I posted this on the 24v engine and drivetrain section but no one responded. When in 5th and 2nd gear especially, there is a chattering noise that comes from the gearbox and up the shift lever. It began after hitting a pretty big rut on a dirt road last week. Is this something serious or has anyone had this happen before and it be a simple fix, something knocked loose. I can stop the noise by tightly holding the shift ****. Any suggestions?
Thanks, Coop

 

My buddy had this happen in his 6speed 3rd gen (he lives about 2 miles on dirt roads). After a lot of trips to the dealer they determined it was the ujoints in his drive shaft.... Maybe check these. Hope that's it, but maybe someone with a 2nd gen has a better idea.

 

My 94 2wd does the same thing. It makes a horrible racket when warm in either of those gears. Hope somebody has an idea for both of us. I replaced the u-joints Sunday, and it is still there on mine.

 

My old clutch was transfering bad harmonics back through the shifter/gearbox. Mine was in 3rd and 5th always, and in 4th on the throttle hard. It made me a bit nervous because this was after all new bearings on both shafts in the case. Never got more than 10k miles on that clutch, burnt it out at a sled pull, then went up to 13" and now it hardly ever makes a racket. Not to say go change your clutch out, you could have bent shift forks or something small...

Maybe pull up the boots around the shifter and make sure nothing broke, or any boots ripped, and the shifter is screwed on tight. The boots can hide a lot of noise you'd never know about, until they open up.

 

Replaced the clutch the same day we did the u-joints. Shift boots are good, shifter is not the screw type but the round type, with a new "hold in" spring. Is there any chance on a bearing on the counter-shaft going out? There is no noise in 4th (direct drive). OP, does this sound like yours? How would the shift forks make noise?