5 Speed Advice

Hello all, and thanks in advance for any feedback. My 03' 2.7 4x4 has been having an issue getting into gear. It is intermittent though. I have 87k on the truck and never replaced a clutch before. Are there any symptoms for a bad clutch? Sometimes I have to force it into 1st gear and all is well for the rest of the gears. Come to a stop and it goes into 1st with no problem. I notice if I have to get in gear quickly it wont go in. but if I slowly pull towards 2nd, then into 1st, it will go smooth. 1st to reverse while parking is usually tough. Toyota wants almost 2k for flywheel, clutch cover, bearing assy and disc clutch including labor. is there maybe a problem with the synchros? Any help would be much appreciated.

 

My 96 Taco w/ w59 will not go into 1st gear when down shifting unless I'm almost stopped.

Does yours go into 1st when sitting still? (Engine running)

 

I have an 09 with 78k and it's pretty difficult to get into 1st while rolling to a stop. I have to be almost at a standstill for it to go in smooth. Matching the rpms doesn't seem to help. I think its quite common. My Mazda pick-up had the same thing it's whole life.
Try putting it in neutral then push the clutch in and go to reverse. (Double clutch) this may help.

Also, have you ever changed the transmission fluid? I recommend Red line MT-90 .

 

Same with mine. Bought my truck when it only had 58,000 miles and took notice to that really quickly. With some research and a fluid change I realized it's quite common for these trucks. From what I gather the transmission lock you out of first if your above a certain MPH, I believe it's 8 MPH. This is to prevent accidental engagement of 1'st gear at higher speeds. 1st gear is kinda low in these trucks anyway. All you really need first gear for is to get moving from a dead stop. From there you can creep in 2nd gear and pull away in 2nd gear from a rolling stop. Unless your lifted with bigger tires and no gear ratio change.

If I need to get into first from a rolling stop. All I do is quickly throw it in neutral, clutch out, rev, clutch in and it will go smoothly into first (double clutch).

Also run redline MT-90 tranny fluid in these transmissions. They like it better then anything else out there.

 

Check clutch free play it may not be releasing all the way.

 

I have the exact same symptoms with mine. Been that way since I got it even after a brand new clutch. Its most likely the bushing in the shifter assembly, it's just a little ring and its easy and cheap to replace. I haven't done it yet but Marlin Crawler sells beefier ones that last longer.

Your clutch and syncros are fine I bet. These trucks are a little rough shifting, it's just the nature of the beast.

 

Link to the Marlin Crawler bushing seat...

https://www.marlincrawler.com/transmission/shifter-parts/heavy-duty-seats

 

Just replaced my shifter bushing not to long ago and made no difference... just how these transmissions shift. Mine is also a bit notchy as well when shifting in cold weather

 

Start simple.

Shifter bushings.

Is the master full of fluid? If not, is the slave leaking?

When was the fluid last refreshed? I've found

Ford XT-M5-QS Full Synthetic Manual Transmission Fluid - 1 Quart

Ford XT-M5-QS to be a fantastic lubricant for units that call for GL4 like yours. It's not cheap, but can be bought OTC at your local Ford store. If the parts guys are confused and have to order it in for you, be sure you get the correct number.

I've seen it turn very notchy 1-2 and 2-1 little sports cars in to butta.

While the lubricant is a good thing to do every 30-50k, my money is on the hydraulics.

 

Good to know, I was going to replace it since it's so cheap and relatively easy but I wasn't sure it would solve the issue. Just seems to be the way these trucks shift. My front wheel drive Scion I had before this shifted like butter, I could nudge it into any gear any time and it would go in without hesitation. RWD trucks just seem to be a little rougher to shift, it takes some getting used to be when you find what techniques work well it isn't an issue.

 

10 to 1 its the shifter ball "seat" as quoted above
Martin Crawler has them.
Mine wore out and was having similar problems as yours.
It was an easy replacement and was like a miracle cure.



Here is what Martin's website states:

It's common for the factory shift lever ball seat to wear, crumble and disintegrate over time.
This often results in a sloppy or loose transmission shifter. The factory seat is soft and is squeezed into position.
Therefore it is fragile. We took a different approach. Instead of squeezing the seat into place, we machine a strong,
rigid piece that rotates & drops into position. This allows us to make our seat from stronger, longer lasting USA-made Delrin.
Our new heavy duty seats will far out last the stock units and will greatly reduce shifter slop.​

 

I will say though. What promoted me to check the shifter bushing was when I shifted into first gear it didn't feel like it was engaging all the way. Like instead of a full shift in it felt like it was only halfway and it was tight. Pulled the shifter out and there was beariley anything left of it. Replaced it and the shifting motion felt smoother. Smooth as in the moment of the shifter only. It didn't get rid of the notchyness nor did it help with shifting into first while moving.

 

Mine has always been rough going into first, 268K doesn't help anything tho. I've found going 2nd then 1st helps

 

I spent a lot of time trying to figure this issue out when I bought my truck. I was surprised how "notchy" it was, as well not being able to shift up/down under very high RPMS. My old Honda Civic could shift smoothly under any condition/RPM. I had a Toyota Tech test drive it and he told me that nothing was wrong at all. But I went ahead and replaced the shifter bushing (it looked brand new), replaced the fluid with Redline MT-90 and overfilled it a little as suggested on various posts. The results were negligible.

I've come to learn that you need to drive these like a dump truck (ie waiting a second for the RPMS to come down before shifting into the next gear). I have since changed the way I drive and now the "notchyness" is negligible.

 

Mine shifted a little smoother with Royal Purple than it does now with Redline MT-90.

 

No. I have to force it in. But other times, it will go right in.

 

I recently changed the tranny and transfer case with Amsoil because of the problem. It got better for a couple months and now is getting progressively worse

 

I recently changed the tranny and transfer case with Amsoil because of the problem. It got better for a couple months and now is getting progressively worse

 

Is it a tough job replacing the bushings? Makes sense to start small and work my way up. Toyota wants me to bring it in for a 2k clutch job.

 

Looks pretty easy. Remove the shift boot, remove 4 bolts and pull the shift lever out. Dig out the old bushing. Put in the new bushing. Put it back together.

I haven't done it but I've taken transmissions apart and put them back together.

I don't consider replacing the clutch that hard a job but it's a lot bigger job than the bushing.