Popping out of 2nd Gear after trans rebuilt..Why? - JeepForum.com
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Unread 05-04-2013, 11:55 AM   #1
itsybitsy
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1977 CJ5 
 
Join Date: Apr 2010
Location: Plainfield IL, IL
Posts: 149
Popping out of 2nd Gear after trans rebuilt..Why?

I just had my T150 trans rebuilt at a local Jeep shop. They used a master rebuild kit with gaskets & seals, plus replaced all gear forks too. They said the gears were fine. We filled it with Amsoil GL-4 Manual Trans Fluid. The first 25 miles it shifted perfectly with ease.

Then it sat for 2 days and now while accelarating in second, it pops out of second gear at around 2500 rpms. I removed the shift boot and metal cover and it still does it. All other gears work fine.

Any ideas as to why this is happening? Please help??

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Unread 05-04-2013, 12:15 PM   #2
Ivehad4
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1978 CJ7 
 
Join Date: Feb 2013
Location: salem, VA
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A few possibilities:

2nd/3rd synchro is worn
synchro teeth on 2nd gear worn
The shop left off a locking ring when assembling it

I would recommend you take it back and tell them to make it right.
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1978 CJ7 304/T150
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1995 XJ 4.0
1998 TJ 4.0
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Unread 05-04-2013, 12:19 PM   #3
itsybitsy
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Yea, there are going to pyll it back out this week. I'm sensing it has been awhile since they rebuilt a T150. All the synchros have been replaced so I'm curious about this locking ring. Is this easy to miss / forget about?
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Unread 05-04-2013, 12:27 PM   #4
Ivehad4
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If someone isn't familiar with the transmission or rushes, yes they could miss one. There is also a tabbled washer that goes under one of the locking rings. If any of these are missing, it could cause significant endplay in the components and possibly affect shifting and/or staying in gear. If they checked their rebuild correctly, then they should have measured that endplay after assembling all of the components. Again, rushing through the job can impact that. Its kinda hard to say what could have happened but they should make it right at their cost if you contracted for a rebuild.
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1978 CJ7 304/T150
1959 Willys CJ5 F4/T90
1995 XJ 4.0
1998 TJ 4.0
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Unread 05-04-2013, 12:36 PM   #5
roboto65
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There is a snap ring holding the bearing in the rear bearing housing if you miss that one it will slip out of second ask me how I know that
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Unread 05-04-2013, 01:12 PM   #6
itsybitsy
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This is very helpful. Sounds like we know where to dial in at.
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Unread 05-04-2013, 05:11 PM   #7
Ivehad4
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BTW. My master rebuild kit didn't include syncho assemblies. It did include synchro blocking rings. The blocking rings are the brass rings that have small teeth on them. Make sure they examined the synchro assembly. This is what slides to change between 2nd and 3rd in the T150. The teeth tend to wear on each end and that can cause slipping out of gear.
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1978 CJ7 304/T150
1959 Willys CJ5 F4/T90
1995 XJ 4.0
1998 TJ 4.0
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