my H55 jumps out of 5th gear

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rossg

rossg

10 Year 15 Year
Joined
Oct 3, 2008
Threads
14
Messages
67
Location
Melbourne - AUS
Hi guys

I cant really find any specific threads on how to fix this problem...

Just put in a second hand H55 into my '79 BJ40. Had the box looked over by a local gearbox guy who put new bearings into it - and gave me the thumbs up on the unit.

All gears work pretty good and is quiet.. but the old chestnut rears its ugly head.. 5th gear jumps straight out as soon as you back off on the go pedal. Happens every time and not intermittently

Can anyone tell me what normally causes this .. I have seen references to

a) 5th gear clutch dog assembly being worn
b) Something in 5th assembly needing to be bent
c) Nylon bush missing from bottom of gear lever (which mine is missing)

But nothing that gives me a good understanding of what is actually going wrong here..

I am hoping with feedback from you cruiser men - that I can hold a educated conversation with my gearbox man later this week..

I assume there is nothing adjustable here?

Is there anything I should try or check before box on ground time?


thanks guys
 
Put a new bush on the bottom of the stick. Mahe sure the two locating pins in the housing are tight. If it still jumps out replace the all the parts in 5 as they are worn. You dont have to stripp the box ,just take the extenshion housing off an you can fix it.Dont use second hand parts, You will have the same problem.
 
hi Aussie 25

thanks for your response..

Can I confirm which two locating pins you are refering to? I assume they are those between gearbox and 5spd extension housing?

Was there a specific list of parts that are normally subject to wear in 5th gear?
 
do you have good clearance for the shifter stalk coming thru the floor?
 
yep - no problem with stick fowling on the floor...

Also got a new bush from toyota this morning for the end of the gearstick. Result: Still jumps out of gear when I decelerate...

Has no problem going into 5th - and is no sign of whining etc...
 
rossg said:
hi Aussie 25

thanks for your response..

Can I confirm which two locating pins you are refering to? I assume they are those between gearbox and 5spd extension housing?

Was there a specific list of parts that are normally subject to wear in 5th gear?
Click to expand...
The two pins that hold the stick into the top of the box where the retaineer locks on. Are they loose in the aloy casing?. I realey think that 5 gear slector hub and gear pice is worn. Did you say the box has had a bearing kit?
 
It takes very little wear in 5th to let them jump out . You have put new bearings in tcase and box, so you omley need a few bits.They arnt cheap. You can do it in the car, but easier if you take it out. Just take the tcase and extenshion off and there is 5th. The parts are No5 pice,gear spline. Syncro ring. Spring shift key x2. Sleve transmission hub no3. Key shifting x3. Go to toyodiy/parts to get the numbers. Not a hard job to fix.
 
thanks Aussie 25...

for those interested - I believe these parts are:


33318 PIECE, GEAR SPLINE, NO.5
33318-36012 BJ7*, HJ75, FJ7*..5F 1 208.69

33369 RING, SYNCRONIZER, NO.3
33368-20012 BJ7*, HJ75, FJ7*..5F 1 42.17

33376 SPRING, SYNCROMESH SHIFTIN KEY
33391-36010 BJ7*, HJ75, FJ7*..5F 2 42.17

33377 KEY, SYNCHROMESH SHIFTING
33394-36011 BJ7*, HJ75, FJ7*..5F 3 2.98

33395 SLEEVE, TRANSMISSION HUB NO.3
33395-36010 BJ7*, HJ75, FJ7*..5F 1 136.23

I will visit my local dealer tomorrow to see what these would cost...
 
went to toyota this morning. All parts I could get except for gear spline piece. They wanted $370 odd dollars for it and would have to come from Japan...

I ordered instead from 4x4world.com.au


1 x 33318-36012 GEAR PIECE C/S 5TH $ 159.50 $ 159.50

2 x 33391-36010 SPRING SYNCRO 5TH $ 2.30 $ 4.60

3 x 33394-36011 KEY 5TH SYNCRO HUB $ 5.20 $ 15.60

1 x 33368-20012 RING, SYNCHRONIZER, NO.2 $ 71.50 $ 71.50

1 x 33395-36010 SLEEVE, TRANSMISSION HUB, NO.3 $ 262.60 $ 262.60

most of the parts are genuine toyota parts..

Hopefully this will fix it..

This box has been a real bad investment.. Cost me $2000 for a suposedly reco box.. But it arrived with a bent input shaft and some bearings that were not new.. Cost me another $350 to get it to this point...

No choice now but to finish what I started tho...
 
Good to see you found the parts. That is a good site they got. That prices are arnt bad, but that sleve 33395-36010 is about $80 overpriced i think. The pices that will be worn are the sleve and the pice,gear spline. The rest you change to make sure. Cheers.
 
just to round this thread off.. and for anyone interested - I have fixed this problem with my box...

I ended up taking the parts listed above to my gearbox man who has successfully fixed it..

this is what he told me:

a) Gearbox cluster wears and slop appears in 5th gear cluster... It eventually gets so bad - 5th gear is engaged only by the end of the teeth on the hub sleeve and gear piece. And the more it jumps out of gear the worse the wear on these teeth become - and the worse the problem gets.

b) There are potentially a number of fixes for this type of problem - ranging from place two or more gaskets between gearbox and 5th gear housing to take up some of the end-play.. Placing new gear piece and hub sleeve may also fix it too (for a short time).

c) He tells me the best (and only good way) to fix this type of problem is to place the 5th gear selector fork in the press and bend it by about 2mm. This ensures that engagement of 5th gear occurs with the hub sleeve and the gear piece fully engaged.

- He noted that my sleeve and gear piece were worn due to this behaviour - and he put my new parts in..

- He also noted that in the past 20 years or so - he has done a quillion of these - and the problem is common..

- He said it was not necessarily a design fault on behalf of toyota, but more a side effect of a gearbox that wears out...

For those interested - cost me $100AUD to get him to fix it.

So for all of you out there that believe this problem equates to needing a new box - maybe investigate a little more.

Thanks to all of you who helped me.. (particularly aussie25)...
 
rossg said:
just to round this thread off.. and for anyone interested - I have fixed this problem with my box...

I ended up taking the parts listed above to my gearbox man who has successfully fixed it..

this is what he told me:

a) Gearbox cluster wears and slop appears in 5th gear cluster... It eventually gets so bad - 5th gear is engaged only by the end of the teeth on the hub sleeve and gear piece. And the more it jumps out of gear the worse the wear on these teeth become - and the worse the problem gets.

b) There are potentially a number of fixes for this type of problem - ranging from place two or more gaskets between gearbox and 5th gear housing to take up some of the end-play.. Placing new gear piece and hub sleeve may also fix it too (for a short time).

c) He tells me the best (and only good way) to fix this type of problem is to place the 5th gear selector fork in the press and bend it by about 2mm. This ensures that engagement of 5th gear occurs with the hub sleeve and the gear piece fully engaged.

- He noted that my sleeve and gear piece were worn due to this behaviour - and he put my new parts in..

- He also noted that in the past 20 years or so - he has done a quillion of these - and the problem is common..

- He said it was not necessarily a design fault on behalf of toyota, but more a side effect of a gearbox that wears out...

For those interested - cost me $100AUD to get him to fix it.

So for all of you out there that believe this problem equates to needing a new box - maybe investigate a little more.

Thanks to all of you who helped me.. (particularly aussie25)...
Click to expand...

Hi Rossg, may I know where your mechanic is?

I am having the same issue with H55 5th gear poping out.

I am in Melbourne.

Thanks.
 
Aussie 25 said:
5TH

That is very interesting. Never to old to learn more info. The next one i build i will fit the top and make sure it gets full engaumentin 5th before fitting the t/case. Hope yours go well :cheers:
Click to expand...

Need to make a mental note to do this. Besides needing to install an F/H input shaft for the B input shaft there now the bearing on the rear output on the transfer case needs attention.

javaman said:
Hi Rossg, may I know where your mechanic is?

I am having the same issue with H55 5th gear poping out.

I am in Melbourne.

Thanks.
Click to expand...

FYI Rossg has not logged on to Mud since February 5th 2016. Would not hold my breath waiting for a response.
 
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