Manual Transmission 6 speed problems

Liberty for All · **Posted:** Thu Oct 13, 2011 12:35 am

Hey folks,
My 2005 Sport is having big problems shifting into first, reverse and occasionally other gears, This happened only recently.
Is it the hydro Master Cylinder, the Slave cylinder or is it because the "lifetime trans fluid" is wearing out after only 35K miles
and needs replacing?

I never abuse my Jeep but used to live in the City and shifted it often each trip.

I would like this thread to also be a place where those of us with these German built transmissions can talk about
maintaining and repair tips.

Please help me so I don't get burned at a garage for repairs not needed.

Thanks D

XJMA · **Posted:** Thu Oct 13, 2011 11:10 am

First thing would be to check the fluid level in the clutch master. If it's down, you know it's a hydraulic clutch problem.

We have an 06 KJ at work with the 6 speed - we take it on powerline ROWs all the time and beat the crap out of it....never a problem and it's got over 80k hard miles on it.

If the hydraulic clutch is fine have someone lay on the ground next the the vehicle with it running, in neutral, and see if they hear any noise when you press the clutch in. You said you've got an 05 with only 35k!! That's a lot of sitting around. Maybe the throwout bearing has gone bad?? Are you hearing any noise from the clutch at all?? I'm not sure if there is any adjustment on the KJ clutch?? If you can't find anything wrong, change the fluid and inspect the old fluid.

TheJawsOfDeath · **Joined:** Sun Nov 05, 2006 3:56 am **Posts:** 305

Since your main problems are shifting into first and reverse it sounds like your clutch might be dragging. The seals in the master or slave cylinder could be faulty or you could have a leak, either way you aren't disengaging the clutch all the way. Definitely check the fluid level and check for leaks. Get the Jeep in the air with the wheels off the ground. Put it in gear and hold the clutch in. The wheels shouldn't be turning, if they do it's a dragging clutch. There will be a line or ring on the master cylinder to show you where your fluid level should be. it's worth noting that the fluid level in the master cyl reservoir will actually increase with clutch wear. If it's above the line that indicates a worn friction disc.

One other thing to check is does your shifter feel sloppy? The shift lever is a 2 piece design with a rubber bushing between the two halves. It's held on with a torx bit and located under the shift boot. Mine came loose causing a lot of play and hard shifting. You can tap down directly on top of the shift knob and it'll push it back into place.

The other poster is right on about the throwout bearing noise. neutral, clutch in, should be quiet. The other possibility is the pilot bearing. The end of the input shaft rides in that bearing in the back of the crankshaft, and it'll be turning when you have the clutch in so that can also make noise if it's going out but it seems pretty unlikely at 35k miles. If it's noisy in neutral with the clutch OUT, you've got something wrong like an input shaft bearing.

Liberty for All · **Posted:** Thu Oct 13, 2011 4:26 pm

OK,
I will find a place to get the Jeep up in the air and listen for what you guys stated.
Much of the driving was done on hills and in City traffic so maybe there is the wear time.

You said that as the clutch wears it causes the master to fill up more correct?
Mine was a little low and I added some brake fluid. It helped a little.

If noise or vibration is detected when I put the Jeep up then should I just have both the throwout bearing and the pilot bearing both replaced?

Where is the slave clutch cylinder located? I cannot see it.

Should I replace both the cylinders or can you rebuild them with new parts?

And also, who has replaced the transmission gear oil? At what mileage and with only the Mopar recommended synthetic or other aftermarket?

I do not want to mess up the trans and hope the Liberty will last me a few good years more.
I will phone Chrysler to see if this comes under the 7 year warranty.

JeepinJarhead03 · **Posted:** Thu Oct 13, 2011 7:03 pm

throwout bearing - if you replace it, replace pilot at same time that's just standard procedure since the process to replace one or the other pretty much requires the same steps and they're cheap enough there's really no reason not to replace them

gearoil = chrysler synchromesh - i think Pennzoil synchromesh has the 9224 stamp - i usually replace straight drive gear oil same time i replace transfercase juice bout every 15k "adios contaminos"

http://www.howstuffinmycarworks.com/How ... works.html
should help you understand throwout's, the slave, etc

the slaves on the side of the transmission, follow the hydrollic line down to it, pull the rubber grommet back and check for fluid behind the grommet

the clutch and slave come pre-assembled with tubing and everything and prefilled

however I have seen bleed-able slaves on the replacement parts shelves for the 6 speed lately for between 40-70 bucks

Liberty for All · **Posted:** Fri Oct 21, 2011 12:08 am

Thanks all,
I twisted off the Master cap and added some fluid. Then pumped the clutch pedal a few times and re installed the cap.
After driving the Lib to work and back the next day, the clutch seemed firmer and no more shifting problems.

The question still is where did the original fluid go? If a leak is somewhere in the clutch hydrolics, I cannot so far see it.
Would a leak be most likely in the seals? If so, then the problem would come back again. So far this week shifting is OK.

In a pinch if I need to top off the master, can I use brake fluid or power steering fluid?
One guy told me that as the clutch wears down, the fluid level can rise.

Jar,
You have had good results with the Pennsoil trans fluid? I have been told to only use the Jeep recommended synthetic stuff.
The manual says it is lifetime and only needs topping off.

When I have a chance, I will also take off the boot on the shifter and see what that link looks like and if it needs tightening.

Manual Transmission 6 speed problems

Who is online