I drive a '97 2500 4wd - Cummins, of course. For the past year or so there has been a rattle from somewhere in the clutch or transmission telegraphing up the shift lever. At times it has been possible to diminish or even get rid of the noise by pushing sideways on either the shift lever or the transfer case lever. Several people have told me not to worry, it's a Dodge trait, so I haven't. The clutch also seems about due as the truck shudders and jerks slightly when engaging the clutch. Or, at least, it did.

Last week when nearly done with a 130 mile drive home something under the floorboards made a crunching, popping, rattling noise. It was loud enough to be heard clearly over the engine and road noise. My first thought was that a bearing in the transmission had failed, or a gear shed a tooth. Before I could stomp on the clutch and pop the transmission into neutral the noise stopped. I slowed and listened closely, but there were no more noises.

The past week I have driven gently around town a couple times listening for anything unusual. The only thing unusual has been the fact that the clutch now engages smoothly - no shuddering or jerking. Today I checked the transmission and transfer case fluids, found the transfer case low so put in 24 oz. Dexron III. A twenty mile test drive on the highway followed. There is no noise of any kind from the shift lever unless it is pulled hard to the right or left while in gear, and the clutch continues to engage smoothly. There is a nearly inaudible hissing noise - think bearing going bad - when off or on throttle in 5th gear. No noise under any conditions in any other gear.

Is there something that could have come loose and dropped through the gears without destroying them? Or is it possible a bearing lost a ball or roller that went through things? Or would the pilot or throwout bearing be a prime suspect? I don't believe in self-healing machinery. Something isn't right inside there.

Any suggestions would be welcome. Thanks all.

DRam

Edit: I should add that the truck has 153,000 miles on it, the previous owner (who bought it new) told me he'd never had anything other than regular maintainence done to it, and I have never had the transmission out. A front driveshat seal was installed by a dealer in the transfer case about twenty thousand miles back.

 

You could have had a spring tooth come loose and get jammed up in there. Then it worked its way out. Drive it until it has to come out. Then replace clutch(get a good HD one maybe Southbend), flywheel, hydraulics, Fix the 5th gear nut, and change fluid in transmission(use correct fluid). Just my experience. I've had mine in and out a half dozen times. Do that and you'll get another 150k..

 

Thanks for the reply. I'm not sure what a a spring tooth is. Can you clarify?

 

In the clutch there are a bunch of long (2-3inches) teeth, they are springs that the Throw out bearing ride against. Sometimes they get bent, or break off sometimes because of a bad throw out bearing. Either way, It is not self healing. If I were you, don't get to far from home before you fix it.

 

Its not nice when 5th gear goes either. I sure am glad i have the 3.55 or it would have been a real long 1400 km drive home.