Engine/Transmission (1994 - 1998) NV4500 gear chatter in 2 and 5

[SteveMiller]

So the subject pretty much says it but I'll give a little more detail.



the truck has 197k on it. I don't know if the trans is orig. and I just changed the fluid about 2-3k miles ago.



The trans still seems to be working fine just making some very unpleasant sounds in 2nd and 5th. I was going to check my 5th gear nut this evening to see if its coming loose and maybe that's the issue but that doesn't really explain 2nd... or maybe it does for someone that knows more than me.



5th is pretty loud just going down the road but 2nd gets really bad when I have my foot out of it and I'm slowing down.





Any thoughts would be great. Don't know that I can really afford a new trans at the moment but maybe I'll have to.



Thanks

Steve

 

[SRadke]

Originally posted by SteveMiller

I was going to check my 5th gear nut this evening to see if its coming loose and maybe that's the issue...

Are you planning to pull the transfer case to accomplish this task? Either way, I had no warning before mine popped off so I doubt that's it.



The one thing that 2nd and 5th have in common is the countershaft. Unfortunately 3rd and 1st use it as well so I can't tell you why it would only be two of them.



If you're going in as deep as the fifth gear nut check for endplay in the two shafts, that will give you a good idea how much wear has occured.



-Scott

 

[Deezul1]

I doubt its the 5th gear nut, mine came off twice and there was no warning and no noise. I drove it 600 miles without 5th also and it never made any noise. Drain the oil and check for metal shavings with a magnet and by pulling the side cover you can try to wiggle the counter shaft and main shaft to check for play and look for unusual wear patterns. Do this in neutral to take strain off of gears.

 

[SteveMiller]

Yeah I was gonna drop the T-Case. It didn't make alot of sense to me either about it being just 2nd and 5th so I put it in 4th and tried to make it make noise and its quiet. I can't say 3rd is silent but I wouldn't say it was making enough noise that I would normally worry about it.



How much play should there be? I guess I'll take a look and post back what I find if anything.



Thanks

Steve

 

[SRadke]

IIRC the endplay spec was in the neighborhood of . 003". If it's loose you have the option of shimming it up or replacing the bearings. Shimming would be a temporary fix.



-Scott

 

[GAmes]

I just went thru something like you have. 1st, 2nd, 3rd and 5th all made noise. 4th gear was fine. I drove from Ogden, Ut to Ft. Worth and had it fixed at Standard transmission. They installed a new bearing set and synchros. I already had a fully splined shaft kit. Rebuild and 2 gallons of syntorque, resurfaced flywheel and new pilot bushing was about $650 including tax. A nearby shop that they recommend charged $325 for R & R of the trans, clutch and press plate. I drove in at 7:30 am on Thursday and was on the highway at 5:30 pm Friday. I believe I may have received a little faster service at ST since I was a return customer, but the reason I went there in the first place was because of the good service I had received the first time I had gone there. If you have the time to make the trip, rebuilding your trans will almost certainly cost less than exchanging it for a reman.

 

[mschoenheider]

You could also pull it and ship it to them for the rebuild. Drive Old Blue while the Green Monster is down... ...

 

[SteveMiller]

Yeah probably not an all bad idea. Of course what is the little woman gonna drive? Guess we'll have to hurry up and get that Diesel Jetta.



Steve