I recently picked up a 88 Cherokee 4.0l 4x4 2 Door with the 5 speed transmission, and yes it is the terrible Peugeot BA 10/5 tranny that i have heard nothing but bad things about after doing some research. When i bought the Cherokee the transmission was not installed and hanging by one bolt, as the owner told me he put a new clutch in but didn't have time or money to put into it anymore, so i bought it. First things first was getting the transmission installed back into the Cherokee, which proved harder than i first thought. After fighting the transmission for a few days, we decided something wasn't lining up right and pulled the tranny off, and found the pressure plate was slightly misaligned. So after using a clutch alignment tool and reinstalling the pressure plate in the right spot, and torquing down all bolts to spec, we put a little grease on the end of the tranny shaft, got it into position, and it slid right into place, mounting up evenly all the way around the bell housing. I had to find some missing bolts for the tranny, as i was missing some from the other owner, and finally got all the right bolts and nuts i needed to finish the install, making sure all were grade 8 bolts. Now, i have the tranny installed and bolted up, shifter is installed, hydraulic line set up and bled for clutch, good pressure on the clutch. So now i know i need to put the cross member support back on for the tranny, and reinstall my drive lines and i should be good to go. But i wanted to start it first to hear the motor fire up and hear how it runs as i had not yet heard the motor, so i hooked up some jumper cables and started it up.

At first i thought i had an engine knock, and check my oil levels oil was a little low. Added oil and some MMO to try and get rid of knock, started it up again today and it still had a bad knocking noise. I followed the noise down to the bell-housing/tranny area of the jeep and heard a bad ticking/knocking sound, not coming from the engine at all like i originally thought but something in the tranny/belllhouse area? Another thing i noticed is that when putting the clutch in the noise goes completely away and there is no knocking sound what so ever. I will post a video showing what i am describing, but i am just curious as to what anyone things could be causing it? I have heard maybe a loose flywheel? I am also wondering if since i don't have the cross member or drive lines on something is maybe slightly misaligned causing a bit of a knock? I know this is a long post its just a lot of information to get out, and i am still somewhat new to this type of stuff so i want to make sure i get all the details in there. Any ideas or suggestions would be greatly appreciated!

 

internal or external slave. im assuming internal and the PO skimped on replaceing that meaning the throw out bearing is bad??

 

its an internal slave and it was a brand new one, i have the old one that came out and saw the new one going in, it looked brand new anyway. It seemed like it was installed correctly too as far as i could tell. I have a video that gets the sound pretty well but im having a hard time being able to post it.

 

Time to take the transmission back out. You may be able to spin the input shaft and see if the knock is in the transmission.

Those Peugeot transmissions are hit and miss. I had one in an 87 Wrangler and didn't have an issue out of it at all.