M5R2 output shaft failure

[Elutheros]

My transmission made some funny clanks a few weeks ago and then stopped moving the truck in any gear but made some ominous sort of grinding noises. The M5R2 only had 8k on it and I'm not beating on it. I filed a claim with the folks who provided the transmission and they say they will ship one to me since it has a 5 year warranty. I removed the TC and trans today and couldn't find any damage inside the trans, but after close examination I discovered that the splines on the output shaft were pretty messed up and the splines on my NP205 were worn down from the spinning of the bad trans shaft. Anyone ever had any issue like this? I really don't want to tear into the TC, but think I have to replace the input shaft.

 

[Josh B]

Check very closely where the two connect for any foreign objects. Did they pull together well when you installed the TC onto the transmission? Were any of the TC mounting bolts looser than they should be when you were tearing it down

 

[superj]

t-case is easy work though so if you have to replace that input, its not hard or time consuming

 

[Josh B]

I just wish the transmission was the same :/

 

[85_Ranger4x4]

The 205 really doesn't fit an M5ODR2 like it should, I had to make an adaptor ring.

How do yours go together?

 

[Elutheros]

I have an adapter ring made from 1/4" steel and it worked fine for 35k miles on the first transmission which was an original from a '94 F150. It had internal bearing failures. Two of the bottom bolts on mating the trans to the TC seemed to be a little loose on removal even with lock washers on them. Since those bolts go all the way into the TC I'm reluctant to put thread locker on them. I'm wondering if the rebuilders replaced that output shaft and it was inferior or? Anyway, I'm waiting for the replacement tranny and I've got the TC apart to replace the input shaft. On the Ford NP205 do you need a puller to remove the gear assembly from the shaft? Hard to find detailed instructions on that part.

 

[Shran]

Good lord, that is chewed up. Was there any water or rust in there...? I can't imagine how that would happen, something is either made wrong or grossly worn out. I would be curious to see the rest of the output shaft is trashed, maybe that piece wasn't hardened correctly?

I don't recall needing a puller when I disassembled my 205, seems like everything was just sort of held together with snap rings or lightly pressed on. I might be wrong about that. It was pretty easy to tear down in any case.