Jamo761 Posted November 26, 2013 Share Posted November 26, 2013 Hello I have a 1991 turbo diesel pathfinder, 5 spd manual. It has developed a problem where it slips out of gear, but not in the normal way. When it slips out of gear, the gear lever doesn't move (and holding it in place doesn't prevent it from slipping out) and it makes some grinding/crunching noises when it does it. It does it in all gears including reverse, stationary or moving. When it does it stationary it feels like it's catching and trying to drive but then drops out again. When it slips out of gear you can have the clutch all the way out with and it doesn't do anything, it doesn't even make any noise. This problem didn't develop over time, it just started happening, however there has been the odd clunk when changing gear, both during the shift and when the clutch is let out, it almost sounds and feels like excessive backlash in the drive train. Does anybody have any ideas? I'm starting to think it's the transfer case. Is there anyway a clutch failure could cause it? I haven't driven the vehicle since it started to happen except to move it slowly back and forth, which it will do under it's own power. Once it begins slipping I can get the vehicle to move again by ether cycling it into 4wd and back to 2wd. The clutch doesn't seems to be slipping, I can stall the engine by slowly letting the clutch out with the hand break on when it's in a setup that where it isn't slipping. Shifting through the gears when stationary feels normal, pumping the clutch feels normal (not that you get much feel from a hydraulic clutch) Any ideas or help would be greatly appreciated. Link to comment Share on other sites More sharing options...
jhamelin819 Posted November 26, 2013 Share Posted November 26, 2013 its jumping out of your normal high range gears? 1 through 5? sounds like a bad syncro through all of the gears Link to comment Share on other sites More sharing options...
Precise1 Posted November 26, 2013 Share Posted November 26, 2013 When it 'slips out of gear', is the drive shaft turning? B Link to comment Share on other sites More sharing options...
Jamo761 Posted November 26, 2013 Author Share Posted November 26, 2013 Nope, drive shafts are stationary.... Link to comment Share on other sites More sharing options...
Jamo761 Posted November 26, 2013 Author Share Posted November 26, 2013 If it was the syncros, wouldn't the gear leave move into neutral? Gear lever remains in posting and holding it in gear makes no difference.... Link to comment Share on other sites More sharing options...
Alkorahil Posted November 26, 2013 Share Posted November 26, 2013 You stated this happened all at once, not gradually, this sounds to me like some sort of issue with your shifter linkage or shifter forks. When you went to engage the shifter or change gears you popped a retaining pin, clip or spring or broke a knickle ball on one of the forks or something. There are many washers, nylon sockets, springs, etc that will all wear out over time in that shifter setup. With a synchro gear propblem it would pop out from gear, which you say it does not do. Link to comment Share on other sites More sharing options...
snowboard419 Posted November 26, 2013 Share Posted November 26, 2013 I would look at the linkage for the transfer case, sounds like it is definitely related to the t-case some how. also being that after you flip in and out of 4x4 hi low etc it fixes your issue for a bit, does not sound like clutch or trans to me. Link to comment Share on other sites More sharing options...
silverton Posted November 27, 2013 Share Posted November 27, 2013 If shifting it from 4wd to 2wd or back lets it move again and you don't notice anything funky in the transmission shifter, I'd say your t-case is well on its way out. Link to comment Share on other sites More sharing options...
Inyourface1650 Posted November 27, 2013 Share Posted November 27, 2013 what happens if your in 4wd? Link to comment Share on other sites More sharing options...
Slartibartfast Posted November 28, 2013 Share Posted November 28, 2013 Sounds to me like the drive to the rear end is getting interrupted, and when you put it in 4x, the front end pulls you out. This sounds like a transfer case issue to me. I'm staring at the FSM diagram and all I can figure is that something's gone wrong with the the shift fork for the 2-4 coupling sleeve. Could be wear, could be an issue with the linkage that moves it. I don't think that sleeve is ever supposed to be completely disengaged; the low/high coupling sleeve is the one with the neutral position, so far as I can tell. I suspect it's moving beyond were it's supposed to and grinding on the bit that's supposed to drive the rear. I may be reading the diagrams wrong, of course; the FSM only says where the parts go. But if I'm right, hopefully it's a simple linkage problem, and the grinding hasn't butchered anything important. If it does turn out to be the linkage, don't forget to change the fluid... you may have some metal bits swimming around in there. Link to comment Share on other sites More sharing options...
Jamo761 Posted December 2, 2013 Author Share Posted December 2, 2013 So, it turns out one of the main drive gears is keyed on to its shaft. The key way was flogged out, the key was amost completely destroyed and there were marks on the shaft where the gear had been spining on it. Ended up buying a reconditioned gearbox and had it swapped out. One odd thing, the overhaul shop filled the gear box with Dextron 6 (it's a manual, so normally it would use GL4...). I have heard of this being common practice on late model gear boxes, but nothing as old as 1991. Anybody heard of anyone doing using dextron 6, and if so how did it go? Link to comment Share on other sites More sharing options...
Kingman Posted December 2, 2013 Share Posted December 2, 2013 No! GL4 only! Link to comment Share on other sites More sharing options...
Precise1 Posted December 2, 2013 Share Posted December 2, 2013 ^x2 There are a few options with Amsol and Redline, but otherwise, definitely GL-4 only. Also, make sure to 'overfill' it with 5 liters of gear oil, easiest way is down the shifter throat... B Link to comment Share on other sites More sharing options...
Kingman Posted December 2, 2013 Share Posted December 2, 2013 Pennzoil also makes. GL-4, its called GM Synchromesh. Seems to be cheaper on average than Redline and easier to come by. Link to comment Share on other sites More sharing options...
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