Hey folks I acquired a 5speed 1996 Cherokee in 4.0 L format 140k miles.
Unless I am incredibly slow in letting the clutch out it bucks back and forth like crazy, same issue when shifting to 2nd gear let out the clutch VERY slow otherwise it bucks like crazy and 3rd is not too bad.
I have a thud in the back whenever I let go of the gas pedal suddenly, when I put mine in 4WD the transfer case is making a loud noise.
I have a 1995 AX15 coming from a salvage yard with 74k miles on it and will prbobably replace all the u joints and rebuild the transfer case.
What should I also replace while i have the bottom front all torn off?
The cooling system is all new, new pump and radiator, and previous owner put in 165 F theromastat for some reason. Temps never get above 180F , would that cause my ATROCIOUS gas mileage ?

 

You problem might be the clutch, not the transmission, regardless I would replace the clutch while the transmission is out.

 

The bucking could be very bad transmission and motor mounts. The thud could have that same cause. Could also be the driveshaft u joints.

I think you are jumping to conclusions by replacing the transmission

 

Side note on the trans, do not use GL-5 gear oil. Use an oil meant for brass synchros like Redline MT90, or synchromesh.

 

Well I am replacing transmission for different reasons. It shifts like a nightmare, had to get in gear grinds occasioanlly and sometimes doesnt want to go into reverse gear.
Ive driven a dodge dakota with ax15 before, and that one was a beatten rust bucket with 260k miles on it and it shifted better and kept its gear.
Honestly it feels like some one ate the synchros and at the shift forks. Most likeley some one used GL5.
If you go to auto zone and ask for a jeep cherokee manual transmission gear oil they will give you the GL-5 stuff.

 

Ugh.. hate to see an AX15 abused so badly it needs replacement. The AX15 is one of the most durable and reliable transmissions ever made.

Yeah, do a new clutch - that one's a must, if you want to replace your exhaust front pipe it's very accessible with the tranny out and you'll probably want to disconnect it to make room. Obviously a new tranny mount would be a no-brainer as well. If you want to do an aftermarket transfer case linkage, it would be a good time to do that.

I use the MT90 in my AX15 and LOVE IT. My 95's has at least 315k on it and it shifts and drives like a dream. My Dad's 94 shifted and drove like a dream as well the entire 400k+ miles he drove it. I don't know what he used, but back when it was his DD GL3 was more readily available. He taught myself and my 2 brothers to drive a stick on it and only ever needed 1 clutch replacement.

 

Why aftermarket shift linkage for t case? also how to check if fly wheel is ok?

 

The shift linkage for the transfer case is a nasty kludge of a thing that routinely rusts so badly (provided you live where they salt the roads in the winter or near the ocean) that it can't be adjusted. The rods bend. The bushings wear out and then people have trouble shifting into 4wd. Because it's attached to the body and to the transfer case, it can be thrown out of whack if you do even a mild (<=2") lift.

An aftermarket shift linkage generally connects directly to the transfer case and provides a smooth and reliable shifting into various 4wd modes.

While you've got the transmission out, you have a ton of room to correctly remove the OEM components and install an aftermarket shift linkage.

For the record, I currently do NOT have an aftermarket linkage in mine. If/when my shifting into 4wd isn't crisp and easy, I'll be putting in an aftermarket linkage. If I would have restored my old TJ (I was considering it but ended up selling it when I got my XJ), I definitely would have installed an aftermarket linkage.

 

The flywheel is likely to be fine. Unless it's scored by a clutch that was severely worn or there are broken or chipped teeth, it's usually just in need of a light polishing up with an emery cloth.

 

There is no reverse synchro in an AX15. Speaking from experience, the wrong fluid will shift like that too. I suspect you have a clutch and possibly a pilot bearing issue, as both can cause diffi. Rebuilding the AX15 isn't too bad, but you'll want a gear puller with very long arms or a bearing separater and a taller press.

 

Sounds like a clutch problem for sure.
If you do put a clutch in, do yourself a favor and just buy a new flywheel. Do not resurface it like you do on most cars.
The factory TSM tells you the flywheel has a slight concave surface. Like pathenry said you can sometimes polish it up a bit with emeory cloth. The TSM also states that is the right way to fix minor problems.

If your buying your fluids from the McParts stores, you can find Pennzoil Syncromesh fluid easier than the Redline, but the redline is really good stuff.
DO NOT LISTEN TO SOME STORE IDIOT ON WHAT FLUID TO USE!

 

I would never tear a vehicle down to the flywheel and not replace it. That's just asking for a clutch break in to go badly.

 

Eggzactly!

 

Interesting, I've never heard that recommendation before. My Dad had one clutch over 400k on his 94 (probably 200-250k when it was done) and it always drove great. I wasn't there when he retired it due to the rust and I'm assuming it was towed away, but it very easily could have been driven away with how well it ran.

I put a Sachs clutch kit in my 95 over a year ago, did NOT replace the flywheel, and it's driving great. I'd assume that after 10k or so miles that would be considered "broken in", right?

Is this just luck? Has anyone had an issue personally? Just curious really.

 

It really does depend on the condition of the flywheel. And it can depend alot on how the vehicle is driven before and after a clutch replacement.

Personally I have never changed a clutch out where the flywheel was still in good shape. They have all looked like someone had no idea how to drive a standard so they pulled out in 2nd gear and slipped the clutch every shift so the car woulsnt buck but luckily somehow got 40k miles out of it.

For me it is one of those "while I'm in there" things that I will always replace if I am replacing the clutch.