Need help on 2nd gear problem...

[mycool88]

My mule is a '91 4x4 Ranger Supercab 2.9L w/Mitsubishi FM146 5-speed manual and electronically shifting transfer case. Last week I was going to work and attempted to shift into 2nd gear, and it wouldn't stay...next time I tried it grinded, but would stay IF I held the stick tightly to the bottom of shift range. BUT, if I normally go into 2nd, it won't hold and I skip it altogether...I also notice that the clutch master cylinder reservoir is a little low. I only bled once when tranny was installed, but worked fine, then. Tranny is about 1 1/2 years old and was remanufactured by reputable local rebuild center.
Any help or advice would be greatly appreciated and welcomed!!! Thanks in advance.

:dntknw:

[MAKG]

Sounds like the "splines" on the 2nd gear are rounded off. This is a consequence of grinding into gear, so it's not too likely to be a primary problem (it's the result of something else, possibly a clutch release problem).

It's also possible that the thrust clearance is getting a bit wide, but I'd expect the problem to show up in some other gear first, especially 4th.

There is no fix aside from replacing 2nd gear and/or the 1/2 synchronizer slip-ring. I suppose it's possible that ring was installed backwards, but the problem would have shown up right away after installation then.

The most cost effective route is to replace the transmission with a junkyard M5OD. I wouldn't suggest paying to rebuild an FM146. It's not a good design.

[mycool88]

thanks MAKG...is this a direct bolt-up??? Will start search at JY...

[Ranger44]

Look for one out of a 4.0. The 4.0 and 2.9 have the same bolt pattern. Also switch in a 4.0 clutch. It is also a bolt on. There is a right up in the tech section. If you have a 4x4 get a 4x4 tranny. Other than that it should be good.

[MAKG]

While 4.0L M5ODs are a LOT easier to find (almost any Exploder with a stick, for instance), the 2.9L ones have wider gearing.

You need the stick as well. Sticks seldom interchange between transmission models. Even closely related ones.