While driving on Interstate 65 with the cruise control on, I lost 5th gear. It happened once before at 111,000 mi. Now I have 157,000 and it did it again. I called the North Vernon, IN Dodge dealership who fixed it the first time and he said he can only redo what he did before. I asked if it would fix it, he said yes, I said can you guarantee it, he said nope. My point is the set screw fix is not the answer. I'm not going to give the Dodge dealership another $740, especially if it's just gonna happen again! Is a new main shaft with longer splines the answer?? I've written letters to dodge on this subject, and I'm trying to get them to admit guilt(yeah right). Any help will be appreciated.

1998.5 12 valve 5 spd quad cab shortbed 4x4

 

you might fill out you sig. so we know what year and model you have?
there are fixes for your problem. cant say i have heard about the set screw one?

 

Call Standard Transmission. Last time I checked they know about the 5th gear issue and I think they will fix yours but you might have to take out the tranny and send it to them.

 

Happened to my 96 twice also. All Tran in Terre Haute IN. rebuilt it the second time with new input shaft and aftermarket output shaft. I sold it to a neighbor when I bought my 03 and the 96 is still going strong. I did not like the set screw fix either that is why I went with the aftermarket shaft with a keyed sleeve to take the torque and keep 5th gear in place.

 

I wouldn't give dodge the money cause they fixed it the first time and it broke. Make them fix it on their own dime. Bet they do a better job. I read on here one time about people tack welding the nut on. Might be somthing to look into.

 

$740 wow that's alot of money! I bought the shaft for ~200 and installed it myself...but a tranny teardown is not for the faint of heart.

As you have guessed, the replacement 5th gear nut is not the proper fix. It seems if it's done before the gear falls off then it's usually not a problem.

The new fully-splined mainshaft will be the ultimate fix. I bought mine from Blumenthals in OKC.

 

As a side note....

You can't hold the dealership responsible. The warranty on replacement parts and labor is 12 months 12k miles.

Also, I would never weld on the shaft.

 

Mike,
yeah your right on the dealership, but the thing is, Dodge is telling the dealership that the replacement 5th gear nut plus set screw is how you fix it, and they are wrong. I guess it's just the point and they won't admit it. I don't have the tranny experience and can't affor to do it wrong. My plan is to eventually replace the main shaft but I can't right now. A local tranny shop said they would fix it for 450 and hopefully it will get me by until I can affor the real fix.
Thanks for the help.

 

I don't know a whole lot about how the 5th gear nut fails, but from the way it has sounded there is a nut that just backs off. If this is the case, would some red Loc-Tite not cure it? Nothing can get that stuff to break loose. It isn't like your really going to tear it down anyway, right? Just one idea that has been bouncing around in my head and finally made its way out...

 

Just to add to the "weld it on" advise. I have read of guys trying this and having problems. The weld breaks or the whole assembly breaks apart. I can only assume that there must be a tremendous amount of force on everything to cause this much problem. Funny thing is no one really knows why it happens to some and not others. Driving styles? No sure. Would be nice if we knew what to avoid to help it not happen.