Engine/Transmission (1998.5 - 2002) NV 5600 repair

[Wyomingcowboy]

Well this goes back awhile, but I finally have the transmission out and I'm ready to tear into it. I copied the instructions left on another site and got some info from AllData. (They have way too much info to look at all at once. ) I'll try to get some pics and stuff and will probably use Blumenthals for parts and any other advice they wanna dole out. All I really need to replace is the 3-4 synchro but I'll give it the once or twice over and maybe notice something else. Sure wish I had the fancy tools AllData talks about... . but I guess I'll just have to get western and tear 'er down and hope for the best!

 

[Wyomingcowboy]

Well... . I'm really wishin I had some more of those fancy tools! It never ceases to amaze me just how smart some of the engineers can be. This transmission is a work of art. There are SO MANY little pieces that all fit so tight and work so great (usually. ) I've just now got it torn apart and I'm strategizing on how best to get after it now. I'll post some pics this afternoon.....

 

[Wyomingcowboy]

some pics of the dissasembly... ...

 

[Wyomingcowboy]

... . and some more... ...

 

[Gary - K7GLD]

JEEZE, that sure looks a lot more involved than the old GM 3-speeds I used to work on! :-laf



Good luck - hope it all works out as hoped for!

 

[Wyomingcowboy]

Here is my homemade fixture at work. It was a little sketchy but it worked out ok. Blumenthal's told me I would need 100 tons and I think I put about 17. 5 down to the shaft. The fixture was flexing a little though, so I'm sure I had plenty of force back upwards, too. It's taking me alot longer than I had hoped for but I have about 100 brands and right now they are all in the fire!

 

[MShaheen]

yikes that looks confusing.

 

[MarkMiller]

I used to work in motorcycle shops and to torture the FNG we would wait for him to get his first case-split job (mc trannies are tight and packed full of crap) and when he had it all apart one of use would walk by and drop an extra gear or shift fork in his box of parts. Just a little torture amongst friends Oo.



Good luck man. Looks like you got it by the neck so far.

 

[Wyomingcowboy]

Or it has me by the... .....

 

[AllianceDiesel]

you got balls for doing a six speed, too many special tools

 

[Wyomingcowboy]

Well, I finally got the counter shaft 6th and 5th gears off and WOW! I had a 25 ton press and it still wouldn't budge it. I had to whack on the press block with 25 tons of force on it and it finally started to creak loose. Blumenthal's told me they use a 100 ton press and I can see why!



Anyway, the synchro I needed to get at was of course that maost difficult one to get to... . #@$%! But, I got off and to my surprise, the friction cone there looked as good or maybe even a little better than the others. What I did notice was the little pices within the synchro that are held in place by springs and a ball bearing were not where they were supposed to be. one of them was just out a tad and probably didn't effect anything, one was in the right spot, but another was facing up and down and the ball bearing was gone. (Anybody here try to fix one of these and know any names?) I'll post pics tomorrow and hopefully can find some part names. I will call Blumenthal's ASAP and see if that might be what was causing my problems. I also chipped several teeth on the 6th gear by not having my blocks in the exact right place.



Just to recap what my complaint was - I had been speed shifting after breaking my pelvis this summer and developed a grind when shifting from 4 down to 3. It wasn't bad, but it did it every time and really bugged me. I changed the oil and that made no difference so I decided to try to fix it myself after I had to pull the engine anyway. It's been slow going but I have been rebuilding my engine for the first time, teaching school for the first time, and coaching wrestling for the first time too. I think I'll have 'er done in another month or so though

So far I have not been too intimidated by the NV 5600 but I definitly see the need for a super stout press and AllData. (And a digital camera for that matter. ) I figured with all the money I save I'll put it aside and if my repair doesn't work I'll send it off to someone next time. Although when things go bad they usuall happen while pulling 6 head over Togwotee pass or somewhere like that.

 

[Wyomingcowboy]

You can see the little springs in there and how they are supposed to work - they keep pressure out while the synchro itself moves back and forth. I'm still working on the part names and have yet to call Blumenthal's. All of the ball bearings were in place (inline with the spring and in a hole in the piece) but one of the springs was actually in 2 pieces.

 

[AllianceDiesel]

Synchronizer spring, shift lever ball, and synchronizer key, I used to know why exactly the key was for but I can't think of it, maybe I will go though my chrysler books from college and see what it does exactly cause its kinda bothering me now.



Once again, you have guts for taking that transmission apart, we would always send those off actually we only had one go bad but thats what our "rule" was

 

[Wyomingcowboy]

maybe I will go though my chrysler books from college and see what it does exactly cause its kinda bothering me now.

Where did you go to college?

 

[AllianceDiesel]

milford nebraska, daimler-chrylser automotive program, 2 year program would go to school for 3 month and then work at a dodge dealership for 3 months and did that for the 2 years, I personally believe its 100 times better than wyotech or some of those popular schools, you learn more and pay half as much, I even heard they don't have tools when they leave, we got our basic set the first week we were there and then we could buy tools that we would need while you were at school and all the tools were 50% off. so I got about $20,000 sitting in my garage for half of that

 

[Wyomingcowboy]

I have not attended WyoTech so I cannot comment, but I kow they get the 50% off deal from Snap On too. My students here in HS get that to some extent as well.

 

[Wyomingcowboy]

Well I was mistaken as far as the synchros go..... I thought the wrong one was the 3-4. I got it apart and the friction cone was hashed. I will post pics tomorrow.

 

[Wyomingcowboy]

You can see the difference in the two... ...

 

[Wyomingcowboy]

I just spent about $400 on friction rings all the way around, springs, dogs, and balls (Synchronizer spring, shift lever ball, and synchronizer key,) and the countershaft 6th gear which I chipped teeth on with my press. I spoke with Monte at Blumenthal's and he was very helpful. He asked the question of "were you speed shifting" when I was asking about the synchros, springs, dogs, and, balls without me having to tell him what was going on. SO, apparently speed shifting is BAD! I know that was a topic on another thread. Hope this helps!

 

[AllianceDiesel]

yes I was gonna tell you that but I kept forgetting, somewhere I was reading that the material that is used for the synchros doesn't like speed shifting, I will try to find it some day again and save the article