Engine/Transmission (1994 - 1998) Lost 5th. and reverse

[jsjaastad]

I took the advice offered on the earlier post and removed everthing including the transfer case, but have not removed the transmission yet. In the bottom of the transfer case I found a broken set screw that came from the fifth gear nut. The nut 'appears' to be tight but I do not have the special tools the manual calls for. As everthing appeared to be ok I put the shifter back in and am now able to shift all gears like it used to... ... ... . All I did was remove the transfer case and now you can shift it. Why is that?

Fifth gear was replaced two years ago by the dealer on my 95.

Do I still need to remove the transmission to inspect the shift cover as I have not found anything that would cause me not to be able to shift into 5th/reverse with the transfer case attached?

Any and all advice is appreciated, Tom/Idaho

 

[moparguy]

I can't offer any worthwhile advise, but it's back to the top now.



Good luck, RJR

 

[bnelson]

It sounds like something has slipped out of place on the shift rail that actuates 5th and reverse. My son had this happen on his '92 with the Getrag box and all that had happened was the roll pin that holds the shift rail to the shifting fork had moved out of its home to allow the pieces to go where they wanted rather than giving him 5th or reverse. If you had the shift lever out of the top of the transmission and now it works with it back in, I would say that the roll pin or whatever holds things together on the 4500 has slipped ALMOST out, leaving just a bit of a friction tight fit that makes it seem to shift correctly now. I think you need to pull the whole top off of the transmission and look over the shift forks and how they work and what holds everything in place. I'll bet you will see something either missing, loose or else just about to fall completely out. IMHO there is nothing that could correct the symptom by removing the transfer case. The shift linkage to the transmission is not connected to the transfer case at all. My only guess at an explanation of what you are observing is that with the transfer case removed, the output shaft of the 4500 is "free-wheeling" and whatever pressure the roll pin or set screw or whatever that holds the shift rail to the shifting fork still has is enough to make it shift without having to deal with the syncros as it would if the output shaft were still attached to the transfer case and driveline. Just one of those mechanical deals where the action that seems to resolve the problem really has nothing to do with what really is going on.



This is why most mechanics with much experience have either gray hair or very little hair. Lots of luck. Brad

 

[jsjaastad]

Thanks to all who offered advice. I removed the transmission and then the cover. Could not find anything missing or loose. Had the local dealer remove and install a new 5th gear nut with lock tite and then staked it with a center punch. Finished late last night and will road test today. I am quite sure the problem was the 5th gear nut allen headed bolt that broke was the problem as it jamed the reverse/5th gear slider so I could not move it. Seems to shift okay now. Thanks again, Tom/Idaho