Need some help! I have an 06 3500 dually 4x4 with cummins, I just had my 7th trans rebuild and housing replacement. What happens is the housing will crack and leak all the trans fluid out and burn up. There is no warning it just cracks, it dose not matter how fast i'm going or if i'm pulling a trailer or not. The first 3 where done by dodge, then they told me I was abusing the truck and they would no longer fix the problem plus warranty ran out. Since then I have paid out of pocket for a local trans shop to fix it, then ran into same warranty issue of them saying I was abusing truck. They said the suspension was weak and told me to have 2 leaf springs added to rear and spacers to front and this would keep trans from moving? No such luck!!! Broke again!!! So went to another well known trans shop and they said no prob we can fix it. They replaced all u-joints front hub bearings and checked motor and trans mount. Said all was good now so they rebuilt trans and replaced cracked housing. Gave me a 3 yr 36,000 m warranty. That worked for 2,000 miles till took family camping with our 5th wheel camper(weighs 7,000#'s), trans went out again after only 20 miles!!! Back to trans shop again. They said I was pulling too much weight? (They came out to get us when it happened and saw the camper). Guess I should have bought another ford instead!!! (my 02 f350 with over 350,000miles does a better job then this POS!

Anyone have any ideas?

 

Your issue is not normal and it would help if you gave a little more detail on how you really use the truck. Also if I had one fail without warning I would be adding something to tell me when the fluid goes low or you lose pressure so you don't burn up another one. Its one thing to let one cow out before you close the barn door but to just keep letting the same cow out time and again is a bit questionable.

That all said since you think it is a POS maybe just fix it and sell it. Your screen name says it all.

 

Well heres the story- I use the truck for transportation purposes only, except a few times a year when we go camping. I do not hot rod or abuse the truck. Only reason I bought a dodge was for fuel economy. I agree with the selling part, but I know how I feel about this and I'm not going to pass it on to the next helpless victom. You would be ticked off if you paid alot of money for truck and had these issues. Anyhow It just came back from trans shop last friday and they have given up on finding the cause of problem and was told they will not honor warranty unless there is no crack but if it cracks or when it cracks again they wont cover it.
Dodge dealer checked carfax and did measurements on frame to see if frame was out of spec, and all was good.
Trans shop also installed an aftermarket trans cooler, thought maybe a heat issue.
I know the new Fiats... I mean Dodges have 2 trans mounts instead of one. Maybe i'm not the only one with this prob
Just looking for ideas.

 

If I were you, I'd install a Dave Goerand built transmission. Throw a few dollars in it and you should not have any issues. Honestly I don't know why you're having that many transmissions crack and fail. I had a 2000 slushbox that I towed heavy with, my dad tows heavy with his 2005 auto and I've worked my 2007.5 pretty good too, with no issues.

Where are you??? Maybe someone here knows of a good place that you can take your truck. You're not doing boosted 4wd launches at the lights are you? Do you have the power turned up? What year is your truck? Fill out your signature and people can help you better.

 

I would venture to say either your ujoints are failing, your driveshaft is out of balance or...no offense...whoever is installing/building your trans is not all there.

 

Not doing any launches or burnouts got all that out my system many years ago. Truck is 06 3500 dually, its all stock except for 5th wheel in bed.

 

Well i've had the dodge dealer and two different trans shops work on it, so if I was going to the same place everytime then the shop might be the problem.
All u-joints have been replaced plus front hub bearings, was told any vibration in drivetrain (front axle or rear) can cause a stress crack.
They also did a runout test on driveshafts and was all good.
I'm out of ideas and tired of flushing money down the drain.
Hoping there is a simple solution to this.
Is there an aftermarket overdrive housing that is made out of different material or thicker/stronger? I have seen the new setup on the 2011 trucks and it has a dual trans mount, instead of single.

 

Sounds like your truck might be a case for lemon lawing it?

 

If it is cracking the OD housing, I'd start looking there. Those housings have a lot of strengthening ribs. Has the rear bearing been replaced? What about a bent output shaft? Possibly a messed up spring or even a defective/ incorrectly machined clutch shell? Has anyone checked the transfer case input shaft and bearing? There is not that much in that section of the trans. Somebody is overlooking something.

One more question, I should have asked this first. Are they just rebuilding yours or are they doing a total replacement?

 

That is really hard to believe. I mean, maybe you are not hearing it or feeling it, but there has got to be something going on there.

 

Thats a good idea about transfer case. I asked the trans shop if transfer case looked ok and was told that has nothing to do with cracking the housing??? Not sure how they can say that when its all bolted together.

They are rebuilding the same one with new case. And new converter each time. at one point they tried to reinforce outside of housing with aluminum straps but it still cracked.

Any Ideas for diagnosis? How to check ? I'm totaly stumped, its been going on for over 2 years so any sugestions would be greatly appreciated.

 

There is a small vibration around 70mph but was told that was my tires, might not be tires. all u-joints and front hub bearings have been changed.


I'm a ford guy and the only reason I bought this truck was for fuel economy and for my wife to drive cause she dose'nt like driving my f350 crew cab dually. Wife says "The ford has a steering radius of a school bus and the dodge is a pretty truck that turns so much sharper".

Anyhow I would realy appreciate any sugestions.

 

Sounds like the output shaft does not have enough play.. There is a write up on this on the Goerends website. I will see if I can find and post

 

You need to take it to a guy who knows these trannies backward and forward. Dave Goerend really knows his stuff. If he fixed it and it cracked, he would step up to the plate.

 

Something else to think about. You mentioned that the "U" joints have been replaced. That's great, but the drive shaft could be out of balance. It could have been from the beginning, as in not balanced correctly from the factory. A drive shaft builder can check the balance and run out.
Ted