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


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Old 02-05-2018
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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..
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Old 03-05-2018
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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
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