This all started with it not going into 2nd gear. I pulled the transmission and had a look inside and couldn’t find any obvious issues. I then reinstalled it to do some more diagnosis and found that the shifter seat was cracked and the shifter alignment pins were very loose. Replaced those. This actually seemed to fix it for a few days. Shifted into second gear no problem then one day I’m driving around and it loses 2nd again.
Condition of the original seat and pins:
After the new seat and pins were installed:
After talking to some local experts they suggested to take a look at the hydraulics. Master and slave were both leaking so those got replaced with OEM parts. The hose for the slave was also in rough shape so I put in a new one of those. Also changed the transmission fluid.
The saga continues. I still cannot get into second gear without double clutching. When I let off the accelerator in second it throws it back into neutral. Additionally, I put the transfer case in neutral to see how it shifts under no load and there is a rattle that seems to get a lot worse the higher the gear I’m in.
Video cycling through the gears under no load, t-case in N
Video of the how the noise changes when revved under no load. 3rd gear.
It is worth noting that this is a BJ42 H42 Transmission but has the BJ60 top plate on it. I have been told that they are interchangable and it has been running with this set up for probably 15 years now. We put a Terrain Tamer trans rebuild and T-case rebuild in 3 or so years ago because input/output bearings were completely shot. The dog teeth on 1st and second still appear pretty sharp and in good shape. There are no chips or teeth missing on the gears them selves. The 1st and 2nd gear brake rings look to be in decent shape with the original machining groves still visible.
I am going to do the same test under no load tomorrow with a stethoscope to try and roughly isolate where the rattle noise is coming from.
Any ideas?
Condition of the original seat and pins:
After the new seat and pins were installed:
After talking to some local experts they suggested to take a look at the hydraulics. Master and slave were both leaking so those got replaced with OEM parts. The hose for the slave was also in rough shape so I put in a new one of those. Also changed the transmission fluid.
The saga continues. I still cannot get into second gear without double clutching. When I let off the accelerator in second it throws it back into neutral. Additionally, I put the transfer case in neutral to see how it shifts under no load and there is a rattle that seems to get a lot worse the higher the gear I’m in.
Video cycling through the gears under no load, t-case in N
Video of the how the noise changes when revved under no load. 3rd gear.
It is worth noting that this is a BJ42 H42 Transmission but has the BJ60 top plate on it. I have been told that they are interchangable and it has been running with this set up for probably 15 years now. We put a Terrain Tamer trans rebuild and T-case rebuild in 3 or so years ago because input/output bearings were completely shot. The dog teeth on 1st and second still appear pretty sharp and in good shape. There are no chips or teeth missing on the gears them selves. The 1st and 2nd gear brake rings look to be in decent shape with the original machining groves still visible.
I am going to do the same test under no load tomorrow with a stethoscope to try and roughly isolate where the rattle noise is coming from.
Any ideas?