Found major issue…trans

DaneGer21

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Had some time today so I decided to let my truck stretch its legs on some back country roads by our house. I went around the “block”, which was about 6miles round trip. Problem was on my way back I decided to go into 5th, shifted fine, went about a 1/2 mile crusading at 45mph and then came to a stop sign. It was STUCK in 5th gear, uh oh. I was about 1/4miles from my house, so I put the TC in low and limped her home stuck in 5th.

I pulled off the transmission top cover and the 4/5 synchronizer is just about in pieces, a few sheared pins/sliders. Apparently something must have stuck and/or locked up, or THIS is the reason the previous guy parked it and didn’t mention. Not good!

First the engine wouldnt start. Fixed that.
Next, wouldn’t build air pressure. Fixed that.
Then some brake issues. Fixed and still fixing those.
Now this tranny issue.

Starting to question weather this truck is worth it or not to continue repairing.

I’ll take some pics shortly…
 

DaneGer21

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Pics…

4/5 synchro is junk. Not sure what else is toast.

The trucks in the driveway and not the garage so that’s all I’m doing tonight, it’s really windy and about 28*f, with out wind chill.

The last pic I carried the top cover into the garage for better light. You can see a very small bend in the 4/5 shift fork(hard to see in the pic). But, for all I know, I could of did that when trying to get it OUT of gear.
 

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glcaines

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The easiest solution is to find a good take-out transmission from a truck being parted out. I can't remember, but I believe I paid either $125.00 or $150.00 for a good transmission. However, that was a few years ago and there aren't as many available now. The transmission is actually not that difficult to pull and replace. I put a beam of wood across the doors with the windows rolled down and lowered it with a come-along. Also, a good time to refresh the clutch if needed.
 

porkysplace

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Wife won’t like that answer haha
The easiest solution is to find a good take-out transmission from a truck being parted out. I can't remember, but I believe I paid either $125.00 or $150.00 for a good transmission. However, that was a few years ago and there aren't as many available now. The transmission is actually not that difficult to pull and replace. I put a beam of wood across the doors with the windows rolled down and lowered it with a come-along. Also, a good time to refresh the clutch if needed.
Add if you do the clutch , go a little deeper and replace the rear main seal while your there.
 

cbrTodd

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You can replace the 4/5 synchro without removing the trans from the truck. I did it this year. Starting where you already appear to be, you have to remove the jack shaft going into the transfer case, remove the output yoke and the seal housing, and pull the rear bearing out the back. Then you can pull the main shaft back and then up and out. I know there is a thread about doing this job on here somewhere. Just be sure to use grease to hold all the roller bearings in place between the input shaft and main shaft during reassembly... after you fish them out from the bottom of the case with a magnet during disassembly, of course.
 

davidb56

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You can replace the 4/5 synchro without removing the trans from the truck. I did it this year. Starting where you already appear to be, you have to remove the jack shaft going into the transfer case, remove the output yoke and the seal housing, and pull the rear bearing out the back. Then you can pull the main shaft back and then up and out. I know there is a thread about doing this job on here somewhere. Just be sure to use grease to hold all the roller bearings in place between the input shaft and main shaft during reassembly... after you fish them out from the bottom of the case with a magnet during disassembly, of course.
I did The same thing replacing 1st gear and the main shaft last year. it was pretty easy with minimal tools.
 

DaneGer21

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Well I was stubborn and I told the wife to suit up. I got on my old trusty tractor, and got the deuce in the garage. I didn’t wanna have to put a few things back together to drive it in. Although I needed the tractor regardless pull it backward before going in. Anyways it’s in.

So, in the mean time I loosened and pulled the jack shaft out of the way, and pulled the cotter pin. Once I find the appropriate socket for the yoke I can move forward, I know it’s here somewhere. Oh well, that’ll be tomorrow. Even though it’s in the garage, the garage has no heat haha.
 

DaneGer21

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Location
Creston, Ohio
The easiest solution is to find a good take-out transmission from a truck being parted out. I can't remember, but I believe I paid either $125.00 or $150.00 for a good transmission. However, that was a few years ago and there aren't as many available now. The transmission is actually not that difficult to pull and replace. I put a beam of wood across the doors with the windows rolled down and lowered it with a come-along. Also, a good time to refresh the clutch if needed.
Dang that is cheap! A NOS 4/5 synchro is about $100 to my door! Hell I would buy two transmissions if that’s the case haha

Maybe you meant $1250, not $125. Lol
 

glcaines

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Dang that is cheap! A NOS 4/5 synchro is about $100 to my door! Hell I would buy two transmissions if that’s the case haha

Maybe you meant $1250, not $125. Lol
No, $125 or $150 in Atlanta. But again, that was a few years back. He had two available at that time and I picked the one that had a tag that said it was rebuilt by Wolverhampton in the UK. Both had come out of running trucks that were being parted out.
 

DaneGer21

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No, $125 or $150 in Atlanta. But again, that was a few years back. He had two available at that time and I picked the one that had a tag that said it was rebuilt by Wolverhampton in the UK. Both had come out of running trucks that were being parted out.
I have family just outside Atlanta. See if he has the other still HAHA I’ll make a holiday road trip! Haha
 

davidb56

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Well I was stubborn and I told the wife to suit up. I got on my old trusty tractor, and got the deuce in the garage. I didn’t wanna have to put a few things back together to drive it in. Although I needed the tractor regardless pull it backward before going in. Anyways it’s in.

So, in the mean time I loosened and pulled the jack shaft out of the way, and pulled the cotter pin. Once I find the appropriate socket for the yoke I can move forward, I know it’s here somewhere. Oh well, that’ll be tomorrow. Even though it’s in the garage, the garage has no heat haha.
heat is over rated, and the average cost of a transmission (used) is Now running 600$+. a few years back they were cheaper. But you dont know what you are getting as far as used goes. Personally, I would repair and refurbish the wore parts, or but a rebuilt one from a REPUTABLE dealer like Boyce or Eastern etc.
 

DaneGer21

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Creston, Ohio
I was able to get the 4/5 synchro out of the transmission without removing from the truck, only after finding my 1-1/2” socket for the nut on the yoke. haha.

More bad news though, after digging deeper for the removal. My main shaft is severely worn where it rides in/on the individual roller bearings inside the main gear, the ones that “fall out” while removing the main shaft. Some of those rollers are also slightly pitted.

I’ve heard people aren’t able to locate those individual roller bearings. Maybe they could be machined if not located? Who knows?

I assume from looking at “new” main shafts mine is actually worn. I’ll post a few pictures shortly.

Im a single dad today while the wife is at another friends baby shower. So garage time is limited with a 1yr running around HAHA!

So far needed for repairs at MINIMUM…
4/5 synchro - $100
Main shaft - $100
Individual roller bearings(probably all) - ???
A few gaskets - >$50

I have located a used transmission about 2hrs away for $550. It’s a spare trans but the guy is selling his truck and parts.

The guy 20mins down the road also has a used transmission still in a parts truck, but hasn’t given me a price yet, and I’m guessing I’d also have to drop that one.


So now I’m almost at the point of saving only a few hundred but don’t have to drop the trans, although not the end of the world, but still.

Or, I pick up a used transmission to get the truck going again, but requires more hard labor of swapping transmissions, but then repair mine over time for a spare?
 
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