Need some NV5600 expertise - leaked fluid , jammed

[hertfordnc]

A couple months ago I installed a rebuilt NV5600 in my 2003. It was perfect. I put about 8000 miles on it and had just completed a 1200 mile trip with 8000 lb tow.

It shifted like a small car, smooth, quiet and easy.

Until it didn't.

No noise, no warning, would not go into any gear, for a while I just had reverse, then nothing, seems to be jammed between gears. If I let the clutch out it stalls. But not like it's stuck in a high gear, because normally this truck would try to roll forward even if you took off in 6th (without a load)

I tore into the shifter and found it loose, like loose enough for the oil to slosh out (which it did). I removed the left PTO cover and drained only 1.5 quarts. I had put in 6 quarts of Penzoil Synchromesh.

Otherwise there are no visible sign of carnage in the gears I can see.

THe rebuilder is 10 hours away and this is not warranty work so I'm trying get some insight as to what might be going on and whether or not I can fix it.

I've read a lot about how hard these are to work on so I know it's out of my league.

But what if I just took off the tail cover and tried to un-jam it? will I run into things that require special tools and expertise?

ANy theories on what's going on?

thanks

Dave

 

[Tuesdak]

It's not warranty work why? Did you leave the shifter loose? If not it's on the installer.

Clearly it ran out of oil and hurt something bad.

Time to call Standard Transmission. Hopefully it only locked up a bearing (likely the famous rear bearing) and didn't hurt/crack the case.
Anything short of rebuilding the transmission at this point risks further expensive damage to it.
I would double check both seals as well for leaks as this is a lot of oil to loose.

 

[hertfordnc]

It's not warranty work because I am the installer, and yes, I apparently did not tighten the shifter properly.

I don't think it's clear that it hurt something bad. When it failed it had only been running for 20 minutes with no load, the first sign of trouble was coming down a hill with the cruise on. First shifting became difficult, then I only had reverse, then it was jammed between gears. All that happened on the side of the road in a few minutes.

I don't think I seized a rear bearing. I believe the burnt smell is either a synchro or if I'm really lucky, just where the forks rubbed against a shaft as it trying to move a gear.

I would not go to a different rebuilder when the one I had did such a great job. THe blunder was mine not his.

I've read about these things jamming up and then getting un-jammed and working fine. I want to go down that road first. This truck is a daily driver and restoration project that never tows heavy, I don't need the same degree of reliability others might expect.

So my question is, how far into this can I get before I need special tools and skills?

 

[Tuesdak]

Here is what you are getting into:
http://blog.genosgarage.com/wordpress1/2012/05/17/tdr-64-rebuilding-the-nv5600-transmission/

 

[hertfordnc]

Yeah, I've read that one and several other teardown summaries.

Still does not answer my question.

Can i get in far enough to un-jam what is hung up without entering the world of shims and dial indicators?

What comes loose when i take off the tail cover?

THere's gotta' be somebody here who's been inside this thing.

 

[S.Morris]

Was the shifter tower loose enough for the end of the gear shift to come out of its socket? Maybe it is engaged in two gears at same time?

 

[hertfordnc]

Yeah that's pretty much it. It wasn't that loose but the plastic bushing is very worn and the bolts were very loose so I am thing it's trying to be in two gears at once.

Going away for a week. ordered a new bushing, hope to add oil and try to unjam it when i get back