Displeased with rebuild on NP435

[Johnnyb]

So I did my transmission and transfer case r&r because my old NP435 was popping out of Granny under load.
Took it out for a test drive and it's extremely difficult to get into any gear but if you yank hard enough you can get first second and fourth.
In reverse and anytime you unload it with the clutch it sounds like there's something slapping around in there, video attached.
I can get it into third gear if it's sitting still and I feel very carefully but I have not been able to shift into third gear in motion.
Any diagnosis or ideas before I put my old one back in?
https://photos.app.goo.gl/PrCRSE5orFt1Ug4VA

-JB

 

[Grey owl]

So I did my transmission and transfer case r&r because my old NP435 was popping out of Granny under load.
Took it out for a test drive and it's extremely difficult to get into any gear but if you yank hard enough you can get first second and fourth.
In reverse and anytime you unload it with the clutch it sounds like there's something slapping around in there, video attached.
I can get it into third gear if it's sitting still and I feel very carefully but I have not been able to shift into third gear in motion.
Any diagnosis or ideas before I put my old one back in?
https://photos.app.goo.gl/PrCRSE5orFt1Ug4VA

-JB

Does not sound good, if you can't get 3rd something is certainly not right..

 

[Oldtimer]

How long are bolts you put in the inserts you added to case?

 

[DirtDonk]

Yep, shouldn’t be hard to shift at all. Rebuild our old and sloppy, they should shift relatively easily into any gear.
And though I don’t think this is the issue, what lubrication are you using?

 

[DirtDonk]

And was this a rebuilt transmission from a rebuilder? Or just a used one from a private party?

 

[Johnnyb]

How long are bolts you put in the inserts you added to case?

Same ones I took out. I did have to helicoil the rebuilt transmission on 3 of 4 holes because of the old adapter.

 

[Johnnyb]

And was this a rebuilt transmission from a rebuilder? Or just a used one from a private party?

Professionally rebuilt Novak master kit, I put 75-90 synthetic gear lube in.

 

[gnpenning]

Since you can't get 3rd, take it to the shop that did the work and show them. It will be going back anyway.

 

[Johnnyb]

Since you can't get 3rd, take it to the shop that did the work and show them. It will be going back anyway.

Problem is, I did the R&R.

 

[gnpenning]

Problem is, I did the R&R.

That's ok. They need to see what is happening under power. It will help them and they might have an idea. Who knows, they may even pull it for you.

 

[gnpenning]

Did you put in a new clutch assembly?

 

[Johnnyb]

Did you put in a new clutch assembly?

Clutch and pressure plate (diaphragm) was new less than 2K miles ago.

 

[bronco italiano]

Pull it and take it apart.
No more good shop sin Flagstaff, but Phoenix area has Arizona Driveshaft. They can get you in the right direction

 

[DirtDonk]

Any chance the clutch isn’t fully releasing?
For a quick check before you do anything else, you could raise the rear wheels off the ground and re-test with the engine running.

 

[mrdrnac]

I agree with "Oldtimer" IF one of the bolts is too long on the trans to Transfer case adapter it can hit the gear inside the 435 case. I'd check to see if one of those bolts is shorter than the others. From memory I "think" it goes in the top right corner of the adapter. I'll see if I can find any more info on it for you.

 

[pcf_mark]

When you installed it did you take the top cover off with the shifter? That could have put the 3-4 shift arm in a non-correct location causing both the noise and lack of 3rd. Before I removed that trans (it is terrible in Broncos) I would take the top over off and look around in there while testing it. At that low speed it is not going to make a mess. I know on car 4 speeds if the shifter is not in the correct position AND the gear sliders in the same the cover will go on but it will only have 1 pair of gears and won;t shift in/out of that set w/o brute force.

 

[Johnnyb]

When you installed it did you take the top cover off with the shifter? That could have put the 3-4 shift arm in a non-correct location causing both the noise and lack of 3rd. Before I removed that trans (it is terrible in Broncos) I would take the top over off and look around in there while testing it. At that low speed it is not going to make a mess. I know on car 4 speeds if the shifter is not in the correct position AND the gear sliders in the same the cover will go on but it will only have 1 pair of gears and won;t shift in/out of that set w/o brute force.

I did, and I was sure I got it on correctly. I will remove it again and check.

THX,
-JB

 

[Johnnyb]

I agree with "Oldtimer" IF one of the bolts is too long on the trans to Transfer case adapter it can hit the gear inside the 435 case. I'd check to see if one of those bolts is shorter than the others. From memory I "think" it goes in the top right corner of the adapter. I'll see if I can find any more info on it for you.

Same bolts/adapter that came out with my old NP435, only just a little more than case thickness protruding through the adapter. All same length.

I am liking @pcf_mark suggestion (if I screwed up) or I am looking at a bad rebuild . I talked to the guys at Novak (nice people!) and they suggested that 3rd. was not shimmed properly. Can check from top.

THX,
-JB

 

[Johnnyb]

Any chance the clutch isn’t fully releasing?
For a quick check before you do anything else, you could raise the rear wheels off the ground and re-test with the engine running.

Worth a check. As an ex-trucker, should be able to shift w/o clutch 2nd-3rd and can't do that either. I also can get 1st with no grind.

THX,
-JB

 

[pcf_mark]

Test it while you have the lid off just set the shifter sliders correct so you are in one gear only. A hundred years ago I used to rebuild 4 speeds (GM) and ran them on a bench with a 5 HP motor and the side cover off with the trans turned upward. At slow speed you could shift and check everything. At higher shaft speed you got a shower!