch line/slave.
I used to fine tune gear shifts with shifter cables, that are adjustable on any clutch car we ever owned. Look into this. But if it chatters metal on metal.....

[Magnatomicflux]

Originally Posted by ukrkoz

Personally, I think you looking at 2 things:
1. CHANGE gear oil to a quality one and see what happens. Quality one as in - Amsoil. Can't beat it.
2. Personally, I think, your clutch plate and pressure plate are worn out, requiring longer release throw to lower pressure plate enough to purchase on the clutch plate. Unless it's a brand new both, of course, but then you may want to look into flushing clutch line/slave.
I used to fine tune gear shifts with shifter cables, that are adjustable on any clutch car we ever owned. Look into this. But if it chatters metal on metal.....

Thanks for the response, ukrkoz.

When I change the gear oil, I suppose the story will be told if I start finding large bits of silver and gold in there. I plan on dropping the tranny anyway to save on labour costs if it does need work, so even if that clutch still has some life to it, I'll be changing her out. I will look into tuning the cables, thanks.

I don't think she was ever wheeled very hard. I just think she had a bad driver who rode the clutch. That on top of a little 4 bangger pushing 32" tires around didn't do the drive train any favours.

Here she is, though....just for ****s n' giggles lol

[ukrkoz]

Looks awright to me, though I am not into this particular type of cars.
I think, at this mileage, indeed, nuggets will be in gear box.
You have great task of replacing fluid in t-case, gear box, and rear diff. Oyts, front diff also? Sure has one? Just seriously, forget the money, do Amsoil gear oil. And Amsoil for all other fluids.
If clutch was never done, it's long term due anyway.
You instantly reminded me of my work on Sidekick. I had a pal, who owned one, and took her to any remote lake in the area possible. He was going through clutch plates every six months or so. Kick is, Sidekicks's gear box with t-case is about half size of the car itself. Sh-ing you not, 2nd time pulled her out myself. Was very lucky, it had a crossmember running underneath the output shaft housing, so I used it to slide that gear box back on it, to clear clutch. Of course, I was young and strong then.
Have fun. It's good project. Manly.

[GarageLogic]

Originally Posted by Magnatomicflux

Folks,

I just picked up a 91 YJ and it seems to be having a chattering issue with the manual AX-5. It shifts thru all the gears just fine, it isn't a problem getting into gear at all.

Now, I bought it like this, because the YJ is structurally sound. Solid frame, solid body, solid little 2.5 4 banger (which, in the next year or so may throw my 4.0 with the AX-15 in). Lift kit, "brand new" BFG 32" A/T tires, nice American Racing wheels....all for 1500 bucks. I hauled the sob 3 1/2 home on a trailer.

The issue arises IN thrid gear. It's chattering, but I can't tell if it is coming from the bellhousing or the tranny itself. It also does it in 4th. The sound is like a metallic baseball card in the spokes. I haven't checked the tranny fluid yet, but I'm wondering if low fluid could cause this to happen in select gears, and not all gears?

Same question goes towards a bad component in the clutch assembly. The clutch doesn't start to grab until its about 3/4 up from the floor. My current YJ with the AX-15 grabs about 2 or 3 inches from the floor. So, I'm wondering if it is bend fingers on the pressure plate causing the chattering. If so, wouldn't it affect ALL gears? Or, is it not allowing certain gears to completely mesh because the fingers in the pressure plate are weak?

OR...am I most likely looking at new gears/syncros?


I appreciate the help.

My first thought is that your clutch plate is worn and the flywheel might need to be turned true.