Originally Posted by Transman
With the Chia pet for a magnet, it’s time to get it apart.

Likely the OD unit is failing. Just a guess at thins point but likely one of the large needle bearing units or a planetary starting to fail.
The most common failure we saw in the Reman program was the bearing on the back of the main case - the OD thrust bearing.
And when it fails you lose the required travel to apply the OD clutch and disengage the Direct clutch.



So, um... If that is what actually made the OD not function, and a guy kept driving it without the functioning OD, is it more costly to rebuild the trans then if it was pulled and rebuilt right after the OD quit working?

I blew a trans cooler line but didn't know it until ran it out of fluid and I coasted into a parking lot. I repaired the cooler line, added 8 quarts of ATF 4 (96 46RE 4x4 trans with 44K miles). The trans seemed to work OK except the OD didn't work. After nearly a year of using the trans, it doesn't seem quite right when leaving a stop light (I might be getting paranoid). Once its moving it seems OK, except the no OD. It shifts very smoothly from 2nd to 3rd.

I'm expecting to have to rebuild the trans (I'm hoping to make it to spring). I could drop the pan if you think it would be helpful, but at this point I suspect the damage is done and a fluid, filter, and maybe a few parts won't help long term. I'm probably going to run it until it fails, or spring, whichever comes 1st, unless you think a new filter and fluid will help. Should I plan on rebuilding a different trans, or is this one going to be OK to rebuild?