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Jeep Wrangler Transmission Spotter’s Guide
AX-15 – 5-Speed Manual Jeep Wrangler: 1988.5 - 1999 with 4.0-liter Inline 6 Factoids: Replaced weak Peugeot BA10 gearbox Related to Toyota Supra Turbo R154 manual Best 5-speed ever installed in a Wrangler Spotting Tips: All-aluminum case & mid-plate, generous ribbing Only mounts to a six-cylinder engine 10 spline input shaft 23 spline output shaft Length: 16 1/2” Spline Stick-out: 7 1/8” Gear Ratios: 1st 3.83, 2nd 2.33, 3rd 1.44, 4th 1.00, 5th 0.79 AX-5 – 5-Speed Manual Jeep Wrangler: 1984 - 2006 XJ, YJ, TJ with 2.5-liter Inline 4 Factoids: Failure prone 5th gear, poor synchronizers, throwout bearing leaks (pre ’94) AX-5 variants include Toyota G52, W58, and R151 Spotting Tips: All-aluminum case, cast iron mid-plate Looks like AX-15 so be wary Only mounts to a four-cylinder engine 14 spline input shaft 21 spline output shaft Length: 15 5/8” Spline Stick-out: 7 1/2” Gear Ratios: 1st 3.92, 2nd 2.33, 3rd 1.44, 4th 1.00, 5th 0.85 NV3550 – 5-Speed Manual Jeep Wrangler: 2000 - 2004 Wrangler with 4.0-liter Inline 6 Factoids: Replaced AX-15 Compatible with 23 spline version of NP231 transfer case Spotting Tips: All-aluminum case 10 spline input shaft 23 spline output shaft Length: 16 3/4” Gear Ratios: 1st 4.01, 2nd 2.32, 3rd 1.40, 4th 1.00, 5th 0.78 NSG370 – 6-Speed Manual Jeep Wrangler: 2005-up Wrangler, 2004-up Wrangler Rubicon Factoids: Replaced NV3550 Compatible with 4.0-liter I6 and 3.8-liter V6 Spotting Tips: All-aluminum case with extensive ribbing 10 spline input shaft 23 spline output shaft Length: 23 1/2” w Inline 6 bellhousing Length: 24 3/4” w/ 3.7-L V6 bellhousing Gear Ratios: 1st 4.46, 2nd 2.61. 3rd 1.72, 4th 1.25, 5th 1.00, 6th 0.84 Shop Re-Manufactured Transmissions
Tools of the Trade: Yukon Driveline Tools
From weekend warriors to master builders, craftsmen worldwide know that no matter what you’re working on, it’s all about the tools. For the mechanic, having the right tools is the difference between a smooth well-executed job and running around trying to find ‘something that works’ —most likely a screwdriver or other blunt, ill-advised tool—just to get the vehicle off the lift. But the difference between getting a job done and getting a job done right, is the proper tools. Yukon knows differentials and in our 40-plus years in the industry we have pioneered many specialty tools just for drivetrain work. From specialized bearing pullers, to simple shim drivers, make it easy on yourself by investing in the proper tools for when a vehicle pulls in with that elusive “vibration in the rear.” Tools are an investment that will build your business. There are four critical steps that ensure a strong, quiet, and long-lasting differential. A high-quality pinion depth-setting tool and a specialized inch/pound torque wrench is to install the pinion gear and set bearing preload. After that, specialized spanner tools or shim drivers allow you to dial in the backlash and carrier bearing preload. Yukon has developed more than 80 different tools that streamline differential and drivetrain assembly. Here are some top sellers to consider: YT P20 / YT P22 Yukon Bearing Pulling Set – These bearing pullers simplify bearing removal for those without a press. They feature different clamshell sizes for a clean, quick and simple way to remove a bearing quickly and without risk. YT SD-01 Shim Driver Set – This set addresses Ford, GM, Chrysler, and many other housings. These half-moon, heavy-duty cradles are perfect for replacing the much-maligned screwdriver, punch, or pry bar so you get the job done right the first time. No more chipping shims or hammering screwdrivers to set your shims. YT BD Bearing Race Driver – Yukon as developed more than 20 race drivers for different applications and they all will make your life easier because they accurately drive races and produce a perfect alignment for the right fit. These drivers are built to take a hammering, which is exactly what’s required to properly set bearings. The tool keeps your races centered and straight and works much better than using a socket or even the bottom of the closest beer can. YT A06 Side Adjuster Tool – It’s almost impossible to reach the recommended adjuster torque of 150+ foot pounds without having the proper tool for side adjustment. Although this tool has a very singlular purpose, it’s exactly what’s needed to get the job done right. No more stacked extensions and cobbled together drivers to get the perfect fit. Yukon also offers bolt extractors kits, spanner tools, spindle boring cutters and more to outfit a shop that wants to do the work and do it well. Tools are an investment that will build your business. Invest in the best, Yukon driveline tools. Shop Yukon Differential Tools
Tools of the Trade: Yukon Driveline Tools
From weekend warriors to master builders, craftsmen worldwide know that no matter what you’re working on, it’s all about the tools. For the mechanic, having the right tools is the difference between a smooth well-executed job and running around trying to find ‘something that works’ —most likely a screwdriver or other blunt, ill-advised tool—just to get the vehicle off the lift. But the difference between getting a job done and getting a job done right, is the proper tools. Yukon knows differentials and in our 40-plus years in the industry we have pioneered many specialty tools just for drivetrain work. From specialized bearing pullers, to simple shim drivers, make it easy on yourself by investing in the proper tools for when a vehicle pulls in with that elusive “vibration in the rear.” Tools are an investment that will build your business. There are four critical steps that ensure a strong, quiet, and long-lasting differential. A high-quality pinion depth-setting tool and a specialized inch/pound torque wrench is to install the pinion gear and set bearing preload. After that, specialized spanner tools or shim drivers allow you to dial in the backlash and carrier bearing preload. Yukon has developed more than 80 different tools that streamline differential and drivetrain assembly. Here are some top sellers to consider: YT P20 / YT P22 Yukon Bearing Pulling Set – These bearing pullers simplify bearing removal for those without a press. They feature different clamshell sizes for a clean, quick and simple way to remove a bearing quickly and without risk. YT SD-01 Shim Driver Set – This set addresses Ford, GM, Chrysler, and many other housings. These half-moon, heavy-duty cradles are perfect for replacing the much-maligned screwdriver, punch, or pry bar so you get the job done right the first time. No more chipping shims or hammering screwdrivers to set your shims. YT BD Bearing Race Driver – Yukon as developed more than 20 race drivers for different applications and they all will make your life easier because they accurately drive races and produce a perfect alignment for the right fit. These drivers are built to take a hammering, which is exactly what’s required to properly set bearings. The tool keeps your races centered and straight and works much better than using a socket or even the bottom of the closest beer can. YT A06 Side Adjuster Tool – It’s almost impossible to reach the recommended adjuster torque of 150+ foot pounds without having the proper tool for side adjustment. Although this tool has a very singlular purpose, it’s exactly what’s needed to get the job done right. No more stacked extensions and cobbled together drivers to get the perfect fit. Yukon also offers bolt extractors kits, spanner tools, spindle boring cutters and more to outfit a shop that wants to do the work and do it well. Tools are an investment that will build your business. Invest in the best, Yukon driveline tools. Shop Yukon Differential Tools
How It Works: Spider Gears - Video
Spider gears are primetime players inside the differential. Also known as satellite gears, spider gears rotate around the side gears in the differential carrier. Side gears may also be referred to as axle gears or planetary gears. To spot spider gears look for the gears with the cross-pin shaft going through them. Read this article in Español What Gears Do The diff’s array of spider and side gears take the rotational energy from the driveshaft and help redirect it outwards to the axles and on to the tires. More importantly, they also play a key role in allowing the tires to rotate smoothly at different speeds when the vehicle is turning. Gears In Trouble Broken spider gears will make a grinding or banging sound when the vehicle is turning because the difference in wheel speeds causes the chatter. You usually won’t hear them when traveling in a straight line because the spider gears remain motionless within the carrier in this instance. But, if they are bad enough, compromised spider gears will make noise even when going straight. When you hear a loud differential think of metal flakes being formed and circulated throughout the unit, usually damaging the vulnerable bearings first. So, noise means trouble. In some cases, the damage may not be the gears themselves. When the spider gears are in motion they rotate on the cross-pin shaft, especially when the vehicle is turning a corner. But there are situations that can cause over spinning and the result can be a heat-scored cross-pin shaft. A common scenario is getting stuck in the mud or snow and free spinning your wheels trying to break free. When this happens, the spider gears can rotate on the cross-pin shaft so quickly that the differential oil is slung away, resulting in metal-on-metal wear. In extreme cases the cross-pin shaft and the gear get so hot that they melt each other, sometimes to the point where they weld themselves together. Damage such as this can not only damage the spider gear set, but also destroy the carrier and ring and pinion gear set. Spider Gear Replacement When replacing spider gears you are, in fact, replacing both the spider gears and the side gears. Over the miles these gears mesh and wear in unison, so dropping in new spider gears with the original side gears can cause an imbalance. Yukon Gear & Axle and USA Standard Gear spider gear kits include two side gears, two pinion gears, a cross pin shaft, a roll pin, and thrust washers. Installation is relatively straightforward. For a more in-depth look, view the accompanying installation video from our YouTube channel. contact us at 866-631-0196 Shop Spider Gear kits
Chromoly: The Science Behind Yukon Performance Axles
Chromoly… the utterance of the word conjures images of superhero strength. The word is derived from chromium and molybdenum, the two main alloying elements of the metal. Chromium brings three major benefits to the table: innate hardness, improved pliability during the quenching process, and outstanding corrosion resistance. Molybdenum also serves to increase the alloy’s hardness. When it comes to performance axles the use of chromoly results in axles that can handle the added stress that comes with running larger tires, adding aggressive traction devices, and other parameters like how aggressively you approach off-roading. Their superior resistance against breakage, distortion, and corrosion mean more peace of mind on the trail or the track. Yukon uses 4340, a high-quality nickel-chromium-molybdenum alloy in the manufacturing of forged gears, pinion gears, high-performance axles, Super Joints, and more. Machining A Yukon Axle Shaft The majority of machining on an axle shaft is done prior to heat-treating, but some applications have machine work that is done post heat-treat. Typical machining procedures include grinding/polishing bearing or seal surfaces, forming flanges and wheel pilots, drilling stud holes, milling ears for full circle clips, boring u-joint holes, balancing etc. Spline creation is the most important machining processes in axle creation. This is a “there are many ways to skin a cat’ scenario. The cutting method which includes spline milling, rotary broaching, bobbing machines, and disc cutting is one part of the equation. Then there’s the spline rolling method which uses CNC machinery to form the splines by the displacement of metal, not the removal of metal as found in cutting processes. Yukon machines its splines by cold roll forming on almost all of its axle applications. Akin to the principles of forging, the axle shaft is subjected to a great deal of pressure via tooling in the machine that contains the splines, both the shape and number determined by the design specs. In only a few revolutions the cam-like tooling dies imprints the shaft with splines. This is the best, most high-tech way to make splines and the advantages of this process are many. The high pressure involved in creating the splines re-arranges the grain structure of the metal throughout the entire tooth profile. This ensures consistent hardness throughout the spline teeth and shaft. Further, the magic happens at room temperature so the final product maintains its tensile strength and hardness, has greater yield, and the process produces superior surface finish versus methods that cut or extrude the splines. This level of attention to detail results in an axle that you can count on in the most trying terrain. Strength Of A Caped Crusader Stock axles are typically made of medium-carbon 1039, 1050, or 1055 alloys, and in some cases 1541 series steel that is forged and heat-treated or hardened. What to call this strengthening process comes down to semantics… it can be called either heat-treating or hardening because heat treating is the procedure and hardening is the result… think cause and effect. Chromoly is a dynamically stronger metal than 1000-series alloys and since one is starting with a superior alloy heat-treating it only improves the material. The goal is to alter the properties of the metal on a molecular level, producing a tighter grain structure that changes the hardness, strength, toughness, ductility, and elasticity of the material in a beneficial way. Types of Hardening/Heat Treating There are two general types of hardening: case hardening and thru hardening. Case hardening only treats the surface layer while thru hardening penetrates to the center of the material. Thru hardening takes place in a furnace where the intense heat has the time to work into the core of the metal. There are a number of methods for case hardening which is the most popular heat-treating technique for stock and performance axles. Induction Hardening This type of hardening has been popularized by OE manufacturers. Induction hardening is fast, economical, effective, and controllable. Speed comes by not having to heat the entire component to its core. With the speed comes an economy of scale as more axles can be treated in a given timeframe, therefore lowering the overall treatment cost per axle. Effectiveness is the production of a part with a surface that is resistant to wear but maintains the toughness and strength of its core. Controllable in that the process can be used to selectively harden areas of a component without affecting the properties of the entire piece. For instance, some original equipment axles are only induction hardened up to the bearing mount surface near the flange. Induction hardening is the method Yukon uses on its entire line of performance axles. The process starts with an axle shaft that has likely been fully machined with splines etc. The shaft is heated with an induction coil to a predetermined temperature usually between 1,550- and 1,600-degrees Fahrenheit then quenched. Quenching is basically dousing the part with water or dropping it in an oil bath to quickly cool it. Yukon’s quality assurance staff tests axles from random production batches to ensure they receive proper heat treating and measure up dimensionally to engineering blueprints. Carburizing Carburizing is somewhat similar to induction hardening but it changes/improves the mechanical properties of the material by introducing a new component. Induction coils, or other heating elements, bring the metal to a high temperature. The steel substrate is then exposed to an external source of carbon (gas, liquid, or solid) to form carbides on the surface of the steel. The material is then quenched to seal the deal. Nitride Hardening Nitriding is a play on the carburizing method except nitrogen carrying substances (ammonia) are infused into the substrate instead of carbon. The surface coating process results in the formation of nitrides on the steel substrate. This particular case hardening process is chromoly specific because nitrides can only be created on metals that contain the elements chromium and molybdenum. Nitride hardening differs from other case hardening techniques in that lower temperatures are used in heating and the quenching step is skipped altogether. This can be beneficial because less heat and less quenching shock produces less distortion in the final product. Yukon does not employ this process because the nitride infused surface does not benefit axle performance, the process is expensive, and it takes longer. Tempering Tempering refers to repeating a heat-treating process until a desired hardness is attained. The Benefits Of Hardening Axles The ultimate goal of heat-treating an axle is to create a hard, abrasion resistant outer microstructure while retaining the steel’s tensile strength within its core… bulletproofing if you will. The result is an axle shaft that can take a pounding, endure a great deal of friction wear, and also possess the torsional strength to absorb the twisting forces encountered in high-traction-demand situations. Need a caped crusader in your drivetrain? Getting serious in your off-roading, planning to run bigger tires, need to replace an axle and want the best?... Yukon goes the extra mile at every stage of chromoly axle development; design, manufacturing, and quality control so you get an axle that will absorb the most extreme off-road punishment for years to come. contact us at 866-631-0196 Shop Yukon Chromoly Axles