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T2180 high gear problem


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My 18 speed in my 1999 E7-460 CH truck is giving me problems.  I have never had any problems with the transmission before.  I have used this truck for about 5000 hours and it has been solid.

I dumped my load at an elevator and was driving back empty to get another load.  After shifting the 2180 into high (I call it 4th gear) 17 or 18, it started to pull and then started to make noise and it seemed like it wanted to disengage.  The gearshift itself remained in its proper position and I didn't have to hold it or anything.  I stopped and inspected the drive shafts and there was no problems there.  I drove it home in 3rd gear.  The hi-low and range selector work for all the other gears.  It is a 4th gear problem of some sort.   4th gear in low range is fine - the problem is only occurring in the high range.   When I drove it home using the other gears, everything is quiet.

What could be the problem?

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I had checked the oil level last year and don't see any leaking. I will check it. A good first step!  Sometimes I do have my hand on the gear shifter.   I should do an operational check today while closer to home on a back road. Maybe I bumped the switch and didn't realize it.  I don't think so but thanks for that tip.  I know that happened once a number of years ago and I wondered what I had done lol!   The truck has really been good to me.   I am sure I would have noticed if I inadvertently hit the range selector and had to move it back up - but I am getting older.  Especially wearing a heavy winter jacket - it turned cold fast in a few days and now it is supposed to warm up again.   I normally would have noticed the mistake if it was there.  My air pressures were good as I keep a little methyl (air brake medicine) in the system.  I usually pour a little into the tank before I start and seems to be good for the winter

My transmission has a double over in it which I assume means in 4th gear whether hi or low, it is in overdrive.  Not sure if that could be a source of a problem as the trans performed good in all the other gears.  I limped it home and wanted to be closer to home before I played around with it.  Maybe time to go on the back road after doing the basic checks!  

Are the main gears the same whether selected in high or low range?   Does it mean the main box is still okay but I have an auxiliary external problem if it is not of my own making?!

Edited by allfritz123
I do run synthetic oil in the transmission

I am glad that the tranny has worked good for you.  as far as the gears goes,  the main box (front) is a 5 speed w/reverse.  the order of the gear sets from front to back is: 4th+5th, 3rd+2nd, 1st+rev..   they are the same gears in low or high range.  the back box contains 2 shift forks,  one for the Hi/Lo synchronizer, and the other is the splitter ( the Gray button on the side of the knob)..  I dont know how long this issue has been around, but may I suggest that you re-ring the Synchro pistons.  that is the one that sticks out the back of the tranny above the yoke. it is easy to do and you do NOT have to pull the transmission. what are your thoughts? and if you are a good mechanic, you can do this job without needing to be a tranny specialist.  My thoughts are that mabey the range shifter is sluggish. Hard to truly diagnose it from my couch, but there are a bunch of us here that will guide you. Jojo

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Thank you so much Jojo for your great input.  You done a great job by pointing me in the right direction.  I think I added about 3 quarts of oil to bring it up to the big bull plug. I guess I am getting parasitical leaks - looks like from the front!  I thought the oil level was maybe an inch down.   Not noticeable as in a puddle on the ground when sitting but you can see where it is likely coming out the front end seal I assume!  You are absolutely correct.  I added oil and there is nor more problem.  I didn't the oil level was that critical as it still had lots of oil in the box.  I thought the oil level was maybe an inch down.  Thanks so much for the advice.   I examined the magnet plug further up at the same time and there was fine silver wear on it - no chunks!

I assume there is o-rings to go on the synchro pistons which may cause issues?    I will have a go at it when I am done hauling and I have time.  I didn't get a good start this morning as I had to do snow removal from my sister-in-laws yard since my brother passed.   I have been busy cleaning out yards and at the same time hauling.   

I did get 2 loads in to the elevator today and the truck never missed a beat in the top gear.   The transmission is very solid and I have found it has always shifted good for me and I enjoy it.  It might be because the rear end is a 4.23.  It always give me lots of power on the gravel roads and close spacing.  I don't mind that the top end speed at 1800 rpm is about 70 mph.   That is about the speed limit up here anyway on the twin highway and I like to stick to 62 mph or thereabouts with a load.

I don't ever recall the range shifter being sluggish - maybe once.     Sometimes the splitter button can be sticky when you first start the truck at the beginning of the day if the weather is very cold.  After about the first shift with the splitter - everything performs without problem.  I don't think it can hurt running synthetic 80w-90 in it either and maybe good for it - especially in the cold weather.

Thanks for explaining simply the gearbox!   I do have a service manual but one never looks at these things until you are forced to!!  Any thought on the double over?  Does that mean the gear size changes at the front box for 5th gear in order to accomplish an overdrive and why it is called a double over because the splitter is giving it overdrive no matter the selection. 

I made a mistake in my first post as I referred to the high gear as 4th!   There are 5 gears - which I almost forgot!  I am not sure about 1st gear as sometimes we call it the cheater gear when you are in high range.  With my ratio and with an unloaded trailer, I will sometimes use it to get across the hi-way quicker!   In the low range we would refer to 1st gear as Bull Low which I start out with loaded or not!  That is why I referred to 5th gear as 4th!  When you range shift, you only use the 4 upper gears! 

I'm glad you are fixed up,  I only mentioned the range cylinder re-build as part of a P.M. idea. I think you said you use air brake conditioner,  thats good, the less water the better, I assume you pull the cables on the air tanks regularly too. as far as a low oil level, I think it holds 28-30 pints, and there is likely an oil pump inside, you should see some stainless steel tubes inside the bell housing, when you are greasing the throw out bearing. and as far as the number of gears, yes 1st. is all the way towards you and down, and that is used to start out, then when you range shift 'up' when you come out of 5th., you come over to the middle, and 'up' skipping the 1st. gear spot.  I know you know this, just sharing info.  Thank you for posting the solution, and for the Respect..  Good deal..   Jojo

Edited by Joey Mack
I made a Boo Boo
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