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97 Ram 1500 Mystery problem (T-Case-Resolved) #2691223
08/25/19 01:12 PM
08/25/19 01:12 PM
Joined: Mar 2010
Posts: 232
Bennett, Colorado
Charger69RT8 Offline OP
enthusiast
Charger69RT8  Offline OP
enthusiast

Joined: Mar 2010
Posts: 232
Bennett, Colorado
Well, still a mystery to me at this point. Daughter's pick up. 5.2 - NV3500 - 4 X 4. Thanks in advance for any input or clues to find this problem.

Problem: A loud grinding / rattling noise coming from the transmission area beginning right before the shift point. Truck has no tach, just shift light, typical shifts done above the shift light coming on. Happens most pronounced at the 1-2 and 2-3 shift points, but sometimes at the 3-4 and 4-5 shifts.

My trouble shooting started with the rear axle on jack stands with an assistant running it through the gears while underneath with a long screw driver (hillbilly stethoscope) to my ear. Noise seemed to be coming from the front area of the transmission. At 180k I think, input shaft bearing going bad in the transmission. Since it also had a problem jumping out of first gear, I decided to rebuild the trans. Didn't find any bad bearings in the process. Replaced input /output bearings plus counter shaft bearings, input to output bearing, synchros, 5/R shift fork, plus 1/2 and 5/R syncro sliders. Engine had been swapped just before purchase about 5k miles before by previous owner who stated a new clutch was installed at that time.I visually inspected the clutch without dis-assembly and could see the flywheel had been surfaced, and fresh appearing pressure plate and clutch disk. The throw out bearing also appeared new and was smooth and free turning.

Got it all back together last night. The good news is, it no longer jumps out of 1st. Huge disappointment to learn the noise is still there. Additional test driving last night revealed the following;
1. Very light on the throttle easing up to much higher shift point than normal, the noise never happens on the 1-2 or 2-3 shifts. Not tried above this.
2. When the noise comes on, clutching with throttle still on to keep rpm's up, letting off throttle without clutching, or normal shift action (off throttle, on clutch), the noise stops immediately.
3. Sitting still, in neutral with clutch pressed or not, and engine rev'ed well past point noise is heard when driving, the grinding / rattle never happens. Load related, it seems.
4. Weird twist 1: When the noise comes on, if I just stayed on the throttle, the engine fell off as though I had let off. While holding throttle position, the noise abated as it slowed until a point when the engine came back and began to accelerate again, at which point rpm's would climb and the noise came back. It repeated this in 1st and 2nd.
5. Weird twist 2: On repeated take off's in 1st and heavy throttle, when it would grind / rattle, I let off then almost immediately mashed the throttle again. On two of these instances, it then wound out with a shift to second without ever making the noise.

Checked codes this morning. None.

Last edited by Charger69RT8; 09/01/19 11:45 AM. Reason: Solution found

2012 Challenger SRT
2012 Charger SXT AWD
69 Charger R/T
78 Chrysler New Yorker 440CI
89 Dodge Daytona ES 2.5L Turbo
99 Ram 2500 4X4 5.9L6
Re: 97 Ram 1500 Mystery problem [Re: Charger69RT8] #2691405
08/25/19 11:13 PM
08/25/19 11:13 PM
Joined: Mar 2007
Posts: 584
Southeast Pa.
SALEM1912 Offline
mopar
SALEM1912  Offline
mopar

Joined: Mar 2007
Posts: 584
Southeast Pa.
Could you be hearing a exhaust rattle. Loose shielding or maybe a cat converter?

Re: 97 Ram 1500 Mystery problem [Re: SALEM1912] #2691421
08/26/19 12:51 AM
08/26/19 12:51 AM
Joined: Mar 2010
Posts: 232
Bennett, Colorado
Charger69RT8 Offline OP
enthusiast
Charger69RT8  Offline OP
enthusiast

Joined: Mar 2010
Posts: 232
Bennett, Colorado
Thanks for the response. I don't believe so. I now believe it is in the transfer case. More test driving this evening resulted in no bad sounds if in 4 wheel drive. 4H or 4L. I can hammer it and never get the sound. It is only making the racket in 2H. Also noticed a correlation between the sound, the speedometer going wacky and the engine cutting out.


2012 Challenger SRT
2012 Charger SXT AWD
69 Charger R/T
78 Chrysler New Yorker 440CI
89 Dodge Daytona ES 2.5L Turbo
99 Ram 2500 4X4 5.9L6
Re: 97 Ram 1500 Mystery problem [Re: Charger69RT8] #2691479
08/26/19 09:48 AM
08/26/19 09:48 AM
Joined: Mar 2007
Posts: 584
Southeast Pa.
SALEM1912 Offline
mopar
SALEM1912  Offline
mopar

Joined: Mar 2007
Posts: 584
Southeast Pa.
Did you ck the crank senor mounting?

Re: 97 Ram 1500 Mystery problem [Re: SALEM1912] #2691568
08/26/19 01:12 PM
08/26/19 01:12 PM
Joined: Mar 2010
Posts: 232
Bennett, Colorado
Charger69RT8 Offline OP
enthusiast
Charger69RT8  Offline OP
enthusiast

Joined: Mar 2010
Posts: 232
Bennett, Colorado
Yes. A new crank sensor was installed as well as a new pickup in the distributor when I put the transmission back in.

edit: And to clarify, when no rattle, the engine does not cut out. Leading me to believe the loss of power / cutting out is tied to the speed sensor which is attached to the T-case.

Last edited by Charger69RT8; 08/26/19 01:15 PM.

2012 Challenger SRT
2012 Charger SXT AWD
69 Charger R/T
78 Chrysler New Yorker 440CI
89 Dodge Daytona ES 2.5L Turbo
99 Ram 2500 4X4 5.9L6
Re: 97 Ram 1500 Mystery problem [Re: Charger69RT8] #2691796
08/27/19 02:01 AM
08/27/19 02:01 AM
Joined: Mar 2010
Posts: 232
Bennett, Colorado
Charger69RT8 Offline OP
enthusiast
Charger69RT8  Offline OP
enthusiast

Joined: Mar 2010
Posts: 232
Bennett, Colorado
BTT. Now that I have a better idea and in hopes for someone to recognize what is happening inside the T-Case. See a couple post up. Noise is not there in 4x4, just 2 wheel drive.


2012 Challenger SRT
2012 Charger SXT AWD
69 Charger R/T
78 Chrysler New Yorker 440CI
89 Dodge Daytona ES 2.5L Turbo
99 Ram 2500 4X4 5.9L6
Re: 97 Ram 1500 Mystery problem (T-Case-Resolved) [Re: Charger69RT8] #2693426
09/01/19 11:59 AM
09/01/19 11:59 AM
Joined: Mar 2010
Posts: 232
Bennett, Colorado
Charger69RT8 Offline OP
enthusiast
Charger69RT8  Offline OP
enthusiast

Joined: Mar 2010
Posts: 232
Bennett, Colorado
Turns out we had a busted snap ring on the transfer case output shaft. Got a tip from user on a Facebook forum (F-books group Dodge Ram Trucks 2nd gens; user Don Huffman) my daughter posted on. Giving credit where due.I verified it by pulling the speedometer gear and using a pry bar gently pushed back and forth on the output shaft trying to ensure I was pushing on the snap rings that hold the output shaft speedo gear on. See pictures for excessive total movement. Easy fix with a $5 snap ring. Other more expensive and more robust solution are available. For example,
Sonnax T-Case Saver Google T-Case Saver for more.

Edit (1st pic: shaft back, 2nd pic: shaft forward, 3rd: busted old ring, 4th; new style upgraded ring installed)

shaft back.jpgshaft forward.jpgbroken snap-r.jpgInstalled.jpg
Last edited by Charger69RT8; 09/01/19 12:02 PM.

2012 Challenger SRT
2012 Charger SXT AWD
69 Charger R/T
78 Chrysler New Yorker 440CI
89 Dodge Daytona ES 2.5L Turbo
99 Ram 2500 4X4 5.9L6
Re: 97 Ram 1500 Mystery problem (T-Case-Resolved) [Re: Charger69RT8] #2693614
09/02/19 11:21 AM
09/02/19 11:21 AM
Joined: Sep 2003
Posts: 11,519
north of coder
moparx Offline
Dreaming of implants
moparx  Offline
Dreaming of implants

Joined: Sep 2003
Posts: 11,519
north of coder
glad you found it ! a real head scratcher for sure.
beer


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