Engine/Transmission (1998.5 - 2002) Stuck Stickshift

[Schmidtski]

I have a 1999 2500 with an NV4500 transmission that seems stuck, and I would appreciate any and all advice as I am much more of a carpenter than a mechanic.

I was coming home last night from a hunting trip in the mountains, during which the truck performed flawlessly in 2H, 4H, and 4L over rough forest roads with a slide-in camper on top. As I came into town on 2H, the stick suddenly wouldn't go into 3rd gear. I pulled over and turned off the engine. With the engine off, the stick moved normally into all of its positions. (So did the shifter for going from 2H to 4H.) With the engine on, the stick wouldn't move into any of the positions. While waiting for a tow, I got the (probably stupid) idea that I could maybe put the truck into 1st with the engine off, keep the clutch pedal pushed down, and start it up. With the clutch pedal down, the truck lurched forward, so I just turned it off and got towed.

Today, the stick won't move at all and doesn't feel like it's in neutral. I checked the oil level in the transfer case, but it's full and the oil looks light brown.

Thanks in advance for any ideas about what sort of trouble I've got myself into.

 

[petersonj]

I got the (probably stupid) idea that I could maybe put the truck into 1st with the engine off, keep the clutch pedal pushed down, and start it up. With the clutch pedal down, the truck lurched forward, so I just turned it off and got towed.

Two things come to mind - either the clutch pressure plate is not releasing or a pilot bearing has seized on the transmission input shaft. If it is the clutch pressure plate not releasing (failure of pressure plate, throwout fork, or hydraulics), clutch pedal effort should have had a noticeable change in feel.

You said, "Today, the stick won't move at all and doesn't feel like it's in neutral. I checked the oil level in the transfer case, but it's full and the oil looks light brown"

You did not say where and how the truck was parked after it got towed. If the truck is parked in gear on an incline, it would be very hard to get it out of gear without relieving the load on the drive train. You may have to use another vehicle with a tow strap to relieve the drive train load while someone in the cab places the transmission into neutral.

Also, wouldn't it have been more relevant to check oil in the transmission versus the transfer case?

- John

 

[Schmidtski]

Thank you very much your reply and suggestions, John. I guess I didn't use the right terminology when I said "transfer case". It was the transmission, with PTO covers on each side and the fill plug high on the passenger side of the, er, case. I'll give clutch effort more oomph tomorrow. Also, the truck may be on a slight incline, so I'll also give the tow strap a try, too. Much appreciated.

Tom

 

[petersonj]

Actually, you could just use your jack to raise one rear wheel off the ground to free up the drive train. Just be sure to block another wheel first to prevent the truck from rolling. Don't forget to release the park brake.

- John

 

[BigPapa]

Man, we’re going to miss Gary.

I agree with John, sounds like a clutch problem. Mine did this when the clutch hub came apart. I was able to limp 50 miles to the shop by starting in gear and “speed shifting” then shutting it down when I had to stop. More pressure on the clutch pedal won’t help with any of these issues. You’re going to have to pull the transmission.

 

[Schmidtski]

Thank you, gents. I managed to get the stick back into neutral this morning by pushing down real hard with both feet.

 

[BigPapa]

If it will pump up or you can press harder/further to get the clutch to release, you could have a hydraulics issue. That would be great.

Wait, did you say it was still pulling with the transmission in neutral?

 

[Schmidtski]

Any chance this problem could be caused by the clutch's hydraulic system? Some people say the clutch master cylinder can fail without visible leakage, and same with the slave.

 

[BigPapa]

Guess you didn’t read my post above…..

 

[Schmidtski]

Sorry BigPapa, I didn't see your reply before posting my last. No, the truck was not pulling in neutral. I'm hoping it's hydraulics, because replacing those looks like a pretty easy fix, especially with a sealed kit.

 

[petersonj]

I'm hoping it's hydraulics, because replacing those looks like a pretty easy fix, especially with a sealed kit.

I am going to guess that this is not the problem, mainly because the problem came on suddenly and you didn't mention that clutch pedal effort felt any different after the problem surfaced..., but, it is only a guess.

- John

 

[BigPapa]

I’d definitely look at the hydraulics before pulling the transmission.

 

[Schmidtski]

Thanks again, both of you. John, as I've given the lead up to this incident more thought, I realize that there were other times stretching back a couple of months when I've been surprised by difficulty getting the truck into gear, usually first or second gear and usually when just setting off while the engine temp was warm (95 degrees or so) but not at full operating temp. I just thought shifting was a little stiff, needed some running time to loosen up, or that I was just being too careless with shifting. Anyway, it always resolved. By saying that this "suddenly" happened, I should have said that it suddenly got a lot worse and extended to other gears.

And Scott, I'm planning to replace the hydraulics tomorrow. If that's not the problem, at least I won't have to worry about them going bad for a while.

Thanks again for helping me (and my great truck) out with this.

 

[petersonj]

I appreciate the clarification regarding the clutch pedal effort. Hopefully, the replacement hydraulics will be your fix.

- John

 

[Ozymandias]

Sounds very much like the clutch.

By the way, a stick shift can be driven safely without the clutch pedal at all.
Drive it like an unsynchronized transmission by pulling the gears in and out, synchronizing it with the throttle pedal.
Start out in second gear, proceed from there up and down through the gears, if needed to come to a full stop stall it or switch it of with the key, watch out for the steering interlock. It's not a lot of fun going through a city that way but highway driving is fairly easy.

No need to spend hundreds or even thousands of Dollars to get a tow truck out into the boonies for this specific fault.

 

[Schmidtski]

Sounds very much like the clutch.

"By the way, a stick shift can be driven safely without the clutch pedal at all."

Great advice, sir. Would have saved my bee-hind up in the Gravelly Mountains if this problem had developed just a couple of hours sooner.

 

[petersonj]

By the way, a stick shift can be driven safely without the clutch pedal at all.
Drive it like an unsynchronized transmission by pulling the gears in and out, synchronizing it with the throttle pedal.

I did that very thing with a 1956 Kenworth many years ago. I was driving for Coast Transport out of Portland, Oregon. I had just dropped a load of produce in Vancouver, B.C. I called the dispatcher for my next assignment and he said I needed to drop my trailer and pick up another trailer from a disabled tractor that was headed to Portland. The tractor had a missing clutch linkage rod, so they were going to have the tractor towed. I told the dispatcher to leave the tractor with the clutch problem connected to the trailer, that I would bring them both back to Portland. He said, "You can do that?" I said, "Yes, I can."

I gauged all of the traffic lights, sometimes just idling along in first gear. I only had to come to a complete stop three times, the third time was to back it into the Portland yard.

Driving was different back then.

- John

 

[NIsaacs]

I did that very thing with a 1956 Kenworth many years ago. I was driving for Coast Transport out of Portland, Oregon. I had just dropped a load of produce in Vancouver, B.C. I called the dispatcher for my next assignment and he said I needed to drop my trailer and pick up another trailer from a disabled tractor that was headed to Portland. The tractor had a missing clutch linkage rod, so they were going to have the tractor towed. I told the dispatcher to leave the tractor with the clutch problem connected to the trailer, that I would bring them both back to Portland. He said, "You can do that?" I said, "Yes, I can."

I gauged all of the traffic lights, sometimes just idling along in first gear. I only had to come to a complete stop three times, the third time was to back it into the Portland yard.

Driving was different back then.

- John

I hauled logs with a late 40's model KW, 5x4, 220 powered with a backdraft manifold. I would use all 20 gears so I could listen to the stack cackle

 

[Schmidtski]

Well...I delayed replacing the clutch hydraulics because I decided to buy the kit through Geno's. Came today. Great kit, super easy install, but apparently the hydraulics weren't the problem. Still scratching my gritty head...

 

[BigPapa]

Dang it, Bobby. Going to have to pull it.