Uh Oh! Look what I found in the Trans Pan.

[Dynomite]

So on top of the issues I have been having with my MAP sensor. See thread here -->https://www.turbodieselregister.com/forums/5-9l-engine-transmissions-2003-2007/215019-odd-combination-dtc-s.html I have also noticed my trans acting up. It refuses to unlock the torque converter once it is locked up at highway speeds. IE if I am slowing down from 70 to a stop normally at about 1200 rpms the converter would unlock and freewheel as I come to a stop. Middle of this week instead of doing that as I slowed the truck started to buck and jump. . initially I couldn't figure out why. Eventually I figured out what was causing it. I checked the trans fluid and it wasn't overfilled but it was time for a change which I knew so I just figured it was because it was dirty. If i shifted into Neutral while rolling before it started bucking and then back into Drive it would release fine.



Well this morning I drained the pan and dropped it only to find a NASTY surprise!!:{ Can anyone identify the pieces below?? For size reference they are about 1/16th" thick and form a circle about 3 1/2" across. Please excuse the poor quality as they are camera phone pics.



Upon inspection of the pan it was a mess! Filings all over and the magnet was covered in about 1/4" of filing sludge. So I figured at this point instead of flushing all the fluid like I was going to I would just clean up the pan reassemble and refill since I already know that it is going to require more work.



The big question is will a rebuild kit fix this or am I looking at a whole new trans??



Thanks in advance for any help!



Oh btw I took it for a test drive after the refill and it shifts fine at partial throttle and unlocks the converter when slowing. The only thing it doesn't do entirely correctly is under full throttle it bounces off the rev limiter one time before it locks the converter in final drive, otherwise under full throttle all other shifts happen fine.

 

[Diesel Power]

So on top of the issues I have been having with my MAP sensor. See thread here -->https://www.turbodieselregister.com/forums/5-9l-engine-transmissions-2003-2007/215019-odd-combination-dtc-s.html I have also noticed my trans acting up. It refuses to unlock the torque converter once it is locked up at highway speeds. IE if I am slowing down from 70 to a stop normally at about 1200 rpms the converter would unlock and freewheel as I come to a stop. Middle of this week instead of doing that as I slowed the truck started to buck and jump. . initially I couldn't figure out why. Eventually I figured out what was causing it. I checked the trans fluid and it wasn't overfilled but it was time for a change which I knew so I just figured it was because it was dirty. If i shifted into Neutral while rolling before it started bucking and then back into Drive it would release fine.



Well this morning I drained the pan and dropped it only to find a NASTY surprise!!:{ Can anyone identify the pieces below?? For size reference they are about 1/16th" thick and form a circle about 3 1/2" across. Please excuse the poor quality as they are camera phone pics.



Upon inspection of the pan it was a mess! Filings all over and the magnet was covered in about 1/4" of filing sludge. So I figured at this point instead of flushing all the fluid like I was going to I would just clean up the pan reassemble and refill since I already know that it is going to require more work.



The big question is will a rebuild kit fix this or am I looking at a whole new trans??



Thanks in advance for any help!



Oh btw I took it for a test drive after the refill and it shifts fine at partial throttle and unlocks the converter when slowing. The only thing it doesn't do entirely correctly is under full throttle it bounces off the rev limiter one time before it locks the converter in final drive, otherwise under full throttle all other shifts happen fine.

Thats bad new bro, that transmission can be salvaged, no problem, but it does need a rebuild, at least the front half does, because that's most likey where the washer came from, i cant place exactly where in the transmission, but i think it's from behind the front drum... .

 

[Dynomite]

Thats bad new bro, that transmission can be salvaged, no problem, but it does need a rebuild, at least the front half does, because that's most likey where the washer came from, i cant place exactly where in the transmission, but i think it's from behind the front drum... .

Thanks man! I will try to locate an exploded view of the trans and see if I see a part like it anywhere.



I am a little hesitant about a rebuild. Given the amount of iron sludge and filings that I found in the bottom of the pan and on the magnet can I really ever trust this trans again?? If a rebuild is done can I reasonably assume that everything should be fine, I mean would it just be a ticking time bomb or could I trust it? What about the torque converter, all of this crummy fluid and filings went through there. Could it have done any damage there?



Next is How the H... E. . Double Hockey sticks did pieces this big end up in the pan? I can't see how they would get in there. I looked for places that they could have fallen into the pan and I just didn't see any. Though you must realize I am no trans expert so I could have missed something, but I saw no obvious place for them to fall in.



Last question... I know it seems silly to ask but this is my daily driver and I put 140+ miles per day on it back and forth to work. Is it OK to drive until I can get something done, or should I park it?

 

[BHanna]

I would think it's going to get worse if you keep driving it and if you damage more parts, your rebuild will get more expensive. Also if it breaks down on you on your long trip to/from work, that's a lot of hassle and expense you could probably avoid.

I don't know how long it's been since you dropped the pan but I change my fluid and filter and adjust the bands about every year and there always seems to be a lot of sludge on the magnet in mine too. I think that's just clutch material. I'm not sure I'd be too worried about that but the washer is definitely not good. Looks like there may still a piece or two of it floating around somewhere and there's no telling what it's tearing into.

 

[Diesel Power]

Thanks man! I will try to locate an exploded view of the trans and see if I see a part like it anywhere.



I am a little hesitant about a rebuild. Given the amount of iron sludge and filings that I found in the bottom of the pan and on the magnet can I really ever trust this trans again?? If a rebuild is done can I reasonably assume that everything should be fine, I mean would it just be a ticking time bomb or could I trust it? What about the torque converter, all of this crummy fluid and filings went through there. Could it have done any damage there?



Next is How the H... E. . Double Hockey sticks did pieces this big end up in the pan? I can't see how they would get in there. I looked for places that they could have fallen into the pan and I just didn't see any. Though you must realize I am no trans expert so I could have missed something, but I saw no obvious place for them to fall in.



Last question... I know it seems silly to ask but this is my daily driver and I put 140+ miles per day on it back and forth to work. Is it OK to drive until I can get something done, or should I park it?

worn out parts and very loose clearances allow funny things to happen.



A full rebuild is in order, the goo at the bottom of the pan is clutch fiber material mixed with oil, normal when the transmission needs a rebuild, the expected life after gathering all this info is not long!!



Shoot me a PM and i can get you to a transmission shop that will get it done right, and quickly. Oo.

 

[Dynomite]

worn out parts and very loose clearances allow funny things to happen.



A full rebuild is in order, the goo at the bottom of the pan is clutch fiber material mixed with oil, normal when the transmission needs a rebuild, the expected life after gathering all this info is not long!!



Shoot me a PM and i can get you to a transmission shop that will get it done right, and quickly. Oo.

PM SENT! Thanks. Oo.

 

[cerberusiam]

That would be a thrust washer out of the trans drive train. Right now your losing lube pressure to the whole drive train and wherever it is from is gouging large grooves in the one or both of the components.



Gonna need a full tear down, cleaning, and rebuild.