Ok, I took my truck for a test drive today, for the first time since the lift and 4x2 to 4x4 conversion. It has the M5OD in it, and is doing some funky stuff. When I push in the clutch, I get a scraping noise after about 2 seconds of holding it in. I let it out and it stops. (sounds like the clutch is not completely disengaging). When driving the truck down the road, 1st is fine, 2 is fine, but to go into 3rd it doesnt seem to synch properly with a little griding, same to 4 but worse, and 5 is even worse. During acceleration in 3rd 4th and 5th it makes a grinding/scraping noise. What the heck? Would a bad clutch do all of this? Any ideas are appreciated.

 

sounds like a trans problem if it were the clutch it would do it in all gears

i assume you just changed the trans when going from 2 to 4wd but did you change the clutch i assume you have the same clutch as before and if it worked fine before with the 2wd trans then it should work fine with the 4wd trans

 

What parts did you change over? What parts did you keep.
Flywheel?
Pilot bearing?
Clutch disk?
Pressure plate?
Throwout bearing?
Slave cylinder?
Hydraulic lines?
Transmission?
Shift Control Housing?
Any gears syncros etc from tranny to tranny?
Tranny mount?
Starter

JMC

 

Thank for the replies guys. Basically, I unbolted the old tranny, and everything that came down I swapped to the 4wd setup, aside from the tranny mount. I did not pull the Flywheel,Clutch disk,Pressure plate, etc. I probally F*CKED myself in doing that. Everyone knows that anxiety bug that crawls around under the truck with you. The thing is that I bought the new/used tranny from a scrapyard online, so I really am not POSITIVE that there was nothing wrong with it. On top of that, I never ran the truck before the swap, so I dont know the condition of the other parts. I unfortunately relied on the word of the people I bought the truck and new tranny/tcase from. As to the internals, I didnt change a thing there either.

 

So you used the scrap yard slave cylinder and throw out bearing as it is bolted to the tranny. That also means that you did not buy a new pilot bearing. So the 4x2 input shaft wore a pattern into it and the 4x4 tranny has to live with it. You have no idea of the condition of the 4x4 slave or the throw out bearing. The 4x2 throw out bearing also left a pattern on the fingers of the pressure plate. The 4x4 throw out bearing has to cope with that too.
Try bleading the clutch first but it that doesn't help what you need to do is pull it off and inspect the slave and throw out bearing. For good measure install a new Pilot bearing. While every thing is apart grab the tranny input shaft and try moving it like a joystick in a circular pattern. It should not move but it should turn if the tranny is in Neutral. I have purchased 4 trannies from scrap yards and they were all in better condition than the one I was removing. In my application I have concluded that the input haft bearing is a weak part of the tranny. If there is any slop at the pilot bearing then the resultant walking of the shaft will create stress on the input shaft bearing and it will start to move in its race. Once this starts the tranny is doomed. In my case the extra torque that the engine develops causes the movement and takes out the bearing. That allows the input shaft gear to move ant is chips teeth. Good by tranny. So take the time to inspect your set up or be prepared to replace it again.

JMC

 

Yup. I rushed. So, if I understand you, if I pull it out, replace the throw out, pilot, clutch, slave, etc. that could make the problem going into 3rd and up go away?

BTW. Thanks.

 

I would at least buy a new pilot bearing as that will help center the input shaft and help keep the input shaft bearing from wandering. Every time I change a clutch or swap a tranny I change it.

Until you pull off the tranny and inspect you will not know what is up.


The old slave worked but the reliability of the slaves is not the best so some shops recommend replacing then as a precaution. They should come with a new throw out bearing but if not get one.

Was the old clutch slipping? If not reuse it unless it is worn out. What year tranny did you get? How many miles?

JMC


PS Don't feel bad. The last tranny I installed was a major pita. I picked up a brand new 1999 new model tranny for $900.00 The slave on it looked brand new.
The tranny had been dropped but I didn't notice it till it was time to install. The shift control cover was cracked where the shift lever pivots. Thank god that I have Hurst shifter because I had to remove the lower shifter to install the short throw and that is when I saw the crack. I ended up using the old tranny cover. I looked over the slave and as it was brand new I did not notice the fact that it had no throwout bearing. What a mess when I went to press on the clutch. Oil every where! I had to pull the whole thing off again and install a new slave. The problem s continued as I decided to readjust the self adjusting clutch. All in all I ended up replacing the slave another time and I had to purchase a new clutch. A few weeks later the shift pin holding the 1-2 shift fork sheared off. The tranny stayed stuck in first. Thank got I had another shift control housing sitting around. That one is still on as I am writing this. I removed the brand new shift forks from the cracked cover and I will be fitting them to the cover this summer.

 

Dang. Thats a crappy deal as well!! Anyhow, I went with a 95 model. It was supposed to have around 80k....

 

What year is your truck? Which engine?

JMC

 

It is a 99 with the 4.2

 

Did you clean and lightly grease the splines of the 4X4 tranny? Any trouble installing the tranny?

JMC