Gearbox Rebuilt Kit Identification Help NV3550 TJ 2004 - AUSJEEPOFFROAD.COM Jeep News Australia and New Zealand

Go Back   AUSJEEPOFFROAD.COM Jeep News Australia and New Zealand > JEEP GARAGE > Technical

Portal Register Forums Trading Your Jeep New Garage Mark All Read

Post New Thread  Reply
Thread Tools Search this Thread
Old 02-05-2018
ajftj's Avatar
ajftj  ajftj is offline
Join Date: Jun 2017
Location: Geelong
Posts: 80
What Jeep do I drive?: TJ
Likes: 3
Liked 6 Times in 6 Posts
Default Gearbox Rebuilt Kit Identification Help NV3550 TJ 2004

Hi, hope there is someone who has actually rebuilt this box who can help.

I am trying to identify which gearbox rebuild kit to buy before I take the box out. I have narrowed it down to a couple of Getrag kits but the various descriptions online don't really give me enough confidence to push the button. As I have a trip to the US shortly I am collecting up parts. I have already ordered a new clutch, but don't think this is the issue. So considering doing a rebuild of the box at the same time as changing the clutch.

Its the 5sp NV3550 box, vehicle was built June 2004.

The difference between the kits seems to be the countershaft journal diameter.

Kit BK235GWS is described as 97 up sync reverse, 3 piece 1-2 syncro 30mm
Kit BK235FWS is described as 00-02 sync reverse, 3 piece 1-2 syncro 32mm

Apart from the characteristic clunk into 2nd (already changed the Oil to Redline), the main reason for the speculative kit buying is "whirring grumble" when at idle which stops completely when the clutch is fully pressed, still in "N". Also if you drive up a short steep hill i.e. a driveway at engine lugging speeds with 1st fully engaged it sounds like a loud rattle from the box. I suspect the input shaft bearings.

Any thoughts or guidance will be much appreciated..
2004 TJ, 4.0L, Manual, $2K spent on maintenance in year 1 and rising 😀

Sponsored Posts
Old 03-05-2018
Struth's Avatar
Struth  Struth is offline
Join Date: Jul 2015
Location: Melbourne, Australia
Posts: 260
What Jeep do I drive?: TJ
Likes: 45
Liked 60 Times in 39 Posts

I cant help you with the ID for the kit but call morris 4x4, they have been great in helping me with things such as that.

I've owned my TJ since new (2001) and I dropped my 97 TJ to upgrade to the 3550 because I knew it was the bees knees of gearboxes at the time and in some ways it still is....

...just saying, the NGV3550 sounds like a bag of marbles rotating in a cloths drier when in neutral with the clutch out.
I understand it has got to do with the way the reverse idler shaft is set up to achieve synchromesh on reverse, like an old crash box is set up.
I specifically remember complaining about it when under warranty and I thought they were B'S'ing me when told it was normal but almost twenty years later it's much the same, perhaps a little louder then when I drove it off the lot but that's to be expected.

As for the "characteristic clunk into 2nd ", have you tried using the factory mopar oil?
I have always used it and when mechanics have used anything else I end up with all the complaints I read about in here, sticky gears, clunk into 2nd, etc.

As for the new clutch, if you want a smooth operation get a new:
Clutch fork
flywheel (don't machine it, you'll end up with a shudder)
Mopar master/slave unit
F'n Great Forest national park threatens 4WheelDrive access, select "4WheelDriving" and "SUBMIT"
Likes: (1)
Post New Thread  Reply

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

» Advertisements_AS2
Powered by vBadvanced CMPS v3.2.3

All times are GMT +10. The time now is 10:28 PM.

AJOR does not vouch for or warrant the accuracy, completeness or usefulness of any message, and are not responsible for the contents of any message. The messages express the views of the author of the message, not necessarily the views of AJOR or any entity associated with AJOR, nor should any advice be substituted as technical advice replacing that of a mechanic. You agree, through your use of this service, that you will not use AJOR to post any material which is knowingly false and/or defamatory, inaccurate, abusive, vulgar, hateful, harassing, obscene, profane, sexually oriented, threatening, invasive of a person's privacy, religious, political or otherwise violative of any law. You agree not to post any copyrighted material unless the copyright is owned by you or by AJOR. The owner, administrators and moderators of AJOR reserve the right to delete any message or members for any or no reason whatsoever. You remain solely responsible for the content of your messages, and you agree to indemnify and hold harmless AJOR, the administrators, moderators, and their agents with respect to any claim based upon transmission of your message(s). The use of profile signatures to intentionally mislead or misdirect any member on this forum is not acceptable and may result in your account being suspended. Any trip that is organised through the AJOR forum is participated at your own risk. If you or your vehicle is damaged it is your responsibility, not that of the person that posted the thread, message or topic initiating the trip, nor the organisers of AJOR or moderators of any specific forum. This forum and associated website is the property of AJOR.

Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2019, vBulletin Solutions, Inc.

AJOR 2002 - 2019 AUSJEEPOFFROAD.COM. All corporate trademarked names and logos are property of their respective owners. Ausjeepoffroad is in no way associated with DaimlerChrysler Corporation or Fiat Jeep.
vB Ad Management by =RedTyger=