Geonovast

Even the newer AX-5s don't have 23 spline transfer cases. You can grab an AX-5 from any 2.5 equipped XJ, MJ, YJ, or TJ. YJ and TJ ones may clock the T-case up a bit, but that's not really an issue. Your best bet is to grab an entire 2.5/4wd/5 speed XJ as a donor. This will give you literally everything you need except for a rear driveshaft, and your best option for that is to have yours cut down. Average for that is $60-$110, which you'll probably spend nearly that much on the correct one anyway. Finding a stock driveshaft for what you need will not be easy. Front axle will go directly on. If you pick up a 3.55 geared front to match your current rear, you're set. However, if you get a complete donor XJ (2.5/5 speed should have 4.10 axles), the rear will need the XJ perches cut off and MJ ones welded on. You will be much happier with 4.10s, as 5th with 3.55 axles isn't very useful.

:needpics:

I'm sorry, but personal money exchanges should not include cards.

For the most part pretty much everything swaps withing the year generations. Front axles are interchangeable, including the 2wd beam axles. 2wd used the same suspension, which makes 4wd swaps very easy. Engines and Transmissions are the same. Rear suspension is completely different. Rear axles are the same, except that the spring perches are in different spots. If you have questions about the interchangeability of anything specific, don't hesitate to ask.

I hate the world today.

That's just a case. All that's in the back half is 5th gear. 1-4 and reverse are in front of the midplate. All he needs to do is remove the shift arm, the (eight I think) midplate bolts, and fenagle it off. There aren't even clips on the bearings like there are on the front half. To OP: I have a YJ AX-15 out in the shed that I can pop the rear section off and take pics tomorrow if you want. I need to take it apart anyway to make sure it's not scrap.

With complete disassemble and rebuild of the transmissions. Would be easier to redrill the rear flange of the transmission if the improvement in ground clearance really bothered you. Uh, no. That's only involved when switching from a 2wd rear housing to a 4wd housing. The ONLY difference between the XJ/MJ ones and the YJ/TJ ones are where the holes are drilled for the T-case. He'll need to take the shift arm out, and the midplate bolts, then just switch them.

Where are you located?

Most likely cause of electrical problems in a manual trans is: that the clutch master is leaking down onto the fusebox, which eats away everything. You have a Pukey BA 10/5. If you don't mind finding a new transmission, this is your best bet. Go get yourself an external slave (should be able to be found 93+) AX-15.

AFAIK, the only springs that push the pedal back up are the springs on the pressure plate.

Yes it can.

If you find one in the Camdenton / Osage Beach, MO area, I probably wouldn't mind taking a look for ya.

I have to ask. WHY?

Could always put up a thread for, say, a week, and anyone who considers themselves active could make one post in it, and see how many replies you get.

I believe there's a way to change the numbers on the Renix cluster, but I'm not sure how to do it. You can, however, move your entire speedometer into the new cluster. This usually isn't done, since most people want the tripometer, but your old speedo already has that.

I may be able to get you a head soon.

Go get yourself a left handed drill bit and an easy out before you start. I have only pulled one crossmember off without losing at least 2 bolts, and if you only have 2 per side, that's a problem.

Yes, but obviously you'll need to run a new clutch line for the external slave. Everything else will go right in. Only other issue you may run into is the T-case clocking, Wronglers clock it up a few more degrees, hitting the floor is an issue with AX-15s, not sure about the AX-5s Also, are you keeping the 3.55 gears? 5th might seem a bit doggy if you don't go with 4.10s, which are what came with the 5 speeds. You'll need a shorter rear shaft, and obviously a front shaft, but there are no crossmember changes.

How could it possibly stretch past being floored? Even if flooring it stretched the cable, it would only stretch to the point of still being WOT. You would have to push the pedal through the floor, stretch the cable out, then fix the hole in the floor.

No, you cannot just swap the gauges around. The "wiring" is completely different. There are clusters out there with gauges minus tach, with a big gas gauge. They are rare, however. But, pamike just/is going to be taking one of those rarities out of his truck, and putting in a full one. Might want to get ahold of him. viewtopic.php?f=2&t=26063 Just simply put the shift indicator and gas gauge from yours into the new one, and you're good to go.

I don't see how a bad TPS can cause it to randomly go into Neutral, but I'm not a slushbox electrical expert. Your TCU may be going out, something to check. If you have access to a good TCU to swap in, try that. You can also disconnect the TCU, and just shift it manually to see if it randomly kicks out of gear that way. If it does it then, you may have a bad solonoid. Did you check the fluid properly? Autos need to be checked while running and warmed up.

Direct swap. AX-5 is identical to the AX-4, aside from some minor interior differences, such as having a 5th gear. T-case for a Wrongler is clocked up a bit, but shouldn't be much of a problem.

Only the last couple inches with the splines are supposed to be sealed in the diff. Rest of the shaft stays dry.

Out of gear, as in randomly goes into Neutral, or randomly shifts up and down gears? If it's the latter, check your TPS.

$$$