Had modified mainshaft put in 5sp trans.

[LWilliams]

My 96 3500 4x4 with 124k finally lost 5th gear. It was painless and uneventful. Up till this point I have had absolutely no problem. It gave no warning. It just went away. I ordered the upgraded mainshaft, new 5th gear and nut, thrush bearing, clutch and pressure plate. I did not want to have this happen again so rather than try to retighten the old nut I opted to fix it right. I have onboard hydraulics that run off of a pto mounted on the right side of the transmission. I also have a GearVendors aux. trans. on the rear of the transfer case. The guys at the trans shop took a deep sigh when they looked under there for the first time. The old mainshaft, gear and nut were in perfect condition. The nut had just simply backed off and the gear slid out of position. The odd thing to me was that there was NO locking system used to keep the nut tight. It had NO set screws nor washer of any kind. It was just a nut screwed up against a gear. I don't know how it stayed there as long as it did. The new nut has set screws and was installed with a coat of loctite and after it was tightened a punch was used to mar the threads behind the nut. The upgraded mainshaft has the splines that run the entire length of the gear which is the way it should have been to start with. As for the thrush bearing, it was still smooth but was not near as tight as the new one, this is expected. It would still have lasted a long time. The clutch, even with 124k miles, still looked almost like new. I was amazed. I pull a 34ft dual axle tandem dovetail with a 16k lb tractor or 17rolls of hay every summer and I expected the clutch to be worn. I could not visably see any wear. I know this note is long but if you are wondering about your 5th gear, maybe this will help your feelings. It's not "if it will happen to you" but "when".

 

[Sled Puller]

Larry,
Sounds like the driver has more to do with clutches and 5th gear nuts than anything else. I think you done good.
You say you were loaded a lot. Did you lug in 5th? Or when you were loaded did you stay in 4th with the RPMs up?
I changed my shaft at 90,000, and the old one was perfect. I never lugged it, always flat out.
I see the guys looseing 5th with real low miles, and I wonder what their driving habits were. Still a factory screw up, but we will never see money out of it.

I think your clutch is impressive for the loads you have on it!
Gene

 

[LWilliams]

When I am loaded I usually stay in 4th and use the GV overdrive which puts me half way between 4th and 5th. If the terrain allows me to roll easy I would then shift into 5th until it loaded up and then go back to 4th and over. I cannot say enough good about the GV overdrive. I do NOT want to be without it. I have a 4:10 rear and I need it to pull the loads but when I am empty and in 5th with the GV in overdrive I am running 2:33 on the ground. It's the best of both worlds.

 

[Forrest]

Larry,

What did the transmission shop charge you?


Thanks

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Money Sink - 96, 5 speed, TST 380, HX40-16, 300 HP Injectors, Scourge BD 4200rpm Governor kit, McLeod, 4", CATless, straight out back, chrome turn down, ISSPRO Pillar, Delvac 1 & Amsiol, K&N, Mag-Hytec, 3:54, Michelin 235s on Alcoas, Rancho 9000's, Valentine One, Garmin.
Dutchmen 27' 5th Wheel.
GoldWing.

 

[Big John]

Larry, Sorry to hear about the transmission problem. Did you use the Standard Transmission Shaft and gear? I toured their place a few weeks ago and was impressed. The 5th gear and shaft they showed me was a definite improvement over the factory setup.

I have @ 87,000 miles on my '96 and am preparing myself for the day 5th gear lets go. I do not work the truck hard except when I pull my 5th wheel. That is not as often as I would like. The shape of the clutch and bearing is good news to hear. Thanks for the post.

Big John

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'94 2500 Diesel Reg. Cab
Auto 3. 54 4X4 TST 230hp
"If you can't Dodge it, Ram it!
'96 2500 diesel clubcab 4x4 5speed

 

[rhoads]

Larry.
you never mentioned what your over all mpg avg. for the year was.
Note i said (year) to get the true picture .
A few years back i was about to install one and after running across other use'er/haulers i opt'ed out of GV and the competion's unit. A nother thing that held me back was there tow'ed wt rating.
And did you install it from the get go? Mile 1. The fact you installed it told me you run in 4 gear(NV) all the time when towing,thats why you got the miles with out the loss of 5 th gear.
I had a call from a member about a year ago that only towed a boat a couple times and lost his around 55k.
Also as mine and his experance & yours with the gear vendors use has proven,the nut will at some milage point in time behind the big gasser & cummins& chevy diesel eng's (uses same transmission except has a vibration damper inside tail section,where cummins has ther's on crank shaft) come loose.
Please tell me while you had the transmission out you installed south bend clutch's pilot bushing??

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96-3500 SLT EXT. CAB AM/FM/CD-RINO LINER. D-CELERATOR EXH. BRK-RED LINE VAC. OVER HYD BRK CONTROL- AIR BAGS W/HVY DUTY AIR COMP. PUTCO S/STEEL DEEPBOARDS FRONT TO REAR. REESE 20K 5TH WHEEL & GOOSE -REESE 20K HITCH BELOW W/17K RECEVER. CLEAR COATED & SOUND DEADINGING &UNDER COATED 5 SPD/W 4:10 MCHLN'S 235/16'S UNIDEN PC76/WEATHER-WILSON 1000 MAG MOUNT ANT. 4 WHL ANTI LOC BRK SYS.
750,000 miles

 

[EZ94]

Thanks, Larry for a really great post.
My '94 has 73,000 miles on it and I do work it during the summer when I carry a slide in camper and tow a boat. Otherwise, it has the life of Riley.
I know 5th gear will someday be an issue... and your post was a reminder to do something about it pro-actively. It also reminded me(again) that it would be a good idea to invest in a gear splitter.
Am curious, though, what was did the install cost you?
Thanks again.

 

[LWilliams]

I only have access to a computer at work so that is why my posts are not made over the weekend. To answer some of your questions...
The total cost of the r/r was $1330. 80. This included all parts, fluids and labor. I did use the upgraded shaft from Standard Transmission in Fort Worth and Athens Transmission and Gear in Athens Texas did the install. I used the Castrol fluid that is required and I had to have an extra quart to allow for the pto. I used all factory replacement new parts. No rebuilts. No South Bend pilot bushing. I guess I did not do enough homework on that one. I went back with stock stuff. It worked fine for 124k and the clutch never slipped under load so far so I saw no reason to change. As for as my mileage, I check it maybe 3 times a year and have always got around 17 mpg. I think I should probably be getting better than that but it runs so good I just don't want to mess with it. I installed the GearVendors when the new truck had about 1500 miles on it. I have pulled the 34ft trailer empty in 5th most of the time but with a load I would go to 4th and over or 5th going downhill to build up speed for the comming hills. I have a 17ft ski boat that I normally pull in 5th and over. It always pulls that with so much ease that I never really worried about it. I do believe that your driving habits make a difference as to how long 5th stays with you, but it's going to happen some day. I'm just glad I was close to home and not on a trip.