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Old 02-03-2012, 07:46 PM   #1 (permalink)
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Removing T5 for repair in jeep cj

Going to attempt to remove my brothers T5 out of his jeep CJ7 this weekend and need some tips. Ive never worked on transmissions before and never seen this done. Was planning to unbolt the gearbox and leave the bellhousing. Sound right? Will that mess up the clutch or anything in the bellhousing. Was hoping we could just unbolt the gearbox, slide it off, get it repaired and bolt it back up. Is there anything inside that will fall out or off? We think he blew up third gear. Can you just remove third and run it or do you have to replace it. Just wanting to put it back together to run it a couple more times until we tear it down to swap in one ton stuff.
Let me know if Im missing anything here. Off to youtube to see if I can find some videos.

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Old 02-03-2012, 08:02 PM   #2 (permalink)
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You can unbolt the trans and leave the bell housing. You wont be able to just remove 3rd gear and run with out it.
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Old 02-03-2012, 08:12 PM   #3 (permalink)
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Thats what I figured. Anything I need to worry about? Ill probably leave the dana 300 attached until we pull it out, assuming the shifters dont get in the way of sliding the assembly back.

Anything special to get it back in?
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Old 02-03-2012, 08:21 PM   #4 (permalink)
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as long as your clutch is not disturbed the pressure plate should keep the clutch disc lined up. If it moves you can center it with an extension with a socket on it or a clutch disc alignment tool
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Old 02-03-2012, 08:27 PM   #5 (permalink)
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Both shifters (the T5 and Dana 300) will need to come off from the top in the cab. Then you can pull the trans and t-case together as an assembly, leaving the bell housing if you like.

When you have them on the ground, you will need to sepparate the trans and t-case so you can tear down the trans to replace the 3rd gear. When you crack the trans open, that's when things get fun.
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Old 02-03-2012, 08:31 PM   #6 (permalink)
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Tip: If you don't have a transmission jack, I would separate the D300 and the T5 and remove/install them separately.
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Old 02-03-2012, 08:37 PM   #7 (permalink)
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Both shifters (the T5 and Dana 300) will need to come off from the top in the cab. Then you can pull the trans and t-case together as an assembly, leaving the bell housing if you like.

When you have them on the ground, you will need to sepparate the trans and t-case so you can tear down the trans to replace the 3rd gear. When you crack the trans open, that's when things get fun.
Im going to do everything I can to not have to remove the shifters. Is that hard?
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Old 02-03-2012, 08:38 PM   #8 (permalink)
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Good call.

But let's throw a wrench into it:

You can pull the shifters, driveshafts and trans bolts, then put a jack under the skid plate, release the skid plate from the frame, drop down the assembly and pull back. Done deal.

Edit: my response was to theytookmyname's post.
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Old 02-03-2012, 08:40 PM   #9 (permalink)
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Im going to do everything I can to not have to remove the shifters. Is that hard?
It won't work and the shifter take 5 minutes tops to remove. 5 or 6 little bolts on the T5, pull up and it's out. Then the shaft nut on the D300. Rotate and slide the piviot shaft off the D300 and remove the lever. 5 Minutes tops.

Or you can leave them, wrestle around till you are wore out, then go back to step one.
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Old 02-03-2012, 08:49 PM   #10 (permalink)
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It is dumb to even try to pull it with the shifters. You will be miserable.

Pull the whole trans shifter tower with the 5 bolts, shove a rag in the hole, yank the 300 shifter, put the jack under the skid plate, pull the bellhousing to transmission and frame to skid bolts, and pull it all out just like Rttoys said. Easy.
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Old 02-03-2012, 10:22 PM   #11 (permalink)
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Alright Ill see if I can remove the shifters. The 300 has twin sticks so I thought it might be difficult to remove. Ill check it out tomorrow and take some pics along the way.
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Old 02-04-2012, 07:50 AM   #12 (permalink)
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Na, it's just as easy. Maybe a few more nuts and bolts, nothing difficult though.
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Old 02-04-2012, 09:12 AM   #13 (permalink)
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Na, it's just as easy. Maybe a few more nuts and bolts, nothing difficult though.
Yep.


It takes longer to try and get them out with the shifters installed, just take them off and save yourself time and energy. I tried to leave them installed the first time I dropped my trans and tcase and it made things a huge PITA.
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Old 02-04-2012, 10:01 AM   #14 (permalink)
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I appreciate all the tips. Gonna get started here soon.
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Old 02-05-2012, 09:07 AM   #15 (permalink)
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Got it out without much trouble. Removed the tunnel cover and shift boots first, then T5 shifter, attached ratchet strap from transmission to rollcage, dropped skid plate, loosened twin stick dana 300 shifters enough to fold them down but left them attached. Unbolted transmission and slid it back and dropped it down with the transfercase still attached.

Now just have to get it fixed and hope it goes back in as easy as it came out.
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Old 02-05-2012, 09:10 AM   #16 (permalink)
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And out.
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Old 02-06-2012, 10:19 AM   #17 (permalink)
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Where is the best place to order replacement parts for this T5?
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Old 02-06-2012, 10:24 AM   #18 (permalink)
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Told ya it was easy.

As far as parts. The few things I needed for mine (bearings and syncro), I was fortunant that there is a manual trans shop here in Houston that has just about everything, so I picked mine up local. On line, it's kind of endless.
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Old 02-06-2012, 10:34 AM   #19 (permalink)
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First place I found was quadratec. I guess thats as good as any. Are there prices reasonable? Looks like 3rd gear is either $79 or $99 depending on tooth count.

What should we replace while its apart?
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Old 02-06-2012, 01:31 PM   #20 (permalink)
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Quadratech is usually a little high. I'd look around a little and check our vendors here befor buying.

Check the input shaft bearing and retainer. Those usually take a beating. Overall, just look for anything worn, pitted or broke.
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Old 02-06-2012, 01:45 PM   #21 (permalink)
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Thanks for sending me the link to a lower price Rttoys. For reference here is the $53 third gear from tellico.
http://www.tellico4x4.com/product_in...oducts_id/5940
And their entire listing
http://www.tellico4x4.com/index.php/...0_508_6461_517

The only 3rd gear they show has 27 teeth. Wonder which one I have. Guess I will have to get the trans shop to count the teeth. Quadratec also listed a 29 tooth gear.
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Old 02-06-2012, 01:59 PM   #22 (permalink)
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Is it hard to change the seals on the dana 300? It seems like we have a leak in a few spots. I'd like to change out seals that are easy, but don't want to really tear into it. What do you guys recommend.
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Old 02-06-2012, 03:11 PM   #23 (permalink)
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My affordable transmission guy quoted me $950 to fix third gear and a some synchro's and some bearings or something. I stopped listening at $950.

Now we are looking for a gearbox to swap out. If we can't find one then we'll just start the one ton swap.
We really wanted to get one or two more runs out of it before we tore it down.

I'm searching for one.
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Old 02-06-2012, 03:22 PM   #24 (permalink)
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Is it hard to change the seals on the dana 300? It seems like we have a leak in a few spots. I'd like to change out seals that are easy, but don't want to really tear into it. What do you guys recommend.
For the outputs, pop the yokes off and change the seals like any other trans, t-case, or diff. I can't remember on the input, but I think it's just pop and go too.

.
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Old 02-06-2012, 03:28 PM   #25 (permalink)
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My affordable transmission guy quoted me $950 to fix third gear and a some synchro's and some bearings or something. I stopped listening at $950.

Now we are looking for a gearbox to swap out. If we can't find one then we'll just start the one ton swap.
We really wanted to get one or two more runs out of it before we tore it down.

I'm searching for one.
WHEN you can find a Jeep T5 used they are worth about $300. The hard part is finding one. The T4, T5 and T176 are all direct swaps (so is the SR4, but we won't go there). You can keep an eye out for any of them and be good to go. T176 would be the best swap, if yo are not worried about the 5th gear.

$950 is outragous. If you just want to make a few more runs, there are cheaper ways around it.

Where are you located?
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