New (reman) transmission should be here tomorrow... I will update.

Glad to hear you got it figured, although it is an expensive touch just before Christmas - but oh well. Youll have a new tranny. Make sure you use the correct fluid in it.

Did you get upgraded synchros?

Yeah the rebuilt transmission was $1000, 3yr/36k warranty, etc. This one is supposed to have "all the updates", etc. I am pulling the tailshaft tomorrow to check out the 5th gear nut/mainshaft and make sure the snap ring is on correctly but I don't know what to look for on the synchros. Also realized today that regular Synchromesh fluid isn't good enough for these? There is an Amsoil dealer up the street maybe they have something that will work for me?

I am also rebuilding the driveshaft at the same time, had 2 u joints with play. Figured I would do the center support bearing while I was at it, turns out only place I could get it was the dealer. $145!

I got some "Brute Force" heavy duty u-joints, went to install them and noticed they aren't greaseable, WTF. Then one of them is a defect, right out of the box. I am ready to finish messing with this shit and drive my Dodge again, dammit. :argh:

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OK after doing a little more research I am pretty convinced the reman that was in the truck when I bought it did not get the correct spec fluid in it from day one and that is what killed it. Even if I had switched to that fluid when I fixed 5th gear the damage was probably already done to the kevlar synchros. From the test drive until it broke the truck would almost always grind 2nd gear when cold, I thought it was air in the clutch master/slave but I am willing to bet now there was a problem with the synchros there, and from the looks of it probably with 3rd synchros as well. The day it broke I had an extra 2K behind the truck, the trans was cold, and when I shifted into 3rd it just gave me the big ':edit: you'.

Turns out all I would have had to do the day it broke to see the carnage was remove the PTO covers with the transmission still in the truck.

http://i424.photobucket.com/albums/p...0/100_9305.jpg

http://i424.photobucket.com/albums/p...0/100_9306.jpg

http://i424.photobucket.com/albums/p...0/100_9307.jpg

This reman transmission was advertised as having all the updates, from what I can see it has a full threaded mainshaft, grooved for thrust washer, locking nut, etc etc etc just like the broken transmission PLUS this one has been welded together. I think it should hold up pretty well, but I'm really careful not to be in 5th gear below 1500-1600 rpm anyway.

http://i424.photobucket.com/albums/p...0/100_9316.jpg

I just need to reassemble everything and get my hands on some correct fluid and I should be all set.

Ladies and Gentlemen, I am pleased to announce the transmission transplant was a success. Drives and shifts even better than before, no leaks so far and my only complaint is an intermittently inoperable back-up lamp switch. :jump:

Probably needs a little electa-clean to rid the dirt and oil. :tu: