Engine/Transmission (1998.5 - 2002) 02 6 speed hard to get into gear at stop light.Clutch not releasing

[d-iron]

2002 with 64000 mi has been getting harder to get into gear. If you are setting at stoplight, you push in clutch and count to three then it will go into 2nd. If you keep it in gear and clutch in it works fine. It seems like I should adjust the clutch for less free play to make sure clutch is releasing full. Had a look It looks to be all sealed unit. This problem has just come up in the last year. The only real work this truck sees is car hauling trailer 3 x a year and two place snowmobile trailer in winter. Anyone else having this problem??

 

[DCreed]

check pilot bearing

 

[ILIANBG]

Have you changed your transmission fluid yet? If not try it. It was a different experience for me when I did that.

Ilian

 

[GCULP]

mine acts the same way, 2nd or reverse both are tricky, I think it's the nature of the beast.

 

[jeepit]

Same here. Changed fluid seemed to help for a while and then back to the same kind of shifting...

 

[Gregg Mig]

Had the same problem with my truck last year with 43000 miles on it, took it to the dealer for a new lift pump and vp, and told them I was having trouble shifting into first,second,and reverse,they said it was the synchros,so they pulled the transmission and rebuilt it with what they said was updated sychros. truck seemed to be better,but funny thing is when Im using 4X4 for plowing it just does not want to go into gear from a dead stop,and thats how it was last year,it was during the winter when I was plowing. When Im not in 4X4 it goes into gear ok. Still slow to respond but goes in. I brought it back to the dealer this winter and they said it was fine,as usuall

 

[JFlagg]

Mine is the same way, second and reverse are tough. After reading alot of posts on here, I have come to the conclusion its just the way it is. Seemed a little better after fluid change, but back to normal a few K later. Its not unbearable, so I just live with it.

 

[Gregg Mig]

J you could be right, its probably from all of the turning mass, the gears in these trannys are huge and heavy. I have my CDL liscense and sometimes drive some big trucks and they go into gear slow and sometimes hard!

 

[JFlagg]

J you could be right, its probably from all of the turning mass, the gears in these trannys are huge and heavy. I have my CDL liscense and sometimes drive some big trucks and they go into gear slow and sometimes hard!

I've also got a dual disc in mine, so I'm sure that doesn't help alot either:-laf

 

[d-iron]

I did change the transmision fluid a year ago, and It was better for a few months. Maybe the wonder fluid that can only be purchased from D/C is not as great as as D/C thinks . Has anyone heard of any other (gear oil) that can be used??Thanks for the help

 

[GCroyle]

Freeplay

D-Iron



Back to one of your original questions. Freeplay adjustment. These trucks were not built with any freeplay or any provision for adjusting the clutch. It is hydraulic and does not have any return spring on the fork to pull the bearing back, creating freeplay. The slave cylinder has an internal spring that pushes on the fork all the time, creates preload, bearing turns continously.

If you feel freeplay, that deserves inspecting further.

Pilot bearings have failed and caused the input shaft to contimue to rotate just enough to keep the disc spinning, makes it hard to pull into gear, when they lock up (total failure), the input shaft turns with more "authority".

Another overlooked cause for shifting problems has to do with the build up of rust that occours with time on the input shaft splines. This corrosion does not allow the disc to float free during shifts and you get hard standing start gear selection. Input shafts should be thouroughly cleaned and run some Scoth Brite in each tooth valley to polish them up, then you can put a LIGHT FILM of hi-temp wheel bearing grease to the input shaft, slide the disc on, then wipe up the excess.

If it is gear specific, then the above is just general information.

 

[RonA]

Mine was very difficult to get into gear while sitting at a light. I took it out and did the ball bearing pilot mod. The difference was like night and day. It's been about 8 months have not had any more issues.

Gary,

I'm interested in trying one of the Zoom clutches on a modest hp truck. Have questions.

PM?



Ron

 

[DCreed]

thats three votes pilot!!

 

[ILIANBG]

I would like to learn more on that ball bearing pilot mod. It's the second time someone has mentioned it. Where do you get it from?