How hard is it to rebuild a T5? I have a new engine for my 86 CJ7 and would like to rebuild my transmission. Is there a kit I can buy somewhere?

Honestly,
I would scrap that tranny before dumping money into it. It's marginal at best and when compounded by more power, gears or bigger tires, it's junk in fast order.

Might want to looking into the NV series of transmissions. Can be found relatively cheap and will give you more longevity and gearing.

Is the T5 working ok right now? I had mine rebuilt by a friend in the business about 5 years ago, and despite what many have said, it has lasted. Bigger motor or tires will put more stress on the tranny. Lower (numerically higher) gears will make the job of the tranny easier as it will take less torque to get the job done, as the rearend will multiply the torque. It cost me just under $1,000.00 for a removal, rebuild (including cluster gear, synchros, bearings, reverse idler gearand seals) and reinstall. If you have hte motor out, and you pull it yourself, a shop might not charge too much. It's good to have someone experienced do the set up (if any is involved). It a lot of work to pull it and reinstall. Might not be too bad to do it yourself.

It is working just fine but it has allot of miles on it. I thought while the engine was out it maybe a good idea to work on it.

The input shaft on it seems a little loose to me. How much play should there be?

I am also contemplating putting in an automatic instead of rebuilding this T5. Is there a automatic tranny that will bolt up to my 258 and D300 t-case? If so, where do I find a rebuilt or new one?

There are definately automatics that came with 258's and Dana 300's in the Cj7s. Some have used the TF727 (you canget them from wagoneers) which can hold up to big torque, but it interferes with the front driveshaft unless you have 4 inches of lift. I think the CJ7's came with TF 999 or 994 and Dana 300's. You'll have to find one from a parts jeep.

As for the play in the input shaft, not sure. I'd imagine the input shaft must ride on a bearing. Possibly yours if worn. I remember my tranny guy telling me that some of the bearings were more prone to failure. Input or Output?

I like a manual tranny, esp having the overdrive. I run 4.56 gears and it's great for highway travel. I'd miss that on an auto.
T
The nv4500 tranny's are stout, but still too much money to buy, let alone the 400-500 dollar adapter to the Dana 300.

While the T5 isn't the best tranny it's not the worst, and it's what you got. We carry rebuild kits with all bearings, snap rings seals etc. they are on sale for $135 They do not have synchro's those are available seperately. Click my sig, for the lame ass for now website or call us m-f 9:00 - 6:00 pst. 800-504-JEEP