05 2.7 timing chain?

[beachbumberry]

So for the past month of driving, I've been getting a funny rattle while driving. The truck is a 2005 2.7 tacoma with a 5 speed. Anyways, I get the rattle only while moving at 2000-2500rpm and when I let off the throttle to slow down or shift. I can't duplicate the sound while sitting still at any rpm. If I press the clutch and try to keep it at that RPM while it's rattling, it tries to go away but sometimes I can keep it going. A few months ago my power steering pump had a squeal and i had the throw out bearing squeak as well, but both of those seem to have gone completely. There isnt any play in my power steering pump but the idler pully has a little bit. I pulled the belt off and drove up the road and back and still have the rattle. Doesnt appear to be any loose body work and my CV's don't seem to have any play either. Any ideas? Right now i'm eaither keeping the RPM lower or higher than that 500rpm window and it doesnt have the rattle at the 60mph I normally cruise at. I'm going to try to find a videoscope and pull the valve cover off and inspect the guides, but I want to avoid changing the chain if at all possible, seeing as the FSM suggests pulling the engine.

edit:150,000 ish miles

 

[beachbumberry]

no ideas?

 

[zolo]

no ideas?

Its 5th gear on the main shaft. PM me with your info.
Ive been through it already. I have photos and all the info you could ever need.
Bottom line the trans is making the noise.
The main shaft that 5th is on is not splined all the way around. It is 2 splines then a gap.
2 splines then a gap, and so forth. On over run. I.E. when you let off the gas it makes a crazy noise.
The gear and some bearings an the main shaft need to be looked at. Eventually it will get worse.
I will post more tmrw.

 

[beachbumberry]

Its 5th gear on the main shaft. PM me with your info.
Ive been through it already. I have photos and all the info you could ever need.
Bottom line the trans is making the noise.
The main shaft that 5th is on is not splined all the way around. It is 2 splines then a gap.
2 splines then a gap, and so forth. On over run. I.E. when you let off the gas it makes a crazy noise.
The gear and a bearing will be load. Eventually it will get worse.
I will post more tmrw.

really? wow! That would explain why I'm only getting it moving. how dire is the situation and what is the fix?

 

[zolo]

Ok here are a few photos of what seems to happen.

You can see on the shaft that the gear has started to try and strip the splines. Both splines on the gear and the shaft get damaged.

It will raise hell on over run and make a terrible noise and some vibration. Mine got really bad before I changed the shaft and gear.
I still have some noise due to a bearing that I didn't change when I did the rebuild but the shaft and 5th gear and the tail bearing have all been replaced. I drove a long time with this noise and it just got worse and worse and eventually I had enough.

If it were me Id just swap in a good used trans from a later model truck and not go through rebuilding it.
It was a ton of work and its not easy to press all the gears and sycros off the shaft and then pressing them on the new shaft.
If you do decide to rebuild your trans Id recommend replacing the shaft, 5th gear, and ALL the bearings while its apart.

I'm 99% sure this is what you are describing and since my truck did the same thing and I went through all this I can say that with confidence. Its only when the truck is moving and when you let off the gas. Wont matter if the clutch is in or its in gear because everything is spinning inside and the damage is done and it will make the noise no matter what if you are moving off throttle.
Its likely louder at higher speeds. If not it will be.

Hope this helps..

 

[beachbumberry]

it does sound like my issue except that it isn't as loud at higher speeds (probably drowned out by the hum of my tires). It also makes the sound while settled down at 2000-2500 rpm in all but 5th gear, but I suppose if in 5th, the gear will always have a load on it, preventing it from slipping? I am going to go with swapping the transmission though.