TRANS HELP!

[franko]

First off before i get into the trans issue here is a little teaser vid

http://www.youtube.com/watch?v=k4kJztkMCYE


Anyway below is my issue with the trans.

The trans will not go into gear; the t-case is in gear and I can feel the trans grab very slightly when shifted into forward or reverse but it's not fully engaging. There is ATF in it. I don't think it's a transmission shifter or linkage adjustment issue because I can slowly move it through the gears and it doesn't ever seem to fully engage. It does not engage enough to ever move the truck; only enough to barely bump it ahead or back. This could be a dirty trans filter causing the pump to not get enough oil or maybe something else. It is not likely electrical.

Anything that you guys can think of that we have not covered would greatly help.

Cheers

 

[proper4wd]

Transmission internal failure. ZF HP22s and 24s like to fail at the A clutch but it could be a number of failures. All of which require a full teardown and rebuild of the transmission. I have seen broken pumps but usually as the result of someone putting in the torque converter wrong.

 

[franko]

Dam i was hoping it was not something that bad,maybe now is a good chance to swap in a 5speed hmmm

 

[Rocket Ship]

Yup, sounds like classic trans failure. If you can feel the gears but there's no grab, it's done. Don't even think about rebuilding it unless you've done it before. Not only is it hard in the best of cases, but there's zero documentation available on how to do a ZF. Make one little mistake, and you gotta do it all over again. And a large number of rebuilt trans fail again shortly anyway.

 

[franko]

So what find a used rebuilt and throw it in there or?

 

[Rocket Ship]

Professional rebuild from a solid company, a good used trans that's never been opened from a donor you can trust, or 5 speed.

Auto trans plants are like clean rooms. Workers in hair nets, epoxy coated floors, etc. You don't just open them up the way you do with... a manual trans.

 

[Quill]

There are few places I would trust to rebuild a trans. Even a used on could have been abused. Send it to a places that specializes in that vehicles repair or go to a manual trans. I don't trust the national chains. Although I had Cottman do one that they did it right. Only had them do one once. I shy away from automatics because I have been burned to many times.

 

[proper4wd]

I would like to clarify some of the information in this thread.

A ZF rebuild/repair is possible. See the following links:

http://www.disgruntledgoat.com/content/vehicles/dakar/ZF4HP22.php

http://www.automaticchoice.com/Catalogue/zf4hp22.pdf

There is also an ATSG rebuild manual available on the web but you have to google really hard for it.

I have had one of these completely apart for a rebuild/upgrade to HP24 internals and it is not that difficult. I ran into trouble because I was combining parts from two completely different transmissions. I did not complete the project.

I would definitely take apart a HP22 just to replace clutches/seals and reassemble. It is fairly straightforward and can be successful if you are detail oriented and "clean" enough. But, I wouldn't recommend it to just anyone. Imagine a motorcycle clutch except about 6 of them stacked on top of each other with planetary gears in between.

The cheapest/easiest solution is to buy a trans from a junkyard and swap it in. See www.car-part.com

I was buying them for $100 each in Rhode Island with a 90 day warranty. At that price, it beats a $1500 (reputably) rebuilt unit.

 

[94Discovery]

Franko I was following your thread on Pirate ,I am glad that you finished the installation of the om617
:jump::jump::bowdown:

 

[franko]

Thanks everyone for the in put, we have yet to deal with the trans issue so I'll keep you all posted and hope to have a running/driving vid soon.