H55 grinding woes...

[gmgardner99]

I wonder what this could be. If you're having trouble getting it in gear it has to be transmission related. The transfer-case could make noise but would not make it difficult to get in gear.

Do all gears work correctly? Once you're into them that is.

I just had a thought. I recently got my H42 transmission rebuilt and it was assembled incorrectly. 4th gear was locking up and would not allow a neutral to occur. When the transmission output was pulled back by tightening the nut things would work a little better. And in various stages of messing with it I was getting grinding in second. Once it was assembled correctly everything worked.

Check the torque on that nut. If it is similar to my H42 it should be a 36mm and torqued to 110ft/lbs IIRC. Remove the rear cover that is on the back side of the split case and you'll see it.

Once I'm in the gears, all is well with the transmission pulling and driving. The slots seem to be easy to find other than a little clunk that I attribute to the gear teeth knocking a little bit. If I wait for the clunking to stop, or go back to neutral and then back into the gear, the shift is usually smooth. Same condition for 2nd, 3rd & 4th (Im not in 5th enough to even know if the issue exists there)

 

[John Smith]

Once I'm in the gears, all is well with the transmission pulling and driving. The slots seem to be easy to find other than a little clunk that I attribute to the gear teeth knocking a little bit. If I wait for the clunking to stop, or go back to neutral and then back into the gear, the shift is usually smooth. Same condition for 2nd, 3rd & 4th (Im not in 5th enough to even know if the issue exists there)

You should stop driving this truck now based on the above; none of that is normal. Did you pull the top cover on this transmission before installing and inspect it?

 

[gmgardner99]

Here are some pictures of the clutch area with the inspection cover off.

The parts installed were:
Release bearing 90363-52001-77
Clutch master Cylinder 31410-60282
Clutch Slave Cylinder 31470-60100 (box also say 31470-60102)

 

[gmgardner99]

The pedal travel isl just over 7" and the slave cylinder throw is about 3/4-7/8"

I put the rear axle up on jack stands and tried to do some diagnostics:

- The clutch seems to completely disengage. When the pedal is depressed I can freely turn the rear driveshaft with no resistance. There is enough room between the flywheel and pressure plate that I can rattle the clutch plate with my finger.
- With no load on the transmission, there is no roar/whine noise from the driveline

 

[woytovich]

Drive shaft angles correct?

Should the clutch plate "rattle"?

 

[klinetime574]

Where did you get the pressure plate? I re-read the thread and didn't see a mention of it. It looks weird to me. May just be the photos though.

You should have no issues if all of the parts are late FJ60 era. Some are the same, not sure about others.

 

[gmgardner99]

With the help of fellow MUD'r John Smith I figured a few things out today, mainly that I'm paranoid. A long time FJ owner thinks that the gear roar/whine is normal. It's much louder than I'm used to but within an acceptable range. The PO also confirmed that he thought it was a little loud, but he drove the transmission/T-Case setup for 5k miles with no issues. Because of the perceived noise, I was worried that I needed to take it easy and was shifting too carefully, letting the gears grind after the shifter had already synced the gear. I started driving it confidently today, and didn't have the grinding issues I had experienced before.

Personally, I was expecting better from a late 80's transmission setup. I wasn't expecting a modern car, but I was expecting a smoother shift and no gear noise from a factory built transmission. Looks like the interior soundproofing is moving up the list of mods!

I appreciate everyone's help and on the plus side I did get my clutch adjusted correctly from some of the initial posts and met a member of the local club.

 

[klinetime574]

Awesome man. Glad everything is good!

 

[gmgardner99]

Well, I think I may have spoken too soon...

So my initial test drives were with the majority of the interior still out, without the shifter boots screwed down. Over the weekend I installed soundproofing mat, and buttoned up the interior. Completely.

On the first drive, it is clear that there is metal on metal somewhere or a bearing going out. The noise appears to be on the Input shaft side:
- Noise sitting still in neutral, with clutch out
- No noise sitting still when the clutch is depressed
- Noise when rolling, clutch depressed, in gear
- No noise when rolling, clutch is depressed, out of gear

This doesn't seem clutch related, and the pilot and release bearing are brand new. Any other suggestions on what I should look for from a diagnostic point of view before I pull the transmission? I can pull the interior out and pull the top cover of the transmission, but I'm not sure of what I'll be looking for at that point. I don't know if I want to break into the transmission itself.

I'malso looking for some recommendations for a transmission shop in the DC area, or someone who has a H55 swapped into their 60/62 so I can see if any of my shifting concerns are typical H55 or also signs of a problem.

 

[klinetime574]

Is the noise louder in any gear?

I just rebuilt my H42. My rear countershaft bearing was toast.

The bearing circled in red. Symptoms sound a lot like yours.

- Noise while in neutral, foot off the clutch
- Goes away with foot on clutch
- Grinding when moving in gear

Mine made the most noise in first and second gear because that rear bearing (the one I circled) is closest to first and second gear.

Read this thread if you want to know more about my case. I even have a video of the problem noises on there.

Transmission Noises w/ video

Noise was a lot louder with the shift boot removed. And now that it is rebuilt there is no noise at all other than a nice transmission.