Hello all, I’ve had this truck for the last 6 years and boy has it been a doozie. Let me start off with a little backstory. The truck had a new crate in-line 6 engine from Jasper Motor Company dropped into it and as I was waiting on deliver of the motor, I had the M5R2 rebuilt. Since then I’ve put 25-30k mi on the combination and I’ve had the usual myriad of issues common with 30 year old trucks. Recently I’ve been noticing an extremely sloppy clutch pedal, hard shifting, loud clanking/banging while shifting, a pinion seal leak (which I believe to be caused in part at least, by dropping the drive line due to a flange yoke on the diff snapping twice), shifter not wanting to stay in reverse (I’ll put it in reverse and go to let the clutch out and it’ll pop out of gear and grind like there’s no tomorrow, most times I have to slam it in 2 or 3 times before it’ll stick, other times I have to hold it in gear a certain way) and an intermittent loss of power, which could be because of something engine related, though I am not sure as it comes and goes whenever, but is mostly noticeable under power. I’m trying to get an idea of what’s going on with the transmission, and how I could go about fixing these problems but as I have never had to deal with a transmission before I have no idea what I’m dealing with or getting into. I am trying to be as helpful and descriptive as I can with what’s going on in this original post, but if there is any relevant information needed or some sort of diagnostic something I need to do please don’t hesitate to ask for or let me know what to do!

much thanks in advance, C.

 

Can you try that again but with paragraphs?

I'm not sure how it's possible to have so many problems with a supposedly rebuilt engine and trans. Sounds like you have clutch issues and/or worn out synchro issues but they can sometimes be confused with each other at the margins.

Have you tried just holding the shifter while you use reverse? I've got a 200k van that pops out of reverse and holding it in works fine.

 

Between me trying to learn what I am doing and taking it to “buddies who can do it for cheap” I’ve learned a few lessons. I am still currently chasing down EGR vacuum problems caused by the last shade tree mechanic that worked on it.

I’ve been doing a little research and it seems likely that some of what I am experiencing is caused by the synchros. Though I believe that I should do a transmission fluid flush, and try bleeding my clutch as well.

I believe I mentioned it in my original post but I am not sure, but yes I have tried holding it in reverse as I try to let the clutch out but it feels like it has very little “grab” in the gear and ends up popping out as well, until I start moving a little.

As for 1st I only have trouble shifting into it from a standstill and it feels like I have to push the clutch pedal through the floor almost to get a smooth entry. 2nd-5th just seem to have a slight barrier you have to pass at the gate.

 

Stay away from folks that claim 'know someone cheaper' as they typically do not know their *** from a hole in the ground.

Check your pedal box bushings. The swing arm for wear and its small bushing. You have a disengagement issue of the clutch if can barely put into 1st.

Reverse popping out? Not sure but always easier to pop into 5, then R as on same shift rail... keeping clutch in the entire time.

 

Is there air that is stuck it the clutch system?