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I’ve kinda got an interesting one. Only had a couple of basic responses from dedicated forums, so I figure this one must be a bit of a headache that not many people have seen before.
Specs:
1995 Ford Explorer
M5OD-R1 Manual Transmission
4wd
4.0 OHV engine
High miles (about 240,000)Recently had major clutch issues, so we replaced everything. Transmission shifts very well at this point (bad slave, and we did a complete full clutch job at the same time-Flywheel/clutch/pressureplate/etc….)
Took it out a few weeks ago and the wife mentioned it had a noise that was in 3rd gear…Not really noticeable in 4th gear. Really talkative in 5th (OD) gear.
I’ve rechecked the bolts to the transfer case, all parts that I can reach to ensure nothing backed themselves off….etc…
Here’s a video of the noise:
You can hear me shifting from 1st to 5th. It just sounds ‘extra geary’ and almost like a metal on metal scraping.
I sent the video link to a transmission company. It sounds to me like the output shaft bearing is on the way out. As the sound doesn’t change pitch or frequency with engine RPM. The rebuild company shot back their opinion: Defective countershaft and input shaft. Full bearing set to be installed as well. They felt it was run extremely low on fluid and it took the ‘temper’ out of the gears and they where at fault. Sounds more like a bad bearing to me… But what do I know? Yeah I did note a minor leak at the output shaft seal, and the trans was a hair low on fluid (about 1/4 a quart) But we’ve not driven the truck more then 1500 miles sense the clutch job. And it was topped off at that point.
Also to note: I brought the speed up to 65 on the highway. Pressed the clutch and put the transmission out of gear. Noise still very present. I goosed the gas a bit. No change in the sounds. I wanted to ensure there wasn’t any issues with the pilot or throwout/release bearing. (both are new with the clutch)
I’m on the fence with how to proceed. Finding an M5OD-R1 that will mate to a 4.0 engine is pretty rare. We did find an M5OD-R2 which would work with mods to the shift stick. (Ford moved the cut out for the retaining bolt 180degrees). However that one had a blown front input bearing. All sorts of play in it. So we didn’t install it, as the one in the truck seemed to be fine after the clutch job.
Of course I’m concerned about the noises. But due to living in upstate NY will have to drive this ol’ girl to work and back if we get pounded with lake effect snow. Wondering if anyone has clues onto what this noise is? Just hope it doesn’t self destruct on the highway…. One guy responded back just not to use 5th gear until warmer weather to pull it apart. Makes me wonder even more about that rear output shaft bearing, as that’s where 5th gear resides as well…
Ideas welcome!
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Replies
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Not trying to pass the buck but see if these guys can help.
No worries about passing it.
Those are the guys that believe the issue is the counter shaft gears assembly and the input shaft gears are in need of replacement.
Still sounds like a bearing going bad. I’ll be hitting another pick and pull yard tomorrow AM early before I go to my scheduled location. If I can find a M5OD-R1 or R2 from a suitable donor…. (Bell housings only seem to fit on a 2.9/2.8/4.0 as they use the same block I’ve been told) Wish a 3.0 would work LOL. I managed to find one in a local yard.
Did note we have a bit of a ‘scream’ sound from the front of the engine. Idler pulley is noisy. Sad reality–it’s an unrelated sound. This sounds more like a geary sound with bearing noise mixed in.
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