According to whomever "Old Crow" is: "You can fix this for like $25
and a day in the shop on your back. The 5th gear is held on the output
shaft by a snap ring, which has broken and let the gear move out of
position. It can be fixed with the tranny still in the Jeep. It'll
take a snap ring and a couple of seals to do the job. Google search this
group for a post titled "WTF happened to 5th Gear" with me as the
author."
God Bless America, Bill O|||||||O
mailto:-------------------- http://www.----------.com/

jwallacq@hotmail.com wrote:
>
> My 94 Wrangler (4 cyl, 170,000 miles) started having problems with the
> 5-speed manual transmission. First I lost 5th gear, then it started
> seizing or locking up in reverse, and finally it started locking up in
> 1st also.
>
> I have removed it from the vehicle, and separated the transmission from
> the transfer case; and now I am wondering if it makes sense to try to
> fix it myself, or if I should send it out.
>
> My biggest concern with trying to fix it myself is whether I will be
> able to find the parts; are there any retailers out there who sell
> individual components for transmissions??? Also, will I need to have
> access to a hydraulic press to get the bearings, gears, etc. off of
> their shafts?
>
> Does anybody have a ballpark idea of how much it should cost to have it
> rebuilt? And where would be the best place to take it?
>
> One other question: As long as I have the transmission down, I
> probably ought to replace the clutch, also. Are there any special
> "gotchas" that I need to watch out for? Will I have to buy some kind
> of alignment tool to get the new pressure plate centered properly?
>
> Thanx in advance!

 

According to whomever "Old Crow" is: "You can fix this for like $25
and a day in the shop on your back. The 5th gear is held on the output
shaft by a snap ring, which has broken and let the gear move out of
position. It can be fixed with the tranny still in the Jeep. It'll
take a snap ring and a couple of seals to do the job. Google search this
group for a post titled "WTF happened to 5th Gear" with me as the
author."
God Bless America, Bill O|||||||O
mailto:-------------------- http://www.----------.com/

jwallacq@hotmail.com wrote:
>
> My 94 Wrangler (4 cyl, 170,000 miles) started having problems with the
> 5-speed manual transmission. First I lost 5th gear, then it started
> seizing or locking up in reverse, and finally it started locking up in
> 1st also.
>
> I have removed it from the vehicle, and separated the transmission from
> the transfer case; and now I am wondering if it makes sense to try to
> fix it myself, or if I should send it out.
>
> My biggest concern with trying to fix it myself is whether I will be
> able to find the parts; are there any retailers out there who sell
> individual components for transmissions??? Also, will I need to have
> access to a hydraulic press to get the bearings, gears, etc. off of
> their shafts?
>
> Does anybody have a ballpark idea of how much it should cost to have it
> rebuilt? And where would be the best place to take it?
>
> One other question: As long as I have the transmission down, I
> probably ought to replace the clutch, also. Are there any special
> "gotchas" that I need to watch out for? Will I have to buy some kind
> of alignment tool to get the new pressure plate centered properly?
>
> Thanx in advance!

 

According to whomever "Old Crow" is: "You can fix this for like $25
and a day in the shop on your back. The 5th gear is held on the output
shaft by a snap ring, which has broken and let the gear move out of
position. It can be fixed with the tranny still in the Jeep. It'll
take a snap ring and a couple of seals to do the job. Google search this
group for a post titled "WTF happened to 5th Gear" with me as the
author."
God Bless America, Bill O|||||||O
mailto:-------------------- http://www.----------.com/

jwallacq@hotmail.com wrote:
>
> My 94 Wrangler (4 cyl, 170,000 miles) started having problems with the
> 5-speed manual transmission. First I lost 5th gear, then it started
> seizing or locking up in reverse, and finally it started locking up in
> 1st also.
>
> I have removed it from the vehicle, and separated the transmission from
> the transfer case; and now I am wondering if it makes sense to try to
> fix it myself, or if I should send it out.
>
> My biggest concern with trying to fix it myself is whether I will be
> able to find the parts; are there any retailers out there who sell
> individual components for transmissions??? Also, will I need to have
> access to a hydraulic press to get the bearings, gears, etc. off of
> their shafts?
>
> Does anybody have a ballpark idea of how much it should cost to have it
> rebuilt? And where would be the best place to take it?
>
> One other question: As long as I have the transmission down, I
> probably ought to replace the clutch, also. Are there any special
> "gotchas" that I need to watch out for? Will I have to buy some kind
> of alignment tool to get the new pressure plate centered properly?
>
> Thanx in advance!

 

Thanks very much for that advice. It certainly sounds like it's worth
my while to investigate this possibility before I go shelling out $900
for a rebuilt!! Hopefully, I will be able to get to it this weekend,
and then report back on what I discover.

L.W.(Bill) ------ III wrote:
> According to whomever "Old Crow" is: "You can fix this for like $25
> and a day in the shop on your back. The 5th gear is held on the output
> shaft by a snap ring, which has broken and let the gear move out of
> position. It can be fixed with the tranny still in the Jeep. It'll
> take a snap ring and a couple of seals to do the job. Google search this
> group for a post titled "WTF happened to 5th Gear" with me as the
> author."
> God Bless America, Bill O|||||||O
> mailto:-------------------- http://www.----------.com/
>
> jwallacq@hotmail.com wrote:
> >
> > My 94 Wrangler (4 cyl, 170,000 miles) started having problems with the
> > 5-speed manual transmission. First I lost 5th gear, then it started
> > seizing or locking up in reverse, and finally it started locking up in
> > 1st also.
> > >
<<<SNIP>>>

 

Thanks very much for that advice. It certainly sounds like it's worth
my while to investigate this possibility before I go shelling out $900
for a rebuilt!! Hopefully, I will be able to get to it this weekend,
and then report back on what I discover.

L.W.(Bill) ------ III wrote:
> According to whomever "Old Crow" is: "You can fix this for like $25
> and a day in the shop on your back. The 5th gear is held on the output
> shaft by a snap ring, which has broken and let the gear move out of
> position. It can be fixed with the tranny still in the Jeep. It'll
> take a snap ring and a couple of seals to do the job. Google search this
> group for a post titled "WTF happened to 5th Gear" with me as the
> author."
> God Bless America, Bill O|||||||O
> mailto:-------------------- http://www.----------.com/
>
> jwallacq@hotmail.com wrote:
> >
> > My 94 Wrangler (4 cyl, 170,000 miles) started having problems with the
> > 5-speed manual transmission. First I lost 5th gear, then it started
> > seizing or locking up in reverse, and finally it started locking up in
> > 1st also.
> > >
<<<SNIP>>>

 

Thanks very much for that advice. It certainly sounds like it's worth
my while to investigate this possibility before I go shelling out $900
for a rebuilt!! Hopefully, I will be able to get to it this weekend,
and then report back on what I discover.

L.W.(Bill) ------ III wrote:
> According to whomever "Old Crow" is: "You can fix this for like $25
> and a day in the shop on your back. The 5th gear is held on the output
> shaft by a snap ring, which has broken and let the gear move out of
> position. It can be fixed with the tranny still in the Jeep. It'll
> take a snap ring and a couple of seals to do the job. Google search this
> group for a post titled "WTF happened to 5th Gear" with me as the
> author."
> God Bless America, Bill O|||||||O
> mailto:-------------------- http://www.----------.com/
>
> jwallacq@hotmail.com wrote:
> >
> > My 94 Wrangler (4 cyl, 170,000 miles) started having problems with the
> > 5-speed manual transmission. First I lost 5th gear, then it started
> > seizing or locking up in reverse, and finally it started locking up in
> > 1st also.
> > >
<<<SNIP>>>

 

Thanks for the suggestion, Bill, but I seem to have a different
problem. I have now taken the rear part of the transmission housing
off (the part where the 5th gears and the shift column are located.
The snap ring was fine, but 5th gear and its counter-gear are all
chewed up!

By the way, I REALLY need some HELP!! on one thing: When I removed
the rear housing, a steel ball (about 3/8 diameter) fell out of
somewhere, and I haven't a clue as to where it came from. If anybody
has any ideas, I sure would appreciate hearing them!

Anyhow, I removed the 5th gear from its shaft, and the rest of the
transmission seems to be functioning perfectly. I stood there for half
an hour, spinning the input and output shafts in each direction, in all
possible combinations of gearing, and everything up in the front half
of the transmission seems perfectly smooth. But as soon as I put 5th
back on, it started seizing up every few revolutions.

The only other thing that I noticed was that the 5th counter-gear
seemed to be very loose & wiggley on its shaft, but maybe that's a
normal aspect of the synchro-meshing. Does anybody know??

I am really tempted to just re-assemble the transmission without the
5th gear, and just use it as a 4-speed transmission. Is that a crazy
idea??? Does anybody see any problems with it? (I really am not in a
position to spend $1000 right now on a rebuilt exchange, and I urgently
need to get the Jeep running before winter.)

Thanks in advance for any suggestions. john w.

P.S. >> One last question: Is it normal for the front input shaft of
these transmissions to have a fair amount of runout? I'd estimate that
I can wiggle the flywheel end of the input shaft about +/- 1/16 of an
inch in each direction -- maybe even a little more.


L.W.(Bill) ------ III wrote:
> According to whomever "Old Crow" is: "You can fix this for like $25
> and a day in the shop on your back. The 5th gear is held on the output
> shaft by a snap ring, which has broken and let the gear move out of
> position. It can be fixed with the tranny still in the Jeep. It'll
> take a snap ring and a couple of seals to do the job. Google search this
> group for a post titled "WTF happened to 5th Gear" with me as the
> author."
> God Bless America, Bill O|||||||O
> mailto:-------------------- http://www.----------.com/
>
> jwallacq@hotmail.com wrote:
> >
> > My 94 Wrangler (4 cyl, 170,000 miles) started having problems with the
> > 5-speed manual transmission. First I lost 5th gear, then it started
> > seizing or locking up in reverse, and finally it started locking up in
> > 1st also.
> >
> > I have removed it from the vehicle, and separated the transmission from
> > the transfer case; and now I am wondering if it makes sense to try to
> > fix it myself, or if I should send it out.
> >
> > My biggest concern with trying to fix it myself is whether I will be
> > able to find the parts; are there any retailers out there who sell
> > individual components for transmissions??? Also, will I need to have
> > access to a hydraulic press to get the bearings, gears, etc. off of
> > their shafts?
> >
> > Does anybody have a ballpark idea of how much it should cost to have it
> > rebuilt? And where would be the best place to take it?
> >
> > One other question: As long as I have the transmission down, I
> > probably ought to replace the clutch, also. Are there any special
> > "gotchas" that I need to watch out for? Will I have to buy some kind
> > of alignment tool to get the new pressure plate centered properly?
> >
> > Thanx in advance!

 

Thanks for the suggestion, Bill, but I seem to have a different
problem. I have now taken the rear part of the transmission housing
off (the part where the 5th gears and the shift column are located.
The snap ring was fine, but 5th gear and its counter-gear are all
chewed up!

By the way, I REALLY need some HELP!! on one thing: When I removed
the rear housing, a steel ball (about 3/8 diameter) fell out of
somewhere, and I haven't a clue as to where it came from. If anybody
has any ideas, I sure would appreciate hearing them!

Anyhow, I removed the 5th gear from its shaft, and the rest of the
transmission seems to be functioning perfectly. I stood there for half
an hour, spinning the input and output shafts in each direction, in all
possible combinations of gearing, and everything up in the front half
of the transmission seems perfectly smooth. But as soon as I put 5th
back on, it started seizing up every few revolutions.

The only other thing that I noticed was that the 5th counter-gear
seemed to be very loose & wiggley on its shaft, but maybe that's a
normal aspect of the synchro-meshing. Does anybody know??

I am really tempted to just re-assemble the transmission without the
5th gear, and just use it as a 4-speed transmission. Is that a crazy
idea??? Does anybody see any problems with it? (I really am not in a
position to spend $1000 right now on a rebuilt exchange, and I urgently
need to get the Jeep running before winter.)

Thanks in advance for any suggestions. john w.

P.S. >> One last question: Is it normal for the front input shaft of
these transmissions to have a fair amount of runout? I'd estimate that
I can wiggle the flywheel end of the input shaft about +/- 1/16 of an
inch in each direction -- maybe even a little more.


L.W.(Bill) ------ III wrote:
> According to whomever "Old Crow" is: "You can fix this for like $25
> and a day in the shop on your back. The 5th gear is held on the output
> shaft by a snap ring, which has broken and let the gear move out of
> position. It can be fixed with the tranny still in the Jeep. It'll
> take a snap ring and a couple of seals to do the job. Google search this
> group for a post titled "WTF happened to 5th Gear" with me as the
> author."
> God Bless America, Bill O|||||||O
> mailto:-------------------- http://www.----------.com/
>
> jwallacq@hotmail.com wrote:
> >
> > My 94 Wrangler (4 cyl, 170,000 miles) started having problems with the
> > 5-speed manual transmission. First I lost 5th gear, then it started
> > seizing or locking up in reverse, and finally it started locking up in
> > 1st also.
> >
> > I have removed it from the vehicle, and separated the transmission from
> > the transfer case; and now I am wondering if it makes sense to try to
> > fix it myself, or if I should send it out.
> >
> > My biggest concern with trying to fix it myself is whether I will be
> > able to find the parts; are there any retailers out there who sell
> > individual components for transmissions??? Also, will I need to have
> > access to a hydraulic press to get the bearings, gears, etc. off of
> > their shafts?
> >
> > Does anybody have a ballpark idea of how much it should cost to have it
> > rebuilt? And where would be the best place to take it?
> >
> > One other question: As long as I have the transmission down, I
> > probably ought to replace the clutch, also. Are there any special
> > "gotchas" that I need to watch out for? Will I have to buy some kind
> > of alignment tool to get the new pressure plate centered properly?
> >
> > Thanx in advance!

 

Thanks for the suggestion, Bill, but I seem to have a different
problem. I have now taken the rear part of the transmission housing
off (the part where the 5th gears and the shift column are located.
The snap ring was fine, but 5th gear and its counter-gear are all
chewed up!

By the way, I REALLY need some HELP!! on one thing: When I removed
the rear housing, a steel ball (about 3/8 diameter) fell out of
somewhere, and I haven't a clue as to where it came from. If anybody
has any ideas, I sure would appreciate hearing them!

Anyhow, I removed the 5th gear from its shaft, and the rest of the
transmission seems to be functioning perfectly. I stood there for half
an hour, spinning the input and output shafts in each direction, in all
possible combinations of gearing, and everything up in the front half
of the transmission seems perfectly smooth. But as soon as I put 5th
back on, it started seizing up every few revolutions.

The only other thing that I noticed was that the 5th counter-gear
seemed to be very loose & wiggley on its shaft, but maybe that's a
normal aspect of the synchro-meshing. Does anybody know??

I am really tempted to just re-assemble the transmission without the
5th gear, and just use it as a 4-speed transmission. Is that a crazy
idea??? Does anybody see any problems with it? (I really am not in a
position to spend $1000 right now on a rebuilt exchange, and I urgently
need to get the Jeep running before winter.)

Thanks in advance for any suggestions. john w.

P.S. >> One last question: Is it normal for the front input shaft of
these transmissions to have a fair amount of runout? I'd estimate that
I can wiggle the flywheel end of the input shaft about +/- 1/16 of an
inch in each direction -- maybe even a little more.


L.W.(Bill) ------ III wrote:
> According to whomever "Old Crow" is: "You can fix this for like $25
> and a day in the shop on your back. The 5th gear is held on the output
> shaft by a snap ring, which has broken and let the gear move out of
> position. It can be fixed with the tranny still in the Jeep. It'll
> take a snap ring and a couple of seals to do the job. Google search this
> group for a post titled "WTF happened to 5th Gear" with me as the
> author."
> God Bless America, Bill O|||||||O
> mailto:-------------------- http://www.----------.com/
>
> jwallacq@hotmail.com wrote:
> >
> > My 94 Wrangler (4 cyl, 170,000 miles) started having problems with the
> > 5-speed manual transmission. First I lost 5th gear, then it started
> > seizing or locking up in reverse, and finally it started locking up in
> > 1st also.
> >
> > I have removed it from the vehicle, and separated the transmission from
> > the transfer case; and now I am wondering if it makes sense to try to
> > fix it myself, or if I should send it out.
> >
> > My biggest concern with trying to fix it myself is whether I will be
> > able to find the parts; are there any retailers out there who sell
> > individual components for transmissions??? Also, will I need to have
> > access to a hydraulic press to get the bearings, gears, etc. off of
> > their shafts?
> >
> > Does anybody have a ballpark idea of how much it should cost to have it
> > rebuilt? And where would be the best place to take it?
> >
> > One other question: As long as I have the transmission down, I
> > probably ought to replace the clutch, also. Are there any special
> > "gotchas" that I need to watch out for? Will I have to buy some kind
> > of alignment tool to get the new pressure plate centered properly?
> >
> > Thanx in advance!

 

Bummer. I don't think you may get away with leaving out the gear, I
would think it's necessary to space and hold together the synchro block
and output shaft position. I can't think of a loose ball it must have
come from a bearing. Maybe search Ebay.
God Bless America, Bill O|||||||O
mailto:-------------------- http://www.----------.com/

jwallacq@hotmail.com wrote:
>
> Thanks very much for that advice. It certainly sounds like it's worth
> my while to investigate this possibility before I go shelling out $900
> for a rebuilt!! Hopefully, I will be able to get to it this weekend,
> and then report back on what I discover.