I thought I would share some pictures and info on a recent issue I had with my AX-15. I'm starting to become an expert on this silly gearbox; lol.

A little over 3 years ago, I rebuilt the entire thing in hopes of fixing this annoying popping out of third issue. Back then, the truck had ~150k on it, so I felt, while I am here, I'll just do a full rebuild and hoped the parts would encompass the problem - it's got to be a syncro; right?? After replacing every bearing, syncro and seal, not to mention the addition of a Hurst shifter, I got it all back together... I discussed the head banging that was to follow HERE and then revisited again HERE

What was almost comical, looking back of course, is that in the first picture I posted in the second thread; the issue was staring me right in the face. Notice the heat scorching on the 3/4 shift fork; duh! Anyways, that problem was identified, I replaced the fork and all was good again. So how is that relevant here in this thread? Well, the damn issue came back. Why? The best I can tell is because the Hurst shift boot failed and while during a deep water crossing, I filled the trans with a little over a gallon of water. Then unknowingly proceeded to drive on it for a few weeks after that wheeling trip. So at this point, the damage was done. What I hadn't realized was that the disintegrating of that boot was the only protection I had from water getting into the trans. The only good news on this was that I had wanted (using "wanted" here loosely) to reseal the trans case halves because I had rushed the sealant last time and so it was leaking just enough to coat everything with trans fluid over time.

On with the pictures...

With the trans back out, I was prepared this time. sucks though, was a lot cleaner the last time I put it back


Cases off and 3/4 fork removed


I knew it!



Notice thought, no damage at all to the hub collar. One "specialist" I spoke to on the repeated issue told me I probably had some damage to that push surface. He was convinced that I had some sort of embedded aluminum pieces or something from the fork. Notta. Luckily those hub teeth area a lot more resilient than you might think. they can take a good deal of grinding before damaging anything. So if you have a problem, don't fret those grinds so much.



Fixed



So why this thread? I don't know, maybe the information will be helpful to someone in the future. Maybe it'll support a trend for the next time this happens. I'm not really sure....

For now though, I'm going on the record to say the AX-15 seems to have lubrication issues in this area of the transmission. This was the reason for the last breakdown and possibly has been for others in the community. Either way, it's only a $35 part, just takes you 8 hrs to install it...

 

I just did mine not long ago, and am not happy with even the stock seal on top

 

hmm interesting.

 

A rebuild or a fork change? the stock seal for the shifter?