AX5 rebuild question

[mikep554]

Yes, as silly as it seems, I am going to rebuild the AX5 trans in my '86 MJ in hopes that my 2.8 will get me along for a while longer before I have to drop a 3.4 into it. Although I've already got the trans out and the casings off, I've run into a problem.

 

I have a factory manual for a later year cherokee that has very detailed teardown/assembly instructions for the trans. However, the instructions are for the '87+ AX5, that has a 5th gear shift fork held on with a bolt, and a snap ring holding on the 5th gear. My trans has a rolled pin holding on the 5th gear fork instead of the bolt, and has a large nut with a punched collar holding on the actual gear instead of the snap ring.

 

My question is, if anyone else has torn down their older AX5, how did you get the rolled pin out and the nut off? I tried pounding on the pin with a small screwdriver and hammer, but only broke my screwdriver handle. Has anyone used some sort of press or something like a gear puller to press against the pin? And for the nut, how do you hold the shaft in place so you can turn the nut? And did you drive something under the punched collar to raise up the punched spots, or did you chisel them off or something?

 

Help!

 

Mike

'86 MJ with a gaping hole between the engine and driveshafts

[jeepthing07]

You have to find a punch that’s just a little smaller than the hole the roll pin is in. If you use a screwdriver and the end fits inside the roll pin the force of beating on it will just want to flare the roll-pin out not drive it through.

[ekulrenlig]

You could try asking one of these guys.

http://www.jeeps-offroad.com/yj-technic ... -help.html

[BIGMASS]

There are special punches for roll pins. They have a small ball on the end to keep them centred over the pin. Like jeepthing07 said, most anything else will cause the pin to expand giving it a better hold

[mikep554]

Thanks for your tips. The like to the discussion on the other board was especially helpful. I'm well on my way now!

[carnuck]

Here's a thought: Look for a Dakota with the 2.5L and get yourself an AX-15 upgrade!

 

 

PS: If you are near British Columbia, my son has an AX-5 from a '94 YJ for sale for $300.

[mikep554]

Thanks for the offer, but I've already got mine halfway torn down and have already bought the rebuild kit, so I think I'll keep going down the rebuild route.

 

By the way, those roll pins come out pretty easy with the properly sized punch.