M/T - Grinding Noise In 2ND, 3RD, & 4TH Gear Lock Up
Bulletin No.: 002/93Issued: 2/26/93
Revised
Category
J
Applicable Model/s
1991 Navajo
(M/T)
Subject:
GRINDING NOISE/FEEL 2ND, 3RD & 4TH GEAR LOCK-UP
NOTE:
This bulletin supercedes Service Bulletin # 003/92, Cat. J, originally issued 3/24/92 and revised 5/6/92.
DESCRIPTION
Shift problems such as 2nd and 3rd gear grind, and 4th gear lock-up, are caused by incorrect synchronization. Synchronizer rings and clutch hub assemblies for 1-2 and 3-4 gears have been redesigned to prevent this condition.
Confirm the condition by test driving the vehicle.
TEST DRIVE
1. Drive the vehicle to bring the transmission fluid to normal operating temperature (approximately 125~F).
2. Accelerate to 4th gear from a stop on a smooth surface using normal shifting speeds.
3. If a grinding noise can be heard or felt through the shift lever, or the vehicle cannot be removed from 4th gear, refer to Repair Procedure for further action.
REPAIR PROCEDURE
1. Remove the transmission from the vehicle and remove the 1-2 and 3-4 clutch hub and sleeve assembly along with corresponding synchronizer rings according to Workshop Manual, Section J.
2. Install all parts from the service kit (P5Y3 22 26XA). The service kit contains 5 parts in 3 individually wrapped packages (Figure 1):
- 1 synchronizer clutch sleeve for the 3rd and 4th gears
- 1 synchronizer (brass) ring for the 3rd gear - has 1 tooth removed in 3 places and 2 teeth bridged together in 3 places.
- synchronizer (brass) rings for the 1st, 2nd and 4th gears
NOTE:
Inspect all P5Y3 22 26XA in your inventory. If there is a punch mark on the 3rd gear side of the clutch sleeve, do not use the kit. A sleeve with a punch mark on the 3rd gear side is a defective part. Return all defective kits using normal parts return procedures.
3. The chamfer side of the synchronizer clutch sleeve installs towards the 4th gear side. Figure 2.
The original 1-2 clutch hub sleeve assembly and 3-4 clutch hub can be reused if they are in good condition.
4. The 3rd gear synchronizer ring and 3-4 synchronizer clutch sleeve are new and must be installed as a set. Failure to do so will result in the inability to shift the transmission into one of the gears. Figure 3.
5. Refill transmission with 5.6 pints of mercon ATF.
PARTS INFORMATION
PART NUMBER DFSCRIPTION
P5Y3 22 26XA Synchronizer Kit
WARRANTY INFORMATION
(Applies to vehicles covered under warranty.)
Warranty Type Code: A
Customer Comment Code: 24
Damage Code: 9M
Part No. of Main Cause: P5Y3 22 26XA
Quantity: 1
Operation No: J0314XRX
Labor Hour: 7.5 Hrs.