Gray Sludge in my Automatic

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Got home from my trip to Colorado two weeks ago, and haven't driven the truck since. Today, I finally got around to dropping the pan to change the filter and see if there was any crap in the pan to be wary of. You bet there was!!

The magnetic drain plug on the Mag-Hytek pan I put on just before the trip (with fresh filter and fluid) was COVERED with about 1/8" to 3/16" of gray crud, and underneath it were black shavings.

Once I drained the rest of the fluid out of the pan, the bottom and sides of the pan were lightly coated in gray sludge also.

The filter isn't clogged, but it's dark from the gray stuff. The metal edge around the filter is gray too. The fluid didn't smell burned... just smelled like ATF.

I knew something was up due to the shuddering I'd get in fourth gear with the TC locked up, regardless of it being on level ground, going uphill, or slowing down against the exhaust brake.

The truck is a '96 3500 4x2 with 51,000 miles on it. The TC is a BD extra-tight unit, and I also have the BD valvebody in there. The TC has been in for 18 months, the valvebody for one year.

So... how bad does it sound? I was kinda hoping I could get a couple more months out of it so I could work out the financial details about getting a transmission from Bill Kondolay, since it's just not in the budget right now.

Rob


[This message has been edited by RobG (edited 10-01-2000). ]

 

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RobG,
It's toasted. Mine was exactly the same way. No matter how much you would like to think it isn't, it is. You are going to take you chances when driving with it, especially towing.

The grey sludge is think enough to write your name in I'm sure. It has gone through the whole transmission.

 

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Rob service manual says sludge is due to fluid break down creating sludge. This apparently caused by overheat condition. Discoloration is caused by this this also. Normal to have some debris in pan but not excessive. Also mentions coolant contaminating fluid, don't know if mixing green dye with red dye would cause grey color.
Recommends reverse flush of cooler and lines and replacing torgue converter.
Here is all possiblities in Manual.
fuid contamination
adding incorrect fluid, failure to clean dipstick and fill tube when cheking level, engine coolant entering the fluid, iternal failure that generates debris, overheat that generates sludge, failure to reverse flush after repair, failure to replace contaminated toque converter after repair.
Now the bad news kept going back wards found this one. " If fluid is black, dark brown, turned to sludge, contains extensive amount of metal or friction material particles, transmission will need overhaul. Main and auxiliary coolers and lines will have to be flow tested and reversed flush as well. "
Gray,sludge and excessive amount of metal in fluid looks like the diagnosis above.
Maybe others will have more knowledge and can pin point your problem and save you complete overhaul.

 

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Rob
I too am not an expert, but will give you the information I got when I had my transmission rebuilt. Both transmission places I talked to said the gray stuff in the fluid is from the clutch plates wearing - some is normal from what I understand; too much is not a good sign. And as far as the exhaust brake with the automatic... . from what I've read and heard, that hasn't proven to be the best combo - - generally. You probably have read enough about the weak Chrysler trannies in these trucks; chances are, that if you haven't had your transmission rebuilt by now, it may be your turn. #ad

 

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The gray sludge you see is ground metal,most likely aluminum. A little is normal,1/8 inch is too much especally since you changed it not too long ago. Sorry to say it but you've got a problem. Ever think about putting a new six speed in it?Thats what I'll do the next time my AT goes south. About $5k,heck thats only three AT rebuilds and a TPS for tax.



[This message has been edited by illflem (edited 10-02-2000). ]

 

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Rob, did the same service before my RV trip had about 6,000 miles on it from the last time. I had a very small amount of grey sludge on the magnet and just a slight amount in the bottom of pan. It was much better than the first time after about 12K from a complete rebuild.
I am hoping that this is normal and that perhaps it takes a while for the clutches to break in. I am going to change fluid service again at 6,000.