Transmission growl shifting into 2nd

[Burlington]

Hello -- this is my first try at one of these forums. Have a 1991 Dodge Stealth TT with 5 speed manual transmission. And one aggravating problem -- the transmission growls/grinds shifting into 2nd (upshifting & downshifting) unless I double clutch or give it time with the clutch depressed until actually shifting. Likely a synchromesh problem? Have heard that this is a common problem with this car/transmission with 2nd gear. This was a problem that developed about a year when I first picked up the car in 1992, used, one year old. Could not get any help to get it fixed, so I lived with it until the car had 130K miles, and I had lots of work done to clean it up about 18 months ago. Including a new transmisssion.

Now at about 20K miles on the new transmission, the problem is here again. Dodge and Mitsubishi aren't helping -- say this is a problem that is not their responsibility. And they claim they don't sell parts for the transmisssion, the only thing they'll do is replace the transmission, at my cost of course.

Anyone know if this is in fact a common problem? Anyone who knows how to fix it?

Burlington

[OthercarisaFiat]

Yes, very common. You can get parts for the transmission from CRS, and one or two other places, but not from the dealer. Check the 3Si FAQ under "Technical Questions;" there should be a topic titled "How do I get parts for my AWD transmission?". You will need a new 2nd synchromesh, as well as a few seals and some case sealant, at a minimum. If you don't want to do the job yourself (it's a lot of work and requires some special tools), you should be able to find a good transmission shop that will do it for you.

This problem is often caused by using the wrong oil in the transaxle. The owner's manual calls for an oil rated GL-4 or better, but this is incorrect. You should be using an oil rated GL-4 ONLY. GL-5 rated oils contain a molybdenum disulfide additive intended for hypoid gearsets, such as in the rear end. This stuff chemically attacks the brass synchro rings and destroys them so that within 20k miles they are worn smooth and no longer do their job. 2nd gear usually is the first to go, but all gears can be affected.

GL-4 oil is not so easy to find, so most shops just use whatever they have handy. It is available online however. The following are a few good GL-4 rated synthetic oils that our members have had good experience with (they run from $7 to $15 a quart, but obviously that is cheap compared to replacing your transmission):

BG Synchroshift
GM Synchromesh
Red Line (50-50 mix of types MTL and MT-90)

Amsoil might also make something that would work, I am not sure. And I once saw a GL-4 rated natural oil at NAPA but I don't remember what the brand was. Everything else you see in the auto parts stores (Pennzoil, Valvoline, Mobil 1, etc) is GL-5 rated and should not be used in the transaxle (it's fine for the rear end and transfer case).

[sluggo]

Fiat/Gearhead,

I enjoyed your post, very informative. My 94 TT is doing that, only from 1st to 2nd gear...downshifting is fine though. I need to do a clutch job anyway, I may see if Mopar Jeff in Milwaukee can do the 2nd gear synchro in his garage.

-Pete