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The owner of a 1998 Jeep Wrangler had several questions about the use of a CompCams 252H grind camshaft in a Jeep 4.6L stroker inline six engine build. His engine core is a 1998 Jeep TJ Wrangler 4.0L...Here is our exchange. My comments are in red: Keith M.: I’ve seen some posts, including on Comp Cams’ site, that say the head on the ’98 has different size valve stems than other years and that cams that will work on other years won’t work on this one. I’m pretty confused by what seems to be conflicting and unreliable information. Moses: I’m not clear why there is so much confusion. CompCams should know parts interchangeability and sizing. 4.0L valve stems are available in both standard size and oversize for a given engine, which may account for the confusion. Parts interchangeability spans many years. Exhaust or intake valve head diameters may change while stem diameters remain common. Federal-Mogul is a well-known reman engine industry parts supplier. We’ll use F-M as a reference source: https://www.fme-cat.com/overlays/part-detail.aspx?brand=SP&PartNumber=V-2527&pt=Intake%20Valve&lu=1998%20JEEP%20WRANGLER&vin= [Intake valves] https://www.fme-cat.com/overlays/part-detail.aspx?brand=SP&PartNumber=V-4554&pt=Exhaust%20Valve&lu=1998%20JEEP%20WRANGLER&vin= [Exhaust valves] https://www.fme-cat.com/Application.aspx?year=1998&make=JEEP&model=WRANGLER&cat=Engine&engbase=4.0L%20L6%20242cid&ga=Y&back=true [Overview of intake and exhaust valves] https://www.fme-cat.com/overlays/part-detail.aspx?brand=SP&PartNumber=VK-216&pt=Valve%20Spring%20Retainer%20Keeper&lu=1998%20JEEP%20WRANGLER&vin= [Valve retainer keepers] https://www.fme-cat.com/overlays/part-detail.aspx?brand=SP&PartNumber=HT-2011&pt=Valve%20Lifter&lu=1998%20JEEP%20WRANGLER&vin= [Lifters are the same over all inline Jeep/AMC sixes] A concern with camshaft installations would be the rocker arm ratio. See the rocker arm interchangeability in this listing. AMC/Jeep inline six rocker arms are essentially the same with the same ratio: https://www.fme-cat.com/overlays/part-detail.aspx?brand=SP&PartNumber=R-905A&pt=Rocker%20Arm&lu=1998%20JEEP%20WRANGLER&vin= Pushrods for 4.0L engines fit the full range of 4.0L years. They are available in different lengths because the rocker arms are non-adjustable. I have discussed this at length in the forums and magazine; see https://forums.4wdmechanix.com/topic/1155-42l-re-build-77-cj-7-project/ and my reply comments from December 25, 2018 and forward. Read the details on fitting the right length pushrods. Here is the F-M parts listing for 4.0L pushrods in a standard (OEM baseline) length. There is selective fit application coverage to compensate for engine block and cylinder head deck height changes, head gasket thickness and so forth: https://www.fme-cat.com/overlays/part-detail.aspx?brand=SP&PartNumber=RP-3275&pt=Push%20Rod&lu=1998%20JEEP%20WRANGLER&vin= Keith M.: I want to use the 252 cam you recommend in your video but I haven’t been able to find a video with specific part numbers. Some of the information I’ve seen indicates that I need to change the valve springs if I go to that cam, other places I don’t see that. I need a timing set but have new lifters so I’m trying to get a package if I can but don’t want un-needed parts. I’m also unsure of which cam works with fuel injection as I have been told this makes a difference. Moses: Sounds like you just need the 252H camshaft if your new lifter set is compatible. If the lifters are OEM replacement, ask CompCams tech if OEM lifters will work with the 252H camshaft. Typically, the camshaft kit includes the cam and lifters, but if CompCam simply uses an OEM replacement type lifter, you could save some here. The 1998 4.0L upper valve train (valves, retainers, keepers, rocker arms and such) should be readily compatible with your 252H camshaft choice. You do need to use the correct length pushrods to attain the right lifter preload as described at the forum exchange and magazine articles. If lifters are the same, you can see whether CompCams is willing to sell the camshaft by itself. They may not warrant the camshaft if you don’t use their lifters…Always use engine break-in lube additive (Lucas, CompCams, etc.) with ZDDP to assure proper seating of the lifters with the camshaft lobes. You still need a timing set from whatever source plus correct length pushrods if the OEM pushrods are not the correct length. As for the PCM compatibility, there is the issue of Coil-On-Plug engines requiring a different camshaft than the 252H. Your engine is not C-O-P, it has a distributor and earlier PCM programming. I’ve not heard of anyone getting an engine code from a 252H camshaft installed in a pre-C-O-P engine like yours. If I were to build my 4.0L 1999 XJ Cherokee distributor type engine into a stroker, I would use the 252H grind camshaft rather than use a stock OEM replacement. I have used the 252H grind with EFI truck engines as far back as a Ford 300 inline six MPI engine (1987). The 252H grind has also been tested repeatedly by Tony Hewes on pre-C-O-P EFI/MPI 4.6L stroker builds. Keith M.: This package would be fine, under specifications it says it works on years 1964-1998. But I can’t be sure that’s correct really, because of the fuel injection and possible valve stem issue: https://www.compcams.com/high-energy-206-206-hydraulic-flat-cam-sk-kit-for-amc-199-258-4-0l.html If I had to replace valve springs I’d use this kit: https://www.compcams.com/high-energy-206-206-hydraulic-flat-cam-k-kit-for-amc-199-258-4-0l.html In specifications it says 1964-1998, but under Installation Notes it states ‘K-Kits will only work in 1964-88 models due to different valve stem diameters” Moses: Valve springs and retainer sizes are governed by the valve stem diameter. This appears to be the reference here. Logically, you do need to match valve springs and retainers to the valve stems and cylinder head spring seats. For your purposes, you only need to use the right diameter 4.0L valves, matching springs and retainers for your cylinder head casting and model year choice. Approach the valvetrain like you’re rebuilding a stock 4.0L engine. Choose replacement parts for the cylinder head casting and block casting involved. Keith M.: And somewhere in here there’s a review for a kit where the reviewer states the kit won’t work specifically on the 1998 engine. That’s strange to me and seems incorrect- I have two heads, one is a 7120 of an earlier (1991-1995 I think) and then there’s the 0630 casting that came off my 1998. Both have 5/16 valve stem diameters by my measurement so I don’t believe there’s a difference. I’m assuming the whole problem with valve stem diameter is the earlier years are a different size so the later heads won’t work with the keepers and other valve spring parts that come in the kit. Moses: My assumption, too. We’re in accord here… Keith M.: I’m just trying to avoid getting the wrong cam and having it fitted to the bearings and then having to get another one. I don’t want to reuse the stock cam really, but I don’t know enough to say a different cam is worth it. This Jeep needs to idle and drive well on the street, I can’t have it be stumbly or rough idling as I will be selling it at some point soon. I do want to learn how to do these builds well as I restore IH Scouts- the 4.2 was an available engine that I think is much better in many ways than the IH engines and if I could find a way to build an excellent and reliable stroker with a 4.0 block and the 4.2 crank I’d do these regularly. Moses: Understood, Keith…I’m a Scout buff, too. If fuel efficiency is an aim and vehicle weight not excessive, a 4.6L build from a 1991-99 (pre-C-O-P) 4.0L block and head could make sense as an alternative to the 304 or 345 I-H V-8. I-H was wise to outsource AMC 4.2L/258 engines, they offered a high-torque design that tolerated emission controls better than competitors. Keith M: Thanks for your help Moses, I’ve done my best to sift through all the info out there and I just can’t come to the right conclusion without your advice...Respectfully, Keith M. Moses: No problem…You want to build a safe and reliable engine. My recommendation for the 252H grind has always been simple: This grind offers increased lift with moderate duration. More lift without increased duration means a “bottom-end” camshaft that actually enhances the idle, tip-in response and mid-range power. This cam is much different than the 260H grind. Since the 1980s, I have recommended the CompCams 252H for fuel efficiency, quicker torque rise (more diesel-like), superior idle and rock crawling tip-in stability. This camshaft raises idle vacuum and maintains higher manifold vacuum from idle to mid-range rpm. This is simply a trailer pulling, rock crawling, high manifold vacuum camshaft for optimal power at low speeds, midrange and to a realistic 4500-5000 rpm maximum shift point. It will make power to 5,500 rpm in a pinch. In your 1998-based pre-C-O-P PCM engine, you should experience no problems. The lift is not extreme and will not create valve spring “coil bind” with stock ratio rocker arms. (Valve springs must be new or in good condition and provide the proper spring rates at specified valve spring heights.) With a stroker crankshaft, the 252H makes even more “stump-pulling” sense. The gearing of your Jeep should target a 4500-5000 rpm maximum engine speed. Your single rail EFI/MPI, the 1998 PCM, MAP sensor and camshaft sensor will find this camshaft compatible. The 302 Ford V-8 injectors described in my articles will make sense. C-O-P engine builders should consider the newer grind from CompCams to avoid engine check light issues. The C-O-P PCM and camshaft position sensor monitors the OEM camshaft valve opening/closing events (lobe valve timing). The CompCams 252H valve opening/closing events can trigger an engine check light on a C-O-P engine with its PCM programming. A roller chain (Cloyes or similar) timing set is always an improvement, though the 252H camshaft will work with a stock/OEM replacement set as well. Your focus should be selecting the correct length pushrods and setting the valve timing to factory marks. This is optimal valve timing for the performance gains I have described…Make sure you install the distributor correctly, which will properly index the camshaft position sensor and ignition rotor in the process. There is nothing exotic about the 252H grind. I have installed this camshaft as an OEM replacement. The valve/lobe timing creates an issue with the C-O-P engines because the later PCM is looking for specific valve opening and closing events in relationship to the crankshaft. Let us know how your 4.6L build turns out and your impressions of the 252H camshaft performance... Regards, Moses -
Moses, I have watched your videos regarding how to approach a stroker motor. I have read tons of info on the internet, and I've seen many calculators for quench height, combustion cylinder volume, etc. It really is baffling to me, and I've begun to realize I could invest a lot of money and end up with an engine that doesn't work. Is there any identifying info on the block that would allow you (or someone) to write me a "recipe" for what parts I need to build up a stroker? I'm realizing that the added weight of the full size truck axles and 38" tires are going to necessitate more power. I've been thinking about Ford 302 power, as I have secured a 1993 EEC IV harness and computer, but that swap has its own challenges. I always thought a stroker was the best way to spice up my powertrain, and I still like the idea if I can be relatively certain if what parts I need to buy to get it right the first time. Please let me know what you think. -
New here and tried searching but came up with nothing similar. My 06 LJ 4.0 (155000 miles) recently developed a habit of going to a fast idle/high rev of around 1500 RPM's or so. If I blip the throttle it settles down until you take of again and it repeats. I installed a Genright 31.5 gallon fuel tank and replaced the fuel pump assembly at the same time because it was a whole lot easier and I didn't want to drop the new tank anytime soon. I had a code for EVAP system small leak which I attributed to the vent hose from the tank to the filler neck as the hose that came with the tank was rather short and had no clamps. I installed it and put some zip ties on it until I could get a new section of line and clamp, which I did a week or so later. I also had a code for O2 sensor which I forgot to write down but it was present long before these symptoms began. I have searched for vacuum leaks but it's possible I might have missed one. Anyone have thoughts on this? -
hi what distributors you recommend for standalone jeep 4.0 ( with cam and crank sensor ) coil pack ( 6 ) -
Hello, I have some trouble with mpgs, idling and acceleration on my Wrangler YJ 1995. 4.0. Recently went to a mechanic, he connected my PCM to a DRBIII scantool, and he told me that the adaptive factor is -80%. He did reset all adaptive memory, and I can feel improvement in mpg and acceleration. Is there any way to reset adaptive memory other than connecting it to a scantool? I've read on internet about touching positive and negative cables (or grounding postitve), that it empties the capacitors in PCM adaptive memory. The reason I'm asking this is because I don't have scantool available all the time, and that this error is due to a bad LPG map (I have converted this JEEP to propane).. So I would like to once again reset memory, and after PCM relearns to copy that map to a LPG controller so there would not be any differences. -
I am working on a 2002 Wrangler 4.0 automatic. I found this connected grounded to the left side of the block. I have no idea what it is or what it does. Any help would be greatly appreciated. Thanks so much, Jake -
I have a 1997 Jeep TJ Wrangler 4.0 with 171K miles on the clock. This mechanic at work is making me very nervous telling me that the oil pump on the 4.0L takes a dump between 150 and 200 thou miles and I should be aware of this..Im a worrier and he's got me going now. Anybody have any input on this and what I should do? the engine runs great. When I start it cold it has 50 lbs oil pressure. when its warmed up its 40 while driving and 20 sitting at a light. Sounds normal to me but have any of you had issues with the oil pump? He says when it goes its too late..New motor time.. -
Going to swap my old 258 w/ 4.0 head for a 99 model 4.0 in my 84 CJ-8. Already have the mpfi setup, just going to use it along with the TF999 trans. Question is will the flexplate and starter both work on the 99 4.0 engine? I've been told that I need the flexplate that fits the engine and to drill it to fit the trans. torque converter. Just need to know which is correct. Thanks -
I have attached a few pictures of this transmission I have but I don't know where its from I need help identifying this transmission the only thing I can identify here is the transfer case because it has the sticker in the back its an NP "new process" 249 J This is a manual 4wd transmission I believe its an ax15 transmission but please give me your input as i'm not sure any help is appreciated one more thing from the shape of the bell housing I don't think this came of a Jeep possibly AMC or other but thanks again -
random, intermittent #1 cylinder misfire. I have replaced the coil-pac, #1 injector, spark plugs, and both upstream O2 sensors. engine leakdown and compression normal though #1 slightly lower in compression. emissions always meet I/M standards (no certificate of waiver needed). have all heat shields including #3 injector so vapor lock not issue. engine runs good when not misfiring though does have a slight roughness noticeable when at idle. Is there any way to check the current of an injector wire or plug while engine is running and showing symptoms to see if all is well in the wiring harness? engine bay is quite clean for 235k mi. and no noticeable damage to wiring harness, but there could be a partial open in a circuit I suppose. Any ideas? don't know where to go from here with repairs/diagnosis etc. Oh, misfire occurs mostly after engine has been under normal-use-load for a couple hours or so, but not always. sometimes it is misfiring at cold-start. -
Greetings from Northern Michigan, I am in the process of building a stroker for a 2002 TJ. I need to check the pushrod length. The engine is still on the stand. Do I need to prime the lifters to get the proper pre-load? Thanks so much, Jake
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The weather has warmed, and we're not using the block heaters. (They provide approximately 140-degrees F coolant temperature at start-up.) When starting the Jeep XJ Cherokee's 4.0L engine on a relatively cold morning this week, I could hear a subtle misfire. This was during the warm-up/enrichment cycle, and by the time the engine came off the warm-up cycle (around 140-degrees F), the idle stabilized. At highway speeds, the engine seemed to run smoothly in terms of cylinder firing, though there had developed an unusual downshifting habit on grades and strong headwinds. Concerns came up about the TPS or oxygen sensor, maybe even a fuel supply issue. Miles earlier, however, the TPS had been replaced, and the O2 sensor as well. Giving this some thought, I pulled the air filter out. Holding it to sunlight, there was little light showing! The filter was neatly and uniformly clogged. This was the burbling at idle and sluggish on-highway at cruise trouble spot. So why didn't I replace the filter earlier? I change oil and the oil filter on cue, watching the oil color constantly. The air filter, however, gets dismissed when our mileage is mostly highway without dust conditions. In looking at the clogged filter, it was clear that winter "road film" was the culprit, and this can be just as impacting as dust and dirt particles. How did the engine continue to run in this state? Because the marvel of modern EFI has the O2 sensor compensating for air/fuel ratio constantly. Unlike a carbureted engine, which would show symptoms of an over-rich running condition much like running with the choke on, the A/F remains normal with EFI. At highway cruise, especially with an engine that chugs along at only 2,000-2,100 rpm most of the time, there is limited CFM (cubic feet per minute) air flow needed to maintain the A/F at that throttle setting. However, when load demands raise the throttle opening and drop the manifold vacuum at the same time, notably with the cruise control operating, the engine requires a transmission (AW4 in this case) downshift to maintain the A/F ratio constant. This creates the needed power at the expense of fuel efficiency. The dirty filter explained the downshifting on hills and subtle misfire at cold idle during the enrichment cycle. The moral: Check your air filter regardless of the season and whether or not you're driving off-pavement. Of course, when driving off pavement, one trip down a desert alkaline road can clog a brand new air filter. On highway, this does take longer, but with winter road debris and salted roads, the dirt accumulation is equally impacting. It just takes a bit longer to produce symptoms. A good rule-of-thumb for replacing the filter is the factory service interval. In our Jeep 4.0L engine's case, I'm targeting every 3rd or 4th oil change when driving strictly on-highway. For dusty off-pavement conditions, inspect the filter regularly and replace it as soon as necessary. Moses
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Im looking at building a motor for my 83 Cj7 I have options, I have a 96 4.0 parts motor with 0630 head plus a spare 7180 head. I have two 258s one is a 1990 (006CL25 / EF3235444) the other an 80 (009C09 / 3235444). The 1990 258 i could just re-ring and drop a 4.0 head on, i wouldn't even have to plug the water jacket holes in the head as the 90 block is squared of on that side like a 4.0 block, re cam with a RV unit and i'm hauling like never before. Pretty strait forward. Or; Take the crank and rods from the 1980 block and put them in the 4.0 block. With this one i would keep the 4.0 pistons, install new rings and because the 1980 crank is the last of the 8 counter weight heavy cranks i would assemble it and assume im pretty close on balance and see what it runs like. Im thinking the second one is a bit of a gamble on the balancing but i've put lighter pistons in small block chevs before and never had to rebalance, so ive been there done that. Anybody out there done a heavy crank to 4.0 swap with all stock stuff? think it could work? -
Ok, here is my situation. i am new to the the jeep owners world. I have wanted a cj since I was 13 yrs old and I finally got one about 2 months ago. I bought an 85 cj7, it has a 2.5 l 4 cyl with a t4 transmission. I bought it with the expectation of putting in a different motor and trans, however, what I did not count on was how much body work I would end up having to do. The body work has taken a huge chunk out of my budget for the motor. A buddy of mine gave me a 4.0 out of his 88 comanche. the engine ran but had been sitting for 7 yrs and all of the seals leaked, including the main seal. My original plan was to use this motor and carburate it since I don't have all of the parts for the fuel injection and I want to keep it as simple under the hood as possible. My question is, would this be possible and could i use the existing motor mounts. Also, what else would I have to do to make this work? Any help on this would be greatly appreciated. Thanks -
I own a 1995 Jeep Wrangler YJ 4.0L just got it reassembled after repainting I'm having 1 issue it's starting hard I replaced the iac valve no change when it starts firing it only sounds like a few cylinders until it warms up i have to keep my foot on the throttle slightly it sometimes back fires but once it's warm it runs perfectly fine. I don't have a vapor canister in it cause it got lost could that be my issue? -
Happy Thanksgiving to all! I've posted before that my CJ-7 has a Cherokee 4.0L in it, but it's not really that simple Here is the history as I know it or can guess from some evidence: 1. Originally a 258/4.2L straight six with the FrankenCarb--this one was sold in California, so I'm sure it was extra-special. 2. MOPAR EFI kit added to the 4.2L. It seems this addition happened sometime after 2000, as the MOPAR labels for the kit have a 2000 copyright on them. I learned from the shop that did most of the work on this Jeep that the lady I bought it from purchased it sometime around 2001. It was owned by 1 family prior to that (1983-2000?). I suspect the Skyjacker lift and sketchy paint job happened about the same time to make it ready to sell. 3. The 4.2L finally gave up in 2014. This engine was replaced with a junkyard 1995 Cherokee 4.0L last May; engine had about 155K on it at that time. I never really knew which version of the MOPAR EFI kit I had, OBDI (with fuel return line) or OBDII from the newer models (returnless). There was also the option that they pulled a complete 1995 engine including the EFI and junked the old MOPAR kit. I just didn't really know. I've done some more research and taken some pics to see if anyone can confirm what I've come to believe. It seems like my system matches the pictures I've seen of a single rail EFI system. That would mean it is: 1. 1997 and newer 2. Returnless 3. OBDII I mostly ask these questions because I've been looking at performance options for whenever I'm forced to rebuild this engine. I really think I want to leave a Jeep engine in there, as opposed to a small block Chevy, for example. It seems like most systems (supercharger, programmers, etc.) are dependent upon the OBDI VS. OBDII distinction. With a 1995 engine, I wasn't sure which items I should be looking at. Assuming this is a 1997 and newer-style EFI kit, I assume I should only look for performance items for the newer model engines, correct? I don't think there was much other than heads (I have the supposedly better casting) that varied in those mid 1990's engines, other than the EFI/PCM. 1. Can I conclusively say this is a returnless/1997 and newer EFI kit? 2. Is this the OBDI/OBDII port I'm showing in the picture? It is about 8" down the main wire harness from the MOPAR EFI kit PCM. Regards, Case
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Members and Guests...We've had some great discussion on rebuilding the popular Aisin AX15 transmission, and my 'how-to' rebuild rental at Vimeo On Demand (http://www.vimeo.com/ondemand/ax15rebuild) has received solid feedback as a resource for shops and DIY level techs! I'm pleased to see many are able to successfully rebuild and thoroughly restore the AX15, made popular in 1989-1999 model year Jeep vehicles with the 4.0L engine. The AX15 transmission rebuild coverage and our discussion here at these forums also serve other applications of the AX15, including the Dodge Dakota, some Toyota truck models (and performance car applications) plus Isuzu and GM use. There are, however, instances when a transmission is simply not rebuildable. You do the teardown, follow my inspection guidelines or a factory shop manual, and discover that the wear exceeds any reasonable parts replacement costs...In these cases, we do have an outlet and sensible alternative: Advance Adapters and a new AX15 transmission! Note: Many owners have discovered that a "good used" transmission is an oxymoron for an off-road 4x4 vehicle that gets oversized tires and a lot of shifting either off-pavement or in city traffic. I'm not an advocate of buying "good used" unless you know the history of the donor vehicle. Any 1989-99 Jeep 4x4 transmission has seen more than enough use and is a candidate for my "blueprint rebuild" or a complete replacement. "Good used" can simply translate to "definitely used"! In the day, a BW T-18 or T-98, a GM SM420 or SM465, a New Process NP435 or other commercial grade, iron case "truck" transmissions (or the more contemporary NV4500 or NV5600) were often still in serviceable condition after the vehicle expired. That will not be the case with a used, higher mileage AX15 transmission, it will not provide long or reliable service as a high mileage used purchase. Optimistically, such a "core" might be rebuildable. I have worked closely with Advance Adapters' full line of transmission to transfer case adapters, Atlas transfer cases and other products for decades now. (We can thank Advance Adapters for its support at the magazine and these forums, too!) For many owners, the fatigue and normal wear of a powertrain provides the incentive for unique and popular upgrading of a 4x4 powertrain. In that arena, the Aisin AX15 has become the contemporary transmission of choice for stock 4.0L restorations and even swaps of moderate horsepower V-8 power into a Jeep 4x4 chassis. For horsepower to the 275-300 range (like an LS3 or a 4.6L Jeep inline six stroker) plus a useful overdrive gear, I consider a freshly and properly rebuilt AX15 as a prime candidate for a street/trail "build". These swaps or buildups do require either a rebuilt or new Aisin AX15. This contemporary transmission has also become the replacement for the later, expensive to rebuild 6-speed Jeep TJ Wrangler transmissions. Yes, a brand new AX15 transmission, ready for bolt-in replacement in Jeep and many Dodge Dakota, Toyota and Isuzu applications! These units are close ratio five-speeds (5th overdrive) that can bring new life into a higher mileage vehicle. They also deliver a desirable level of contemporary torque and stamina for moderate horsepower V-8 transplants where an overdrive is desirable. (These units even look great, click on these photos!) The exciting news is that you have the option of buying a new Aisin AX15. These units, available through Advance Adapters (a direct Aisin distributor), provide all of the legendary features and reliability found in new Jeep 4x4s from the Jeep YJ/TJ and XJ Cherokee era (or Dodge Dakota 3.9 V-6 models and other AX15 applications). Advance Adapters has a long reputation for serving the 4WD community, whether sponsoring enthusiast runs at Moab, Utah or supporting the off-road racing community. Advance Adapters maintains this approach with the pricing of these new Aisin AX15 transmissions. So, if your AX15 is either too worn for rebuilding or you're building a contemporary Jeep 4x4 project for the street/trail or off-road use, consider the Advance Adapters AX15 option! For more details, visit the Advance Adapters website at: http://www.AdvanceAdapters.com! Moses
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Hi, Just swapped out my AX15 transmission on my 97 Jeep Wrangler. After I completed the job, with the engine off, I was able to shift through the gears without issue. I pressed the clutch pedal and it was easy the first few times then became extremely stiff. I removed the external slave cylinder from the bell housing and manually pushed in the clutch fork with my finger. The fork moved forward easily, then I heard something fall inside the bell housing. I pulled the tranny back off and found the clutch fork retaining clip had fallen off. I proceeded to put it back in place ensuring it was secured. After attaching the tranny back on, I tested the clutch pedal which appeared to operate normally (engine off) as well as ensuring I could shift through the gears without issue. I then continued with attaching the rest of the harnesses, transfer case, etc.. I fired up the engine and heard a knocking sound which appeared to be coming from the external slave cylinder area. As I depressed the clutch, the knocking stopped. I turned off the engine, removed the slave cylinder and had my wife press on the clutch pedal. It became stiff again. I pulled the transmission again and the clutch fork retaining clip was still secured. This is where I have left off for the night. I plan on bleeding the master / slave cylinder system tomorrow and see if that fixes the issue with the stiff clutch pedal. Some questions: 1) How far should I be able to press in the clutch fork manually with the external slave cylinder removed from the bell housing? 2) Should the clutch fork return after being depressed manually (like a spring) with the external slave cylinder removed from the bell housing (mine didn't. After pressing on the clutch fork, it remained in the position I had pushed it to). 2) Should the clutch pedal move freely with the external slave cylinder removed from the bell housing? 3) Could it be the throw-out bearing? It appears to be ok from visual inspection, it slides along the transmission shaft easily, the springs are all intact. Any suggestions would be welcomed. Thanks. -
I have a 95 YJ 4 litre let's running extra rich. It will foul out the spark plugs with carbon fouling within a few minutes. Let me start at the beginning, I bought this Jeep running terrible. I was told it had a dead battery while jump starting they hooked up the cables backwards. I thought this was probably true due to the fact that both alternator fuses were blown. I drove it nine miles home and went through over 4 gallons of gas. Most of that ran out the tailpipe or was dumped into the crankcase. The number 5 and 6 injectors we're running fuel anytime the key was in the run position. I diagnose that problem to a burnt PCM. The PCM was sent out to a repair facility and upon return was installed and no start. the light on the dashboard would not even light up. I was told by the repair facility that that was their fault send it back and I would get a replacement. Upon installing the replacement PCM, the engine would start but still running very rich. The injectors no longer run when they're not supposed to. I started doing test procedures according to the Chrysler service manual. Cylinder leak down test shows all cylinders between 12 and 10% leakage. All cylinders 125 to 130 psi compression. Cam position sensor checks out ok crank sensor okay distributor cap rotor wires and plugs all new. timing ok per the book. ignition coil showed a low ohm reading on the primary side so I replaced it. spark is OK MAP sensor is OK idle air control solenoid was sticky so I replaced. Sprayed carburetor cleaner all around intake and didn't show any vacuum leaks. Manifold vacuum on my gauge reads low. About 5 inches at idle and up to 12 to 15 inches when rev up. Pulled the o2 sensor and plugged in a pressure gauge to do back pressure. Shows 1 pound pressure. Doesn't go up when engine revved so catalytic converter doesn't seem to be clogged. Running rich enough that in the three weeks I have been trying to figure this out, the new spark plugs were fouled enough to make hard starting. Since then I have installed fresh spark plugs. It will start and run but terribly rich. It acts like its not timed right, but all that is controlled through the PCM. Every check I do seems to point to the PCM still not being right. I am now one step away from doing the 5 gallons of gas and a match procedure. What in the heck am I missing? -
I've owned a 2004 TJ Wrangler Sport for a couple of years now and it has been stalling in 2nd gear the last few weeks. I gave the car to Berwick jeep service centre and all they tell me is that their computer doesn't show them what's causing it and that there is no problem. Has anyone had this issue? i know its not my driving!!! -
AMC/Jeep® always leaned forward in both car and utility vehicle designs. By the mid-'80s, the CJ needed a contemporary replacement, a vehicle with wider track for handling and a better highway ride package. The Wrangler emerged just as AMC sold to Chrysler, and the Wrangler and XJ Cherokee were the profit items Mopar wanted! The Wrangler four- and inline six era represents huge growth in the 4WD/SUV market overall, and there are huge numbers of enthusiasts, owners and buyers who can build a "community" at this forum! —Moses Ludel At left is an '87 YJ Wrangler, leaf springs articulating on the rocks! Middle is the Quadra-Coil™-suspension TJ Wrangler Rubicion edition, the engineering and off-road pinnacle of the Wrangler inline four- and six-cylinder era! At right, Moses Ludel's Jeep Owner's Bible, 3rd Edition, covers models through the Wrangler YJ and TJ...
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I've been a Jeep enthusiast since 1997. My first Jeep was a 1982 CJ8 Scrambler. One YJ and 4 TJs, the current one being a 2004 Rubicon with 52,000 original miles and trail modified. I have been experiencing the famous P0301 trouble code very intermittently unless it was cold outside, then it was steady. Rain or shine didn't seem to change anything. I live in Minnesota where winters are cold. Started with the obvious tune-up, copper plugs and the coil rail. Battery connections, grounds, injector cleaning and replacement, throttle body cleaning. The works. Could not isolate the misfire. Started chasing wires. No luck. Many live data scanners, no luck. Compression tests and leak down well within spec. Valves also seating and rotating well. Became very frustrating. Pulled the alternator, tested good. The battery tested good ( the first time). Wasn't sure what to do. Finally, the other morning it was -17 degrees F. The Jeep just didn't have the juice to start. Thought that was strange. Rain or shine it always started. Jumped it and went to auto parts store. Dead cell in battery. Thinking back first good freeze, we experienced this and had the same test done. I overlooked the issue and accepted its first passing test. No one on any of these forums makes mention of voltage or battery replacement or testing. Well I replaced the battery. Not a single misfire in a month. I've wasted countless hours diagnosing this misfire, and it ended up being my battery. Turns out they're pretty sensitive to low voltage. Thx for all the info on your site! -
There has been a long thread of exchanges at Timmy960's topic on harsh shifting after rebuilding an AX15 transmission. The problem around 3rd/4th gear shift issues has a basis in the redesign of the synchronizer sleeve, bronze blocking rings and the third gear cog teeth for the sleeve engagement. Jason Logan and I had an exchange about this issue when he rebuilt his '99 TJ Wrangler unit. That exchange was just prior to the launch of the forums. For the benefit of all AX15 rebuilders, I am starting a new topic around this issue, beginning with the in-depth Q&A exchange that Jason Logan and I had...Since this exchange, Jason, Gary, Tim and I have been using the new forums to disseminate AX15 transmission rebuilding details...Here is the original exchange with Jason. I have highlighted important facts: Jason: Hello Moses! I have recently taken advantage of your detailed instruction on how to rebuild an AX15 manual transmission. I am currently working on an AX15 manual transmission from a 1999 jeep tj 4.0L that has never been rebuilt. I have a question regarding the stock 3rd and 4th synchro ring and the corresponding slider [sleeve]! The stock slider has an angle cut on one side and a straight cut on the other side. Also, the stock 3rd gear synchronizer is angle cut and the 4th synchronizer is straight cut. (I may have these backwards). Why is it that the dealer and aftermarket only show that both 3rd and 4th synchronizers are identical (either both are an angle cut or both are a straight cut). I ordered a 3rd and 4th synchronizer from Chrysler and they are identical (straight cut), and when I ordered a set from the aftermarket, the 3rd and 4th were also identical but with an angle cut! Should I use the Chrysler synchronizers (both straight cut), the aftermarket (both angle cut) or should I use one of each to replicate the stock setup as described above? I have put this rebuild on hold for weeks now trying to get some answers from many sources but nothing has been rock solid. I was hoping you could help me and give me some clarification on what is the best set up and why? Why does the slider [sleeve] have different cuts? Why do the replacement synchros have different cuts, different part numbers and configuration of teeth? Thanks for any information you can give me. Jason Logan These photos courtesy of Jason Logan ("JayDLogan"), forum member...Note the 3rd/4th gear sleeve and cog design for his 1999 TJ Wrangler AX15 transmission. Click on each photo to enlarge image. Moses: Jason, I would match synchronizers precisely to the originals and in their original locations. Measure the diameters of the rings, their angles and, most importantly, their fit against the synchronizer hubs in their correct positions. Make sure you face the synchronizer sleeve in the correct direction. Start with the original rings in correct relationship to the synchro hubs and sleeves. Note the overall “width” of the synchronizer assemblies, and then compare this with the aftermarket (new) synchros from both generic and Chrysler sources. The goal is to have synchro rings that will behave and fit just like the originals. Wear on the OEM rings is typically slight, perhaps a few thousandths, so you will know immediately if the parts are either wrong or in the wrong locations. AX15 synchro rings are not the same diameter, and the difference is slight, often confusing the assembly. My article provides details on the kind of “fit” and end plays you should achieve during assembly. Take your time, Jason, you’re already ahead of the game by questioning the parts to make sure of their fit and placement. The OEM layout and fit is your template. Match this and you will “restore” that AX15! Trust this helps…I’ll be at Moab through Thursday and out of communication. Let me know your findings in an Email. I will answer next Friday…Best of luck, I know you will do the right thing here… Moses Jason: Thank you very much for all of your information and help - my dilemma is - when I have ordered the synchro rings from Chrysler (they sent me 2 identical 'straight cut' synchro rings) and when i ordered from the aftermarket (they have sent me 2 identical 'angle cut' rings) but my original synchro rings have 'one of each' cut (one ring is a straight cut and the other ring is an angle cut). Although all synchro rings ordered are the same diameter, angles and fitment as my originals, I'm not sure if I should be using what Chrysler sent me (the 2 straight cut rings) or what the Aftermarket sent me (2 angle cut rings) - or should I be using one of each cut to match identically up to the original set up? I would have thought Chrysler would have sent me one of each (angle and straight cut synchro ring) based on the fact that my original rings are 'one of each' cut. And my second dilemma is - the number of teeth and location of the teeth on each ring ordered are not set up identically to my original configuration of teeth on my original rings - does that matter? I'm extremely grateful for your reply and value your expertise. Jason Logan Jason added these parts details: I found some other information, Moses! If you look at earlier years of the Jeep Wrangler 1997-1998 they have used part number 4897051AA (for both 3 & 4 synchro) or 4897052AA (for both 3&4) depending on the month the jeep was made. Part number 4897051AA is a synchro ring that has teeth that are angle cut and part number 4897052AA has teeth that are straight cut (shaped like a house). The jeep I am working on is a 1999 that calls for part number 4897052AA for both 3 and 4. It looks like at the factory, they have put part number 4897052AA for synchro 4 (near the input shaft) and 4897051AA for synchro 3 (near third gear). Very confusing! I also found, like I noted before in my second email, that the teeth of part number 4897052AA and 4897051AA are in a different configuration around the ring slightly than the originals as you can see in the pictures. I have purchased many 3 and 4 synchro rings but none of the teeth patterns match up! I had no problems matching up 1,2 and 5 synchros. I hope this helps you understand what I am up against! Thanks again! Jason Logan P.S I purchased part number 4897051AA today from Chrysler to clarify if it was angle cut and indeed it was! Moses: Hi, Jason, I’m just back from Moab, UT Jeep Safari…You sent great photos, this is all very interesting! Since the gear/ring in question is really 3rd gear, my belief is that Chrysler/Aisin discovered downshifting to 3rd problems and implemented a remedy. The angle cut would engage the shift sleeve differently, apparently allowing easier engagement on the downshift from 4th to 3rd. It would seem like either ring would work, as they each engage the sleeve troughs accurately (taking a straight-on view). The difference is that the angled ring would engage the sleeve with a different pressure and slight rotation of the ring. Just a guess, but this seems the only identifiable issue. Think about the third gear engagement: Shifting up, there is the lag in the shifter’s neutral gate and a “slower” engagement of 3rd gear. Shifting down, however, would be a direct, quick movement of the shift level and fork. Consequently, the sleeve would want to quickly rush over the brass ring teeth—without providing smooth or effective braking action at the gear hub. This would cause harsher gear engagement. Apparently, the slight angle makes the downshift to 3rd gear smoother, with better braking action and less risk of gear clash. Probably, either design would work if all drivers shifted up and down smoothly and without taxing the synchros. However, American drivers (and others with Jeep vehicles) want to affect a quick downshift to 3rd gear. The concern here, though, is to match the bronze rings with the updated synchronizer sleeve design. Does this make sense, considering the parts layout? The tooth spacing and offset on the rings has more to do with keeping the ring as close to square as it moves onto the gear hub. If nothing else, this is a testimonial to the precision design of Aisin transmissions, more like Euro types than U.S. gear products. The aim with a wedge ramp instead of arrow teeth is the shift “timing”, and that’s a precise consideration. This reflects the rest of the AX15 design quality and fitment. These are more complex units for a reason. I’m sure your build will be stellar, Jason! Let me know how this turns out. Regards, Moses Jason: Makes perfect sense Moses! Would it make sense to you to use the angle cut synchros for both sides of the slider even though the slider on one side is straight cut and the other is angle cut? I am still unsure if I should use both angle cut synchros, both straight cut synchros, or use one of each. The rebuild kit I purchased had two angle cut synchros, I am wondering if this is the upgrade? To me it is like rolling the dice on this decision! Thanks for all your input. Very much appreciated. Regards, Jason Photos courtesy of forum member Jason Logan...Note the OEM synchronizer design for this late version of the AX15—Mopar parts. Moses: I would follow the OEM approach if you’re sure the transmission is original, never before apart (which you believed from the start). The model year is late enough in the game for the synchro "solutions" to be in place…I would match the bronze rings and synchro sleeve carefully to the OEM layout. If this transmission shifted well for all of those miles, I would take this approach! As a final check, place the new synchro rings against the gear hubs to be sure the fit is aligned. You can put a light film of grease on the ring contact surface to read the fit. Wipe the grease away before assembly and coat the ring with a thin film of gear lube. Let me know how this all turns out, Jason… Best, Moses Jason: Thanks again Moses! I hope you had a successful trip to Moab, UT Jeep Safari. I have wanted to go for many years. Wish me luck on the AX15! Regards Jason Moses: Hi, Jason…Moab is breathtaking scenery, with contrast ranging from sandstone/slick rock to alpine peaks capped with snow this time of year, the Colorado River, arches and formations, all of it! I trust you’ll make it at some point, and if so, let me know. I do make the Moab Jeep Safari each year…Like Canada, we live at a “winter zone”, 4400 feet elevation near Reno. We look forward to winter’s end, and Moab Jeep Safari has become our annual end of winter/early spring gathering! You’re going to do a great job on this AX15! Follow the assembly steps faithfully, there are no shortcuts. When completed, you’ll have a smooth-shifting unit, as new, and that will be very gratifying! Let me know the outcome… I launched a message board today with a large number of forums at www.4WDmechanix.com/forums. It would be great to see your involvement if you have the time. Tech forums need detail-oriented members! It’s new, and I’d value your feedback about the forums you find interesting, the sign-up procedure, member validation and use. Best, Moses Note...Jason and I moved this conversation to the new forums at this point...When rebuilding an AX15 that has never been rebuilt before, lay out the parts as you take the unit apart, identify the synchronizer design for 3rd/4th gear, and match parts to the original design. There is a distinct difference between "earlier" AX15 and "late" AX15. The rebuild core in my magazine article and the A150 (Toyota version of the AX15) depicted at the Weber State University YouTube video (click for post topic threads containing the embedded video) are 1990-92 "early" AX15 design. Later model Jeep vehicles with the AX15 use a redesigned 3rd/4th synchronizer assembly...Rebuild accordingly, matching and using the right parts! Jason has added charts from an Aisin direct dealer that show the synchronizer applications for 1998-99 AX15 transmissions. Make sure you check your synchronizer rings and the synchro sleeve design for 3rd/4th gear. Install matching rings for your transmission. Be certain to install the synchro sleeve in the correct direction! ("House" or arrow shaped points match the 4th gear ring with house or arrow point teeth.) Here is an approximate application list with Aisin part numbers (not Jeep/Mopar): Click on image to enlarge...Thanks to Jason Logan for the chart!
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In this video discussion, I describe the symptoms of hydraulic clutch linkage leaks in 1987-95 Jeep YJ Wrangler models. Originally part of the Q&A Vlog at the magazine, the viewer's question refers to hard shifting and loss of hydraulic fluid. I share what causes these troubles in this how-to HD video on troubleshooting: Moses
