Baystate Jeepers

So about a year ago my tj started making a driveline noise while in 2wd, it goes away in 4wd, sounds like I have mud tires on, but I don't. So far, no one has been able to diagnose it definitively. Recently I've started to hear a clunking noise when engaging first gear. seems to go away after things warm up. My guess is the throwout bearing. I know I'm rambling here. So the point is, I have about 140k on my driveline, and about 55k on my clutch. I'm thinking about picking up a used transmission and transfer case, and rebuilding/refreshing the transmission (which I've never done before) and then swapping them in. this would then give me a spare I can keep on my shelf, and some experience ripping apart a transmission.
thoughts? suggestions? crazy idea? wast of time? anyone want to help(please please)
it's a 99 tj, 4cyl.
what's involved in swapping out a transmission?
I hope the end result will be to eliminate all noises and have a good confidence level on the transmission. If it isn't the source of the noise, then at least it's ruled out.

You really ought to determine the real cause of the noise before you start replacing parts.

I have a set of inspection tires you can use that are quieter to help locate the noise.

Tcase & tranny fluid levels?
Slop in front DS?
Front R&P?
Front U-Joints?

Swapping out the AX-5 tranny and/or tcase is straightforward. Done it many times.
Usually the biggest challenge is getting the 6 skid plate bolts out without spinning them in the frame.
- There are tricks to help prevent this from happening. Drill 6 small holes, lotsa PB....
After that it fairly routine to drop the tranny. Support the engine, drop the skid, drop the shafts, yank the starter, disconnect the linkage, drop the tcase, disconnect the electrics, yank the shift tower, drop the tranny.
A good E12 socket and a few extensions are needed to get the top bell housing bolts out.

As always I can give you a hand an/or garage space to do it.

X2 on what Kurt said.

When was the last time you changed U-joints? The front driveshaft always spins, so the force of driving in 4WD may mask a poopty joint or CV.

if you need help rebuilding it let me know.

I just remembered... it could also be a worn (loose) tcase chain (since it's a TJ)

Kurt wrote:You really ought to determine the real cause of the noise before you start replacing parts.

I have a set of inspection tires you can use that are quieter to help locate the noise.

Tcase & tranny fluid levels?
Slop in front DS?
Front R&P?
Front U-Joints?

Swapping out the AX-5 tranny and/or tcase is straightforward. Done it many times.
Usually the biggest challenge is getting the 6 skid plate bolts out without spinning them in the frame.
- There are tricks to help prevent this from happening. Drill 6 small holes, lotsa PB....
After that it fairly routine to drop the tranny. Support the engine, drop the skid, drop the shafts, yank the starter, disconnect the linkage, drop the tcase, disconnect the electrics, yank the shift tower, drop the tranny.
A good E12 socket and a few extensions are needed to get the top bell housing bolts out.

As always I can give you a hand an/or garage space to do it.

So far I've done the front wheel U-joints (right one was bad), Tcase and tranny and diff fluids, and have had several different sets of tires on it. All with no change to the noise. 2 weeks ago I pulled out the front DS to change those U-joints. they weren't in bad shape. and one of the replacements was the wrong U-joint in the right box, so I now have the right part but still havn't put it all back together. still no change to the noise. for a while now the clutch has not been engaging smoothly. within the last week that has turned into a clunk clunk noise as I engage first gear. dosn't seem to do it if I'm already moving.

I have had the skid plate off several times, so those bolts will not pose a problem.
what's a good price for a used AX5?

zenophryk wrote:...what's a good price for a used AX5?

Bad timing
I just sold the one good AX-5 I had last night.
Had the buyer lined up before your post went up....

Kurt wrote:I just remembered... it could also be a worn (loose) tcase chain (since it's a TJ)

A worn chain sounds very plausable.

Kurt wrote:

zenophryk wrote:...what's a good price for a used AX5?

Bad timing
I just sold the one good AX-5 I had last night.
Had the buyer lined up before your post went up....

that's ok, I'm sure I'll find something. are all AX-5's created equal? or do I need to look for one from a tj? and what did you get for yours?

how does this sound? http://nh.craigslist.org/pts/1761831303.html
the plan is to open up whatever I get and check out things like syncros and gears and such and replacing whatever common wear items I can before swapping it in.

zenophryk wrote:

Kurt wrote:

zenophryk wrote:...what's a good price for a used AX5?

Bad timing
I just sold the one good AX-5 I had last night.
Had the buyer lined up before your post went up....

that's ok, I'm sure I'll find something. are all AX-5's created equal? or do I need to look for one from a tj? and what did you get for yours?

zenophryk wrote: are all AX-5's created equal?

Yep, they are all very light duty and weak.

zenophryk wrote:... and what did you get for yours?

The buyer scooped it up for $200.

So I'm planning on getting a tansmission and tcase this weekend. then comes the fun task or doing a quick(hopefully) rebuild. Not sure if Wesley has done his ax5 rebuild yet, but maybe we can have a rebuild day and do both?
I don't have a hydraulic press, but my shop is walking distance to you-do-it, and I know Casey has one. '
any ideas on what a rebuild kit costs and if it's a NAPA item?

I believe Wes changed direction and is going to do the Dakota bell housing & AX-15 upgrade to his.

A rebuild kit should run about $350.00. You'll defintely need a press for the bearings.