t5 manual, shift problem

[MortenB]

Just took apart 2 t5's, looking for problems.   Both trannys have problems shifting from 3-2 and 2-1, as well as into 1 and 2 when standing still.   Part of the problem lies in the clutch; it was missing the clutch ball in the bellhousing, causing the clutch not to disengage totally.   This, I think, explains the problem of getting it into gear while standing still (no prob with engine off).
Seems to me that the brass syncros are at fault, but I don't see anything wrong with them.    The first tranny was almost empty of oil, and was charred inside.   The second tranny had gear oil in it.   

I have not taken the syncros/gears apart, just inspecting the gears while still in the tranny.

Any ideas?   

[HappyPappy]

There is a good  shop manuel in the download section on t-4 and t-5. Gives all the specs etc.

[Monkeyjoe]

Have you tried shifting since replacing the pivot ball?

Make sure you are using the correct lubricant in the transmission.  Most T5 transmissions use ATF, NOT Gear oil.  That may be why the other trans is burnt up inside.  If you use gear oil when ATF is required, you may have problems shifting and you will cause extreme heat in the transmission that will cause the seals, bearings, bushings, etc to fail.

If you need parts, Vintage jeep, I think it is on the web under VJ. Parts are cheap and available.  I rebuilt my daughters T5 in her CJ7 for $600.  I replaced input and output shafts and third gear along with all new bearings, bushings, seals etc.  I met the father and son who own the business, great guys and very helpful, It is located in south Texas.

[MortenB]

I have not tried shifting since I installed the clutch ball.     I inspected the brass synchro rings, and the teeth are worn a little.   Some of the teeth don't have a sharp point.   This is more noticeable on the 1st and 2nd gear syncros.    The steel gears all look ok.

I have ordered a synchro kit and seals, so I'll see how it goes after I get everything assembled.

[MortenB]

The tranny is not installed yet, but it had been filled with thick gear oil.   Now it has transmission fluid.  I have put in the new synchro gears and new seals, etc.   Its ready to go in.   Just have to finish rebuilding the clutch cylinders first.    That's what started all this work, leaky clutch slave cylinder.   Now, the bellhousing, tranny, transfer case are all clean and shiny, the trans tunnel is cleaned up and undercoated, same for the brake and fuel lines.   Working my way towards the back of the car, I'm considering removing the rear axle and gas tank to clean up and undercoat the underside of the car.  It is easiest now, with the exhaust out of the car.   Seems almost as easy to remove the engine and clean it and the engine bay up at the same time.   If I do that, then I may as well rebuild the motor and make a stroker out of it.   I have a parts Cherokee sitting there just waiting for me to have time...