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The new 45220 cup OD measures 4. 125" which matches the specs on Timken's website. The "Bad" cup OD measures 4. 138" to ~ 4. 141". It doesn't appear to have spun in the housing. It does look like there was a lot of heat and wear on the tapered face. See pic below, its fairly obvious the old vs...

I started reassembling the transmission today, using a cherry picker I lowered the input/output and counter shafts into the bellhousing along with the shift forks. It was a little tricky getting everything lined up while slowly lowering making sure nothing was binding. Got that all done and then...

My only theory at the moment is that the trashed rear bearing allowed enough endplay/chatter into the output shaft to allow the syncro to accidentally engage two gears at once, possibly 3rd and 4th. I seriously doubt the rear bearing alone could seize the entire driveshaft/axle.

Figured you guys might get a laugh at a couple of these pics, some of these press setups have been real sketchy. Definitely a two man job, one guy to work the jack, another to hold and then catch the shaft assembly once the bearing pops off. One problem area, had to cut out the outer race on the...

The stand is an old squat rack I had lying around, used that along with a hand winch to lift off the transmission case. Wasn't pretty but it worked.

It wasn't too difficult, the hardest part believe it or not was getting the 3 10mm starter bolts loosened. I had to bring out the torch on those guys and couldn't really get a socket on them to break them loose. And bringing the transmission down was a little sketchy, I didn't get the CG centered on...

I dropped the transmission this morning, pulled the case off, and started looking for anything out of the ordinary. The only thing I noticed was the rear tapered bearing on the end of the output shaft. It looks like it has been running hot and dry. I also noticed before disassembling the transmission there...

Hey guys, I got the truck towed back to my house today. Started troubleshooting, jacked the truck up on all 4 corners. Rear diff is fine. There was a noise/chatter coming from the transmission, only noticeable when applying brake pressure while idling in gear. It doesn't sound like a bearing. I kind...

Hey guys, I found this DIY guide on another website. What am I getting myself into! DIY: Transmission Work NV5600 - DodgeForum.com AEdelheit, this write up actually mentions spreading the frame rails. Who would have thought. "To get the cross member out I used a port-a-power to spread...

I completely agree, it is a little out of the my DIY capabilities but would be a good thing to learn to do. At the very least I'd like to pull the transmission myself and then take it to a rebuild shop. Thanks again for all the feedback...

Anybody know of a good DIY guide to pulling the transmission and replacing the rear bearing? Has it been covered in a TDR issue in the past? I try to avoid taking my vehicles to a shop but this job has got me a little worried!

Thanks for all the responses, I think I've got a good idea where to start troubleshooting. I'll dig into it this weekend and let you all know what I find...

The truck has almost 160k miles on it, I've only owned it for 2 years and put ~15k miles on it. When I bought the truck, the previous owner had an impressive stack of service records from a local dealership which led me to believe it had been well taken care of. I believe the transmission fluid...

Looks like the consensus so far is the transmission, and I thought the 6spds were supposed to be bulletproof! Once I get it towed home I'll jack it up as described and start troubleshooting. Scary to think if this failure would have happened while doing 65mph on the highway. Thanks again for...

I was driving home last night, slow right turn, push in the clutch to downshift as I'm turning, rear tires lock up and truck slides to a stop. Both rear tires left a nice 10ft skid mark on the pavement. I try to move, tires still locked, put it in reverse and move backwards slightly, then back...