Archived Nv5600 Shifting unusually hard

[ThomG]

My 04 3500 4x4 CTD with 224,000 ish miles rather suddenly today began shifting unusually hard. Stiff side to side, 3rd and 4th unable to shift into either, feels like a brick is in the way. I've changed lube [Amsoil syncromesh] 3 times since I've owned the truck the last time about 5000 miles ago. I'm in New Richmond Wi. with my 36' 5ver and need to get this to where I can move on with our planned trip. Any suggestions or help is greatly appreciated.

 

[Gary - K7GLD]

Sounds like a mechanical issue, is the clutch fully disengaging - if the transmission isn't totally disengaging, there CAN be shifting problems because the syncros won't operate properly - does the shifter seem normal in travel stopped with the engine off?

 

[ThomG]

Side to side seems normal now not running. Shifting into 1=2 and 5-6 and reverse seem ok if not running still no 3-4 at least without undo force, which I haven't tried.

 

[Gary - K7GLD]

Can't always shift into all gears while engine off at rest, unless geartrain is positioned just right - but if the side to side shifter movement seems normal at rest, engine off, but restricted under way, I'd still suspect clutch disengagement issues or worn clutch. Your sig indicates a rebuilt and beefed up transmission - what was done, and how many miles back - and was clutch replaced then also?

 

[GCroyle]

Clutch pedal feel normal? And as Gary pointed out, need any clutch replacement history.

Feel normal, pedal starts creating pressure almost immediately, no real perception of "freeplay" which our trucks do not have.

 

[ThomG]

The NV 5600 is stock as far as I know. I purchased the truck in 2007 with 112,000 ish miles on it. The clutch was new South Bend Clutch {rated for far more horsepower than I expect to see], hydraulics and throw out bearing in 2012 at about 185,000 ish miles. The clutch doesn't get abused. Too much $ and I use it primarily to pull the 5ver or my gooseneck w/ tractor to shows.

 

[Slow Six]

Just a guess but could it be the pilot bearing? When I had my earlier trucks the pilot bearing would go dry and start piling up. The clutch would act normal but the input shaft kept turning because the bearing was seizing making for hard shifts and at times not wanting to stop. If this is the case you will want to change it ASAP to hopefully prevent damage to the shaft. When I changed clutch in my 2003 truck I went South Bend with their fly wheel and the improved pilot bearing. Failure of the stock pilot bearing is common

 

[ThomG]

Yes, all of the clutch components were changed in 2012 with South Bend Clutch components.
GCroyle: If you remember, you were of great assistance to us in 2012 when we had clutch issues in Whitehorse Yukon. You were greatly appreciated then and now. Once again ThankYou.

 

[RVTRKN]

Have you tried clutchless shifting (speed shifting), you could have lost the sycro's to 3rd and 4th, and speed shifting might work until it's convenient for repair. Try to make it to Blumenthal's in Oklahoma


Light Duty Manual Transmissions,
Transfer Cases, Clutches & Differentials
301 S. Western Ave.
Oklahoma City, OK 73109
(405) 232-9557 or (800) 262-9557
(405) 236-4014 FAX

 

[ThomG]

No issues with free play. Clutch feels normal. No warning or unusual noises, went to downshift to 4th when approaching a stop sign it seemed difficult or more difficult than normal, so I gave up the downshift and braked to a stop. I felt the "stiffness" in the neutral gate when I moved the lever to shift to 2nd, but it went into 2nd ok. Other shifts afterwards to 2nd or 5th or 6th seemed normal and the side to side "stiffness " in neutral seems to be gone.

 

[JPM]

the shifter might be binding the shifter rods if it was not put together correctly, pushing down on them .

 

[GCroyle]

ThomG,

If you can select 1st or REV from a standing start, engine running, push clutch pedal to floor, normal delay then select your gear. If it does that then for grins go thru a normal engagement. If it goes into gear as normal, engages normal but has shifting difficulty in other gears, starting to smell like a selector or other internal trans issue. The clutch really has no clue what gear you are selecting. You just want it to transmit torque or not transmit torque under the drivers control.

Good luck and thanks for the kind comment.

Gary

 

[ThomG]

It will engage normally in all but 3rd and 4th running with clutch engaged or w/o running. 3 and 4 really do not care what else is happening, they are not playing. I had a recommended shop here in New Richmond Wi. look at it today, he suggested the synchronizers were probably bad. I was thinking along those lines also from the way it was acting. We talked about that if I were to continue to drive it, the "keys" under the syncro rings could come out, and get into the gears...not a pleasant thought!! I asked what the worst case scenario to do a quality rebuild, he responded with $2500 which sounded fair to me. So it was dropped off a short time later, Wish me luck.

 

[RVTRKN]

Keep us posted, and if possible pictures please.

 

[MMeier]

It will engage normally in all but 3rd and 4th running with clutch engaged or w/o running. 3 and 4 really do not care what else is happening, they are not playing. I had a recommended shop here in New Richmond Wi. look at it today, he suggested the synchronizers were probably bad. I was thinking along those lines also from the way it was acting. We talked about that if I were to continue to drive it, the "keys" under the syncro rings could come out, and get into the gears...not a pleasant thought!! I asked what the worst case scenario to do a quality rebuild, he responded with $2500 which sounded fair to me. So it was dropped off a short time later, Wish me luck.

Where will he get parts needed? Have to remember New Venture stopped supporting that Trans over 10 years ago.

 

[ThomG]

Well the synchronizers were bad, worse than that the "keys" came out and went through some gears. So, a new factory rebuilt transmission with 3 year warranty is going in, just shy of $6000 we'll be back on the road.

 

[ThomG]

The not not so pleasant thought is what it was drat. A rebuilt NV56oo from the local Dodge dealer [ makes me wonder my trucks a Dodge is the dealer still a Dodge dealer or are they only Ram dealers now???] was procured close enough to$6000 to call it that out the door. Oooh that hurt!!! I have three pictures I'll try to post them soon.