Need help with T-150 Tranny Popping Out of 2nd
 

I have a 79 CJ-5 with 304 and T-150. Tranny was just completely rebuilt, all
gears. I have replaced tranny mount, torque-arm bushing, and motor mounts
with new poly ones. I also rebuilt the shifter myself with new spring,
retaining pins, etc. and completely replaced and adjusted the clutch
bell-crank linkage.. The shifter is not hitting any part of the body in any
gear. The belly pan is secure as well. Upon driving, all is smooth except in
second gear. The shift seems a little short into second compared to all the
other gears. When driving in second, I can hold the shifter in gear and feel
a pop through the shifter right around the same RPM range every time. If I
was not holding it in, it would come out of gear. I does not seem to like
cornering in second gear very much either. I inspected the shifter assembly
and both shift forks look to be in good shape except for a minimal amount of
wear from years of driving and they don't bind on anything that I can see.
The shift fork for second gear does have an extremely minute amount of play
on the shift rail compared to the other fork, but it does not seem too out
of whack. Also, I drained the crud gear oil out that the mechanic put in it
and replaced it with Mobile 1 75W-90 GL-5. That really helped smooth things
out a bit, but did not solve the second gear issue.

Any help would be greatly appreciated. I cannot simply take it back to the
guy who overhauled the tranny because that was done several months back by
the previous owner. Also, if I have to take this into a shop, what kind of
$$$$$ should I expect?

Thanks,

GK

Re: Need help with T-150 Tranny Popping Out of 2nd
 

Assuming it's as you say and the shifter's not hitting something or being
kept from full engagement, first thing to be suspicious of when popping out
of gear problems occur is wear on the clutch gear/gear engagement teeth, and
the clutch gear dogs & springs.

If there's a lot of wear on the engagement teeth on either the sliding ring
or the gear itself it won't be able to hold. Another concern, if it's
feeling like it doesn't go all the way into gear there's the chance he's got
clutch gear assy or one of the components installed on the shaft backwards.
Not sure that's possible on a T150, but one thing to check.

Any way you cut it, sounds like it needs to be pulled out of there and torn
down. $? Hard to say, but it's probably a 4hr R&R, teardown & reassy job.
Will depend upon what's found inside.


"GK" <nospam@nospam.com> wrote in message
news:V%o3b.2623$eG2.262597@twister.austin.rr.com.. .
> I have a 79 CJ-5 with 304 and T-150. Tranny was just completely rebuilt,
all
> gears. I have replaced tranny mount, torque-arm bushing, and motor mounts
> with new poly ones. I also rebuilt the shifter myself with new spring,
> retaining pins, etc. and completely replaced and adjusted the clutch
> bell-crank linkage.. The shifter is not hitting any part of the body in
any
> gear. The belly pan is secure as well. Upon driving, all is smooth except
in
> second gear. The shift seems a little short into second compared to all
the
> other gears. When driving in second, I can hold the shifter in gear and
feel
> a pop through the shifter right around the same RPM range every time. If I
> was not holding it in, it would come out of gear. I does not seem to like
> cornering in second gear very much either. I inspected the shifter
assembly
> and both shift forks look to be in good shape except for a minimal amount
of
> wear from years of driving and they don't bind on anything that I can see.
> The shift fork for second gear does have an extremely minute amount of
play
> on the shift rail compared to the other fork, but it does not seem too out
> of whack. Also, I drained the crud gear oil out that the mechanic put in
it
> and replaced it with Mobile 1 75W-90 GL-5. That really helped smooth
things
> out a bit, but did not solve the second gear issue.
>
> Any help would be greatly appreciated. I cannot simply take it back to the
> guy who overhauled the tranny because that was done several months back by
> the previous owner. Also, if I have to take this into a shop, what kind of
> $$$$$ should I expect?
>
> Thanks,
>
> GK
>
>

Re: Need help with T-150 Tranny Popping Out of 2nd
 

Assuming it's as you say and the shifter's not hitting something or being
kept from full engagement, first thing to be suspicious of when popping out
of gear problems occur is wear on the clutch gear/gear engagement teeth, and
the clutch gear dogs & springs.

If there's a lot of wear on the engagement teeth on either the sliding ring
or the gear itself it won't be able to hold. Another concern, if it's
feeling like it doesn't go all the way into gear there's the chance he's got
clutch gear assy or one of the components installed on the shaft backwards.
Not sure that's possible on a T150, but one thing to check.

Any way you cut it, sounds like it needs to be pulled out of there and torn
down. $? Hard to say, but it's probably a 4hr R&R, teardown & reassy job.
Will depend upon what's found inside.


"GK" <nospam@nospam.com> wrote in message
news:V%o3b.2623$eG2.262597@twister.austin.rr.com.. .
> I have a 79 CJ-5 with 304 and T-150. Tranny was just completely rebuilt,
all
> gears. I have replaced tranny mount, torque-arm bushing, and motor mounts
> with new poly ones. I also rebuilt the shifter myself with new spring,
> retaining pins, etc. and completely replaced and adjusted the clutch
> bell-crank linkage.. The shifter is not hitting any part of the body in
any
> gear. The belly pan is secure as well. Upon driving, all is smooth except
in
> second gear. The shift seems a little short into second compared to all
the
> other gears. When driving in second, I can hold the shifter in gear and
feel
> a pop through the shifter right around the same RPM range every time. If I
> was not holding it in, it would come out of gear. I does not seem to like
> cornering in second gear very much either. I inspected the shifter
assembly
> and both shift forks look to be in good shape except for a minimal amount
of
> wear from years of driving and they don't bind on anything that I can see.
> The shift fork for second gear does have an extremely minute amount of
play
> on the shift rail compared to the other fork, but it does not seem too out
> of whack. Also, I drained the crud gear oil out that the mechanic put in
it
> and replaced it with Mobile 1 75W-90 GL-5. That really helped smooth
things
> out a bit, but did not solve the second gear issue.
>
> Any help would be greatly appreciated. I cannot simply take it back to the
> guy who overhauled the tranny because that was done several months back by
> the previous owner. Also, if I have to take this into a shop, what kind of
> $$$$$ should I expect?
>
> Thanks,
>
> GK
>
>

Re: Need help with T-150 Tranny Popping Out of 2nd
 

For the reasons Gerald gave, give it back to them. Check to make
sure you don't have an after market shifter with stops to prevent
synchro damage, that are too tight.
God Bless America, ßill O|||||||O
mailto:-------------------- http://www.----------.com/

GK wrote:
>
> I have a 79 CJ-5 with 304 and T-150. Tranny was just completely rebuilt, all
> gears. I have replaced tranny mount, torque-arm bushing, and motor mounts
> with new poly ones. I also rebuilt the shifter myself with new spring,
> retaining pins, etc. and completely replaced and adjusted the clutch
> bell-crank linkage.. The shifter is not hitting any part of the body in any
> gear. The belly pan is secure as well. Upon driving, all is smooth except in
> second gear. The shift seems a little short into second compared to all the
> other gears. When driving in second, I can hold the shifter in gear and feel
> a pop through the shifter right around the same RPM range every time. If I
> was not holding it in, it would come out of gear. I does not seem to like
> cornering in second gear very much either. I inspected the shifter assembly
> and both shift forks look to be in good shape except for a minimal amount of
> wear from years of driving and they don't bind on anything that I can see.
> The shift fork for second gear does have an extremely minute amount of play
> on the shift rail compared to the other fork, but it does not seem too out
> of whack. Also, I drained the crud gear oil out that the mechanic put in it
> and replaced it with Mobile 1 75W-90 GL-5. That really helped smooth things
> out a bit, but did not solve the second gear issue.
>
> Any help would be greatly appreciated. I cannot simply take it back to the
> guy who overhauled the tranny because that was done several months back by
> the previous owner. Also, if I have to take this into a shop, what kind of
> $$$$$ should I expect?
>
> Thanks,
>
> GK

Re: Need help with T-150 Tranny Popping Out of 2nd
 

For the reasons Gerald gave, give it back to them. Check to make
sure you don't have an after market shifter with stops to prevent
synchro damage, that are too tight.
God Bless America, ßill O|||||||O
mailto:-------------------- http://www.----------.com/

GK wrote:
>
> I have a 79 CJ-5 with 304 and T-150. Tranny was just completely rebuilt, all
> gears. I have replaced tranny mount, torque-arm bushing, and motor mounts
> with new poly ones. I also rebuilt the shifter myself with new spring,
> retaining pins, etc. and completely replaced and adjusted the clutch
> bell-crank linkage.. The shifter is not hitting any part of the body in any
> gear. The belly pan is secure as well. Upon driving, all is smooth except in
> second gear. The shift seems a little short into second compared to all the
> other gears. When driving in second, I can hold the shifter in gear and feel
> a pop through the shifter right around the same RPM range every time. If I
> was not holding it in, it would come out of gear. I does not seem to like
> cornering in second gear very much either. I inspected the shifter assembly
> and both shift forks look to be in good shape except for a minimal amount of
> wear from years of driving and they don't bind on anything that I can see.
> The shift fork for second gear does have an extremely minute amount of play
> on the shift rail compared to the other fork, but it does not seem too out
> of whack. Also, I drained the crud gear oil out that the mechanic put in it
> and replaced it with Mobile 1 75W-90 GL-5. That really helped smooth things
> out a bit, but did not solve the second gear issue.
>
> Any help would be greatly appreciated. I cannot simply take it back to the
> guy who overhauled the tranny because that was done several months back by
> the previous owner. Also, if I have to take this into a shop, what kind of
> $$$$$ should I expect?
>
> Thanks,
>
> GK

Re: Need help with T-150 Tranny Popping Out of 2nd
 

I took the shifter assembly off again to have another look. It appears that
one of the small parts inserts from the 1st/2nd synchronizer hub is missing.
According to my rebuild manual there should be 3 inserts per synchro. I
guess I missed it the first time and I have no idea if it's in the bottom of
the case or was never put in. Probably the latter. Luckily, the whole "small
parts" kit for the T-150 is around $35 from 4WD Hardware. Now I wonder if I
can actually install it myself without a full disassembly??

Thanks,

GK

"GK" <nospam@nospam.com> wrote in message
news:V%o3b.2623$eG2.262597@twister.austin.rr.com.. .
> I have a 79 CJ-5 with 304 and T-150. Tranny was just completely rebuilt,
all
> gears. I have replaced tranny mount, torque-arm bushing, and motor mounts
> with new poly ones. I also rebuilt the shifter myself with new spring,
> retaining pins, etc. and completely replaced and adjusted the clutch
> bell-crank linkage.. The shifter is not hitting any part of the body in
any
> gear. The belly pan is secure as well. Upon driving, all is smooth except
in
> second gear. The shift seems a little short into second compared to all
the
> other gears. When driving in second, I can hold the shifter in gear and
feel
> a pop through the shifter right around the same RPM range every time. If I
> was not holding it in, it would come out of gear. I does not seem to like
> cornering in second gear very much either. I inspected the shifter
assembly
> and both shift forks look to be in good shape except for a minimal amount
of
> wear from years of driving and they don't bind on anything that I can see.
> The shift fork for second gear does have an extremely minute amount of
play
> on the shift rail compared to the other fork, but it does not seem too out
> of whack. Also, I drained the crud gear oil out that the mechanic put in
it
> and replaced it with Mobile 1 75W-90 GL-5. That really helped smooth
things
> out a bit, but did not solve the second gear issue.
>
> Any help would be greatly appreciated. I cannot simply take it back to the
> guy who overhauled the tranny because that was done several months back by
> the previous owner. Also, if I have to take this into a shop, what kind of
> $$$$$ should I expect?
>
> Thanks,
>
> GK
>
>

Re: Need help with T-150 Tranny Popping Out of 2nd
 

I took the shifter assembly off again to have another look. It appears that
one of the small parts inserts from the 1st/2nd synchronizer hub is missing.
According to my rebuild manual there should be 3 inserts per synchro. I
guess I missed it the first time and I have no idea if it's in the bottom of
the case or was never put in. Probably the latter. Luckily, the whole "small
parts" kit for the T-150 is around $35 from 4WD Hardware. Now I wonder if I
can actually install it myself without a full disassembly??

Thanks,

GK

"GK" <nospam@nospam.com> wrote in message
news:V%o3b.2623$eG2.262597@twister.austin.rr.com.. .
> I have a 79 CJ-5 with 304 and T-150. Tranny was just completely rebuilt,
all
> gears. I have replaced tranny mount, torque-arm bushing, and motor mounts
> with new poly ones. I also rebuilt the shifter myself with new spring,
> retaining pins, etc. and completely replaced and adjusted the clutch
> bell-crank linkage.. The shifter is not hitting any part of the body in
any
> gear. The belly pan is secure as well. Upon driving, all is smooth except
in
> second gear. The shift seems a little short into second compared to all
the
> other gears. When driving in second, I can hold the shifter in gear and
feel
> a pop through the shifter right around the same RPM range every time. If I
> was not holding it in, it would come out of gear. I does not seem to like
> cornering in second gear very much either. I inspected the shifter
assembly
> and both shift forks look to be in good shape except for a minimal amount
of
> wear from years of driving and they don't bind on anything that I can see.
> The shift fork for second gear does have an extremely minute amount of
play
> on the shift rail compared to the other fork, but it does not seem too out
> of whack. Also, I drained the crud gear oil out that the mechanic put in
it
> and replaced it with Mobile 1 75W-90 GL-5. That really helped smooth
things
> out a bit, but did not solve the second gear issue.
>
> Any help would be greatly appreciated. I cannot simply take it back to the
> guy who overhauled the tranny because that was done several months back by
> the previous owner. Also, if I have to take this into a shop, what kind of
> $$$$$ should I expect?
>
> Thanks,
>
> GK
>
>

Re: Need help with T-150 Tranny Popping Out of 2nd
 

If it's one of the three "dogs" that goes under the slider on the clutch
gear / synchro hub, you'll most likely have to have the shaft apart to get
the thing in there...then again, there's always the chance that the great
God of shade tree magic may find a way!

"GK" <nospam@nospam.com> wrote in message
news:dcI3b.11356$Pn6.9893@twister.austin.rr.com...
> I took the shifter assembly off again to have another look. It appears
that
> one of the small parts inserts from the 1st/2nd synchronizer hub is
missing.
> According to my rebuild manual there should be 3 inserts per synchro. I
> guess I missed it the first time and I have no idea if it's in the bottom
of
> the case or was never put in. Probably the latter. Luckily, the whole
"small
> parts" kit for the T-150 is around $35 from 4WD Hardware. Now I wonder if
I
> can actually install it myself without a full disassembly??
>
> Thanks,
>
> GK
>
> "GK" <nospam@nospam.com> wrote in message
> news:V%o3b.2623$eG2.262597@twister.austin.rr.com.. .
> > I have a 79 CJ-5 with 304 and T-150. Tranny was just completely rebuilt,
> all
> > gears. I have replaced tranny mount, torque-arm bushing, and motor
mounts
> > with new poly ones. I also rebuilt the shifter myself with new spring,
> > retaining pins, etc. and completely replaced and adjusted the clutch
> > bell-crank linkage.. The shifter is not hitting any part of the body in
> any
> > gear. The belly pan is secure as well. Upon driving, all is smooth
except
> in
> > second gear. The shift seems a little short into second compared to all
> the
> > other gears. When driving in second, I can hold the shifter in gear and
> feel
> > a pop through the shifter right around the same RPM range every time. If
I
> > was not holding it in, it would come out of gear. I does not seem to
like
> > cornering in second gear very much either. I inspected the shifter
> assembly
> > and both shift forks look to be in good shape except for a minimal
amount
> of
> > wear from years of driving and they don't bind on anything that I can
see.
> > The shift fork for second gear does have an extremely minute amount of
> play
> > on the shift rail compared to the other fork, but it does not seem too
out
> > of whack. Also, I drained the crud gear oil out that the mechanic put in
> it
> > and replaced it with Mobile 1 75W-90 GL-5. That really helped smooth
> things
> > out a bit, but did not solve the second gear issue.
> >
> > Any help would be greatly appreciated. I cannot simply take it back to
the
> > guy who overhauled the tranny because that was done several months back
by
> > the previous owner. Also, if I have to take this into a shop, what kind
of
> > $$$$$ should I expect?
> >
> > Thanks,
> >
> > GK
> >
> >
>
>

Re: Need help with T-150 Tranny Popping Out of 2nd
 

If it's one of the three "dogs" that goes under the slider on the clutch
gear / synchro hub, you'll most likely have to have the shaft apart to get
the thing in there...then again, there's always the chance that the great
God of shade tree magic may find a way!

"GK" <nospam@nospam.com> wrote in message
news:dcI3b.11356$Pn6.9893@twister.austin.rr.com...
> I took the shifter assembly off again to have another look. It appears
that
> one of the small parts inserts from the 1st/2nd synchronizer hub is
missing.
> According to my rebuild manual there should be 3 inserts per synchro. I
> guess I missed it the first time and I have no idea if it's in the bottom
of
> the case or was never put in. Probably the latter. Luckily, the whole
"small
> parts" kit for the T-150 is around $35 from 4WD Hardware. Now I wonder if
I
> can actually install it myself without a full disassembly??
>
> Thanks,
>
> GK
>
> "GK" <nospam@nospam.com> wrote in message
> news:V%o3b.2623$eG2.262597@twister.austin.rr.com.. .
> > I have a 79 CJ-5 with 304 and T-150. Tranny was just completely rebuilt,
> all
> > gears. I have replaced tranny mount, torque-arm bushing, and motor
mounts
> > with new poly ones. I also rebuilt the shifter myself with new spring,
> > retaining pins, etc. and completely replaced and adjusted the clutch
> > bell-crank linkage.. The shifter is not hitting any part of the body in
> any
> > gear. The belly pan is secure as well. Upon driving, all is smooth
except
> in
> > second gear. The shift seems a little short into second compared to all
> the
> > other gears. When driving in second, I can hold the shifter in gear and
> feel
> > a pop through the shifter right around the same RPM range every time. If
I
> > was not holding it in, it would come out of gear. I does not seem to
like
> > cornering in second gear very much either. I inspected the shifter
> assembly
> > and both shift forks look to be in good shape except for a minimal
amount
> of
> > wear from years of driving and they don't bind on anything that I can
see.
> > The shift fork for second gear does have an extremely minute amount of
> play
> > on the shift rail compared to the other fork, but it does not seem too
out
> > of whack. Also, I drained the crud gear oil out that the mechanic put in
> it
> > and replaced it with Mobile 1 75W-90 GL-5. That really helped smooth
> things
> > out a bit, but did not solve the second gear issue.
> >
> > Any help would be greatly appreciated. I cannot simply take it back to
the
> > guy who overhauled the tranny because that was done several months back
by
> > the previous owner. Also, if I have to take this into a shop, what kind
of
> > $$$$$ should I expect?
> >
> > Thanks,
> >
> > GK
> >
> >
>
>

Re: Need help with T-150 Tranny Popping Out of 2nd
 

I know, but why lose hope??? ;-)

"L.W. (ßill) ------ III" <----------@cox.net> wrote in message
news:3F4F8C18.C81D9DF2@cox.net...
> Dreamer.
> God Bless America, ßill O|||||||O
> mailto:-------------------- http://www.----------.com/
>
> GK wrote:
> >
> > I took the shifter assembly off again to have another look. It appears
that
> > one of the small parts inserts from the 1st/2nd synchronizer hub is
missing.
> > According to my rebuild manual there should be 3 inserts per synchro. I
> > guess I missed it the first time and I have no idea if it's in the
bottom of
> > the case or was never put in. Probably the latter. Luckily, the whole
"small
> > parts" kit for the T-150 is around $35 from 4WD Hardware. Now I wonder
if I
> > can actually install it myself without a full disassembly??
> >
> > Thanks,
> >
> > GK
> >
> > "GK" <nospam@nospam.com> wrote in message
> > news:V%o3b.2623$eG2.262597@twister.austin.rr.com.. .
> > > I have a 79 CJ-5 with 304 and T-150. Tranny was just completely
rebuilt,
> > all
> > > gears. I have replaced tranny mount, torque-arm bushing, and motor
mounts
> > > with new poly ones. I also rebuilt the shifter myself with new spring,
> > > retaining pins, etc. and completely replaced and adjusted the clutch
> > > bell-crank linkage.. The shifter is not hitting any part of the body
in
> > any
> > > gear. The belly pan is secure as well. Upon driving, all is smooth
except
> > in
> > > second gear. The shift seems a little short into second compared to
all
> > the
> > > other gears. When driving in second, I can hold the shifter in gear
and
> > feel
> > > a pop through the shifter right around the same RPM range every time.
If I
> > > was not holding it in, it would come out of gear. I does not seem to
like
> > > cornering in second gear very much either. I inspected the shifter
> > assembly
> > > and both shift forks look to be in good shape except for a minimal
amount
> > of
> > > wear from years of driving and they don't bind on anything that I can
see.
> > > The shift fork for second gear does have an extremely minute amount of
> > play
> > > on the shift rail compared to the other fork, but it does not seem too
out
> > > of whack. Also, I drained the crud gear oil out that the mechanic put
in
> > it
> > > and replaced it with Mobile 1 75W-90 GL-5. That really helped smooth
> > things
> > > out a bit, but did not solve the second gear issue.
> > >
> > > Any help would be greatly appreciated. I cannot simply take it back to
the
> > > guy who overhauled the tranny because that was done several months
back by
> > > the previous owner. Also, if I have to take this into a shop, what
kind of
> > > $$$$$ should I expect?
> > >
> > > Thanks,
> > >
> > > GK
> > >
> > >