Engine/Transmission (1994 - 1998) rebuilt 5sp , lost 5th?

[angelbay]

Hello, just put in a rebuilt 5spd, 230,000mi, one month ago. I was assured there was a fully splined shaft. This morning the shifter would not not move into the 5th gear position. After some wiggling of the shifter got it into the 5th gear position but it is as if there is no gear there. Can someone explain what may have happened? I do not have a good idea or picture in my head of the problem and fix. I hope it is under warranty and still do not look forward to the labor involved. Can it be approached while still in the vehicle by removing the transfer case? 4wd, '96. Thanks, Steve

 

[angelbay]

drivable?

P. S. Is it ok to drive it within rpm limits using 4th only or is more damage possible, until I can fix it? Thanks, Steve

 

[Nick2]

I lost fifth yesterday for the first time too, what a bummer. Ive been doing a lot of reading in the archives and it seems like it's okay to drive in 4th as long as you need to. I think there's a guy on the boards who's gone something like 12 or 13K miles without 5th. I've been trying to find to find a place to bandaid the problem - but so far the guy wants to pull the whole trans and update the mainshaft (2200). This obviously didnt work for you so Im still on the fence.



I know there have been about a million posts about this topic, so if you do some reading you might find the answers your looking for... . or call the place you bought the trans from and see what they have to say.



Turns out- I bought a Cummins and got a Dodge..... dammit.



ps- anyone in SE minnesota have any ideas or suggestions??? otherwise Im gonna drive this big dumb animal back to Il 300 miles and tear into it myself (no garage or jack here).



pps- this sucks

 

[SMorneau]

Nick,



Talk to the guys at Midwest transmission in Haber, MN. They are in your area and will sell you what you need for a lot less than $2,200. They have the fully splined shafts and can make you a good deal on a rebuilt.



Try 1-888-824-2012.

 

[Nick2]

thanks, Ill give them a call

 

[SRadke]

If you had said the shift into 5th went well but there was no gear there I'd say drive it. The fact that it didn't want to shift into 5th makes me a little nervous. That may be more than a gear sliding back on the shaft, but it may not. If all the other gears work properly and it doesn't make any odd noises you're most likely in good shape to drive it.



If you remove the transfer case and the aluminum extension housing (between trans and transfer case) you should have no problem seeing the problem. Most everything that's involved with 5th gear is outside the main transmission case in the back. Where did you get the rebuild?



-Scott

 

[angelbay]

I am holding off publicizing the name of the rebuild place until I speak with them. It is under warranty but the labor is not what I am looking forward to as I am recovering from shoulder surgery I had just after I put the transmission in! I do hope to get it resolved as I really like the truck. When I spoke with them about the splined shaft and nut. before I bought the transmission, they implied that just the shaft was necessary, the nut was not the problem. I will search the posts. I am glad to know I can get to the problem by dropping the transfer case and not dropping the transmission. I guess I will have to check and ensure I have a fully splined shaft and make the nut stay on, thanks, Steve

 

[angelbay]

Well I spoke with the rebuilder and yes their warranty is in effect and it is national. This is what it means, I or someone I pay, removes the transmission (they will refund $145 for the labor :--) and then I ship it back empty (they pay ) and then I wait..... then it is shipped back repaired??? and reinstalled (included? in the previously mentioned $145 :-laf ). Great right? NO :-{} I have to depend on some one to do this labor for $145 or do it myself with a post surgery shoulder, I just got the rebuild in before surgery 6 weeks ago. This is not to mention doing without the truck! Any suggestions? I plan on tacking the nut on the shaft if I do it but that will probably void the great warranty. I wonder why the problem after 6 weeks and less than 2000miles? If the workmanship is that bad maybe I need to stick with the warranty, delays, etc. just to hold them accountable. Any suggestions guys? I will let you know who did it when I finally make up my mind, after warning them. Thanks, Steve

 

[BV]

Steve - Sorry for your troubles - I would hit up some of the local TDR members that might feel like helping a fellow CTD owner that is in a pinch. Have them pull out the trany so you can send it back on Warranty. If you were closer I would lend a hand for beer and donuts

 

[SRadke]

Hmm..... beer and donuts I'm not willing to drive to NC for them though



There are some possibilities as to what's happened. Most obvious and well known is the nut problem. It's also possible to strip the gear (not likely with a fully splined shaft) or you could have stripped the center out of the 5th gear syncro hub, that's been known to happen. Either way there will be some dissasembly required so after that you just have to decide to fix it yourself (if it's an obvious problem) or ship it back. That also will depend upon what the down time is worth to you.



-Scott

 

[Andy Redmond]

Don't tack weld the nut, you will likely "anneal" the heat treated qualities of the steel. I've got a broken main shaft over in the corner that had the nut welded on, it finally took the splines off the shaft. From the looks, the nut had been tacked then welded.



A trans rebuild cured this truck and its been in Hotshot service for a year with no probs. Not sure of how many miles he has run. .



Get a new fifth gear and split nut and some locktite and all s/b well, It may have not damaged the shaft.



It can possibly be repaired in the truck with the trans. case and adapter housing removed.



Good luck

Andy

 

[angelbay]

Thanks for the warning Andy. That is the first negative I have heard although it seems that just "tacking" would not affect the shaft that much. I may just bite the bullet and rip it out and send it back. The more I think about it the madder I get. They seem to think it is no big deal and they are doing all they have to. The big question is what really happened and why. If I send it back I may never really know, in addition to the loss of time and money, again. There was no noise or warning of any problem, just no go into the 5th position and then it did go in eventually, after a few more tries, and it is as if no gear there, ie. in neutral, no noise, vib. , nothing. Thanks, Steve

 

[Dbonzi]

I put two small spot welds on mine almost 100000 miles ago and no problems so far. If I was going to break it would have done so by now. My dad has spot welded his about 20000 miles ago. No problems there either. So I don't buy the idea of it breaking if you just spot it.

Just my opinion

Dennis

 

[angelbay]

update

Well, I now have the rebuilt, rebuilt transmission back in my truck after about 2 weeks. I have paid the mechanic $200 but have not been reimbursed by the rebuilder yet for the $130 allowed! It takes about 5 days to refund a debit, amazing since the banks just went to a system to ensure monies are removed from your account that same day! The warranty period does not start over now either. I have to pay for fluid replacement. Now for all who are curious, as I certainly was, the problem was a snap ring broke. That's all. Why? Who knows. What gripes my butt is their attitude. It seems like no problem to them, they do have a warranty after all. No problem. Well, I for one would at least like an apology. No, business as usual. I told them I expected a little more "customer" service attitude for repeat business, to please me so I spread the positive word, and to keep me from slamming them on this website! I doubt that I wll do business with them, in Tallahassee Fl again,..... Steve.

 

[SRadke]

Good to hear you're back on the road. Bad news is a broke snap ring was probably either broken during their install or it was put on incorrectly, but yes, it definitly would be a problem.



-Scott

 

[angelbay]

thanks

Thanks Scott, I am glad my truck is on the road again too. I really like the truck and with 230,000 mi. and an unknown past I expect some problems but they are compounded when the methods or parts we use to fix our trucks are incorrect or substandard. I am now going to replace my steering pump discharge hose and install a Frantz bypass oil filter to help longevity. I love the website. Thanks again, Steve