More problems with 6 speed, 5 gear popping out - Diesel Forum - TheDieselStop.com
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99 & up 7.3L Power Stroke Engine and Drivetrain Discussion of the 99 & up 7.3L Power Stroke diesel engine and drivetrain in the 1999-Up Super Duty trucks and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 7.3L Power Stroke engine.

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Old 01-07-2006, 04:31 PM   #1 (permalink)
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More problems with 6 speed, 5 gear popping out

My last 6 spd made it 180,000 miles before she went. I knew it was going to eventualy go because the pilot bearing went out and I didn't fix it soon enough. So I just put a new reman transmission in it and have about 6000 miles on it and it is trying to pop it self out of 5th gear. When I put the new tranny back in I also put a new clutch and and pilot bearing in. It doesnt sound like the pilot bearing has gone out because it doesn't make any noise when I am first taking off plus it was a brand new one. Is it just a bad reman or could it be something else causing it. Thanks for any info.
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Old 01-07-2006, 04:43 PM   #2 (permalink)
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Re: More problems with 6 speed, 5 gear popping out

The warranty on your reman should be more than 6000 miles. I'd be talking to the folks you got the tranny from about making it good.

Then again, your pilot bearing may be lunched again. Did you put in the stock roller type or an aftermarket such as a kevlar bushing?
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Old 01-07-2006, 04:52 PM   #3 (permalink)
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Re: More problems with 6 speed, 5 gear popping out

It was an aftermarket bushing. The tranny has a 1 year unlimited miles warranty, so it is still covered. I was just wanting to see what everyone else thought on the issue.
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Old 01-08-2006, 10:24 AM   #4 (permalink)
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Re: More problems with 6 speed, 5 gear popping out

5th gear coming out is a pilot brg thing. In this "gear" there is no gear involved, just the coupling between the input shaft and tailshaft. When the input shaft is crooked (supported on the front by the pilot brg) it walks the sleeve out of the synchro and spits out the fork. In no uncertain terms, it is warrantable IF you bought the pilot from the gearbox vendor. If they were separately sourced, you can see the gearbox vendor's point - why should they warrant a $2k part for the sake of someone else's $10 part failure?

Of course, the other thing (you will hope) is that the pilot is fine, and the last failure of the gearbox was not properly repaired. Was it a genuine ZF reman or done by another shop? I hate to cast doubts, but a fair number of "reman" trannies are simply junkyard parts that are carefully washed and shipped. Of course, that is NOT the case for ZF!
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Old 01-09-2006, 09:16 PM   #5 (permalink)
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Re: More problems with 6 speed, 5 gear popping out

That is what I heard about the fifth gear being a direct drive gear. I dont think the pilot bushing went this time because it isn't making any noise. Anytime I have ever had a pilot bearing go, you could easily hear it rattle when it is under a load or first taking off but nothing this time. So I dont think it is that. I didn't go with a zf reman I went with a local shop and now I am wondering if I should have. I called the guy I got it from and he told me to run it longer and see if it does it again. When it is cold it seems fine. Once the tranny warms, if you hold your hand on the shifter in 5th gear and let off the throttle you can feel it put slight pressure against your hand but it hasn't pop out of gear again. Yet.
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