Transmission Rattle

[RWBeringer4x4]

so, does it shift into 4L now ?

Nope, tried to free up the linkage but one of the bolts is stripped (probably why the PO didn't do it). Then my 12mm socket fell into the frame rail and vanished...

That, and losing my clutch hydraulics pulled me away from this issue.

Poor old truck has a long way to go!

I have a sneaking suspicion that the rattle in 3rd and 4th has something to do with the shift fork - in 4th it rattles the shifter like it wants to try and toss itself out of 4th gear - not quite as bad in 3rd. Either the fork itself, or the collar that engages the gear, may not be fully engaging the gear or simply loose. Totally a guess but, having stared at my Haynes manual for an hour trying to learn me something about transmissions, that's the best guess I can come up with.

 

[RWBeringer4x4]

On a similar note - if it is a gearshift fork, or toothless gears, can I even get the replacement parts anymore? I know they have soft part/bearing rebuild kits, but I haven't seen anything about actual replacement gears.

 

[Fast Eddy]

At that point it's usually cheaper to get a used tranny rather than replacing individual parts. People have parts around. Try Valley Hybrids or Mark's Off Road.

 

[RWBeringer4x4]

At that point it's usually cheaper to get a used tranny rather than replacing individual parts.

Kind of what I figured. A lot less down-time as well. The only thing I can't stand more than mystery rattles is when they stop because the truck is dead!

 

[DSRTRDR]

I have had all kinds of mystery rattles by now - some of which originated, out of all places, in the glove box

seriously, you should go and systematically test all possibilities before you come to any ad-hoc conclusion that may be wrong

 

[RWBeringer4x4]

seriously, you should go and systematically test all possibilities before you come to any ad-hoc conclusion that may be wrong

I am systematically going through it - and trust me, I'm not going to go rip out my transmission tomorrow. I'm still tapped financially from buying the 40 to start replacing major components yet! I'm just trying to feel it out and figure out exactly what I'm in for so I can plan accordingly. That said, I am 99% certain that the rattle in question is coming from my transmission, or the shifter itself.

Testing my FJ40 for rattles is like testing the ocean for water. I can confirm that the glove box just contains an ever growing pile of receipts, and the factory speaker (not rattling), but I understand what you're saying!

 

[DSRTRDR]

Testing my FJ40 for rattles is like testing the ocean for water.

not that that would be any news to me

it's a never-ending quest . . . 7 years and going . . .

 

[RWBeringer4x4]

not that that would be any news to me ************

it's a never-ending quest . . . 7 years and going . . .

It's just so frustrating because I bought this 40 for it's smooth, quiet ride

In all seriousness though, can't wait to get over the hump of reviving the truck and on to the "creature comforts" like...weather stripping...

 

[DSRTRDR]

I spent about 4 months on it after I got the truck, replacing and re-wiring - a few hours every day or so, went through everything - thought we had it all going fine, and sure it was, drove 1000 miles to Moab and wheeled for 5 days . . .

and a few days more in Arizona - and then I had a major frame break . . . https://forum.ih8mud.com/az-copper-...putable-shop-do-frame-repair-east-valley.html

what I am sayin' is: there is no end to it - once you get the immediate things done, others will creep up . . .

decide whether you like your truck right now, if not, sell it ASAP ;p you will be financially ahead if you sell, for sure

 

[jpeterson]

I have the same exact rattle in my tranny. 2f with an h55. I took off the access panel to look at the clutch and found the throw out bearing rubbing on the pressure plate. Haven't fixed yet. I believe the retaining spring is out of adjustment. It makes me nervous to mess with it and possibly break it, so I plan on taking everything part soon.

 

[RWBeringer4x4]

Jpeterson- Wouldn't that rattle be in every gear of it was the throw out bearing? I don't even have the spring on my slave to adjust! I have one on the way I guess I'll see if that fixes it.

 

[jpeterson]

It probably does make that nose in every gear. I only hear in the higher gears, usually decelerating with the clutch in or in neutral, above 30ish. On mine, I can see some of the wear on the release springs of the pressure plate.

I feel it in the the shifter as well, just like you mentioned. Let me know how you fix it!

Josh

 

[RWBeringer4x4]

I'm installing the slave cylinder spring that was missing when I installed bought the 40 today when I replace the clutch master. I will let you know how it goes!

 

[RWBeringer4x4]

I feel it in the the shifter as well, just like you mentioned. Let me know how you fix it!

Josh

Hey Josh,

Just wanted to follow up - I (finally) replaced my clutch master and installed the clutch slave spring. No dice, still rattling. I'm actually going to be dropping my driveshaft to look into my e-brake next, I figure I might just remove it all together, drop it into 4WD and drive around with the front wheels a little to see if the rattle is eliminated.

I tried rattling the yokes and U-joint before and they seemed solid, but stranger things have happened.

Have you made any progress on this?

Thanks,

Rick

 

[RWBeringer4x4]

I figure I might just remove it all together, drop it into 4WD and drive around with the front wheels a little to see if the rattle is eliminated.

On second thought, can I do this or will my transfer case drain if I remove the driveshaft?

 

[RWBeringer4x4]

Still Rattlin'...

Ok guys-beautiful weekend in Delaware, figured I'd might as well spend the day under my truck trying to identify this rattle. Today I:

1. Changed the oil - because I hadn't since I bought it from the PO and figured I should.

2. Changed transmission fluid (1/2 bottle of PB blaster on tranny drains).

Transmission wasn't filled to the max, but pretty close - drain plug was FULL of metal dust. (See picture) - Now I have no idea what is considered "normal wear" and what is "way out of the ordinary" but the metal was like a finely ground sand, almost like the consistency of anti-seize grease - a few pieces were a little larger, but nothing larger than the ball on a ball point pen.

Can anyone chime in on whether this is really bad or just kind of bad? Unfortunately I don't know if this is a month of build up or 37 years of ground gears...

2b. Also - replaced my socket wrench plugs with MAF allen wrench style heads - should make life easier next time

3. dropped the rear driveshaft, drove around. The U-joints, as I mentioned before, felt solid - dropping the shaft didn't make any noticable change in the rattle.

4. Found a place on the front driveshaft that LOOKED like it was rubbing on my exhaust - duct tape test proved it was not.

I didn't get around to getting into my parking brake since I don't have a replacement stake nut, but now that all the bolts are free, it should be cake to get back in.

SO, unfortunately nothing conclusive to report, unless that metal powder was way out of the ordinary. Let me know what you all think!

 

[RWBeringer4x4]

Sunday night bump!

Again - does anyone know how much metal dust is "normal" and what size bits are normal - mine was mostly "glitter" but there were a few chunks I could physically feel/roll around in my fingers, but still no bigger than 1/2 a pin head.

How concerned should I be? Should I be looking for a new transmission or is this "normal wear and tear?"

 

[NikP]

So do you get the same noise with the transfer case in neutral and you can run through the transmission gears with some acceleration? If its transmission you should be able to re-create it without moving. Best to try this in 2H with the rear on jack stands just to make sure nothing engages unexpectedly.

I had a noise that I thought was transmission or tcase and finally isolated it without both driveshafts connected so I could run through the gears.

 

[RWBeringer4x4]

So do you get the same noise with the transfer case in neutral and you can run through the transmission gears with some acceleration? If its transmission you should be able to re-create it without moving. Best to try this in 2H with the rear on jack stands just to make sure nothing engages unexpectedly.

I had a noise that I thought was transmission or tcase and finally isolated it without both driveshafts connected so I could run through the gears.

Hey Nik, thanks for responding. Unfortunately, the shift linkage on my transfer case is jammed, so I only have 2H and 4H right now. (only owned the 40 for about a couple months, still working the kinks out)

The only reason I don't think it has anything to do with the transfer case is that I don't get ANY vibration/shaking in the transfer case shift lever, but my transmission shift lever shakes like crazy, almost like it's trying to buck itself out of gear. (It never does though).

Not a bad idea disconnecting both of the driveshafts though, I disconnected mine one at a time, probably accomplished the same thing. Still rattled running just the front and just the rear...

 

[RWBeringer4x4]

Rattle Fixed!

Hey all, wanted to follow up on this thread, in case anyone else runs into this issue in the future.

The rattling in my drivetrain was actually coming from the transfercase, which grenaded at my mechanic's shop a couple weeks later - it had sheered the clutch gear between the high and low side of the case...and the chunks had torn up a bunch of the other gears.

I bought a replacement case from a fellow MUD member (THANKS!) and had my mechanic reseal and install it, since it was stuck at his shop anyway.

The Bellhousing had also stripped some bolts and worked itself loose, but this was not the source of the rattle.

The rattle is gone, truck shifts like a dream, and I finally have a functional parking brake!

One final thing if anyone bothered to read this far - the shifter still shakes/vibrates like crazy, particularly at higher speeds - is this normal?