1989 2.5t a555 Caravan Stuck in 1st help!

[TopGunRMNP]

Emergency help please:

Stuck in Yellowstone. 89 2.5t a555 caravan 198k miles.

Car is locked in 1st gear. Noticed some clutch smell pulling out of snow but didn't think much of it until a mile down the road.

Loud humming and whining so I took it out of gear. Tried to put into 2nd going slow and it wouldn't.

Then I put it into 1st it drove 100ft chattered then locked in place. The engine runs and clutch goes in and out, but something is surely broke. Can't disengage 1st or move the vehicle. No linkage broke that I could see.

Towing it to Gardiner, what happened???

Van idles fine, and still stall if clutch engaged. Wheels roll 1 foot then both lockup, can't get 1st out when the van is on or off or clutch in or out.


So far it's thought to be: fork break, tob break, differential pin pop, or intermediate shaft break?

- - - Updated - - -

The shop can't work on it until Monday, I've got to get back to CO tomorrow. Getting a ride from a local to the next town 2hrs away for a rental in case.

I can look at it for 2hrs this morning to diagnosis.

[135sohc]

Front intermediate shaft bearing and shaft end have let go.

[TopGunRMNP]

Update: it drove into the shop, then locked up again coming out. Said there's gotta be something loose in there.

I checked cable, linkage and fluid, all good fluid smells burned. Sinclair won't work on it so it's going to the dodge freaked in Livingston.

[shadow88]

Front intermediate shaft bearing and shaft end have let go.

If you mean the one by the pinion gear, I completely agree. Mine did the same thing, but stuck in 2nd. It lasted a very short time until it completely came apart, locked the front wheels solid and left me in the middle of the road.

[Ondonti]

And the good news is that those bearings are NS1 right :(

[TopGunRMNP]

So we believe FISB and end have let go, repairable? What else could it have damaged?

[shadow88]

The shaft the bearing rides on is often in pretty poor shape with a groove worn into it.

[TopGunRMNP]

Well, how much is a new a555 going to cost from the dealer you all think? Looks like that's the way it's going, front intermediate shaft bearing and end are likely gone.

On top of this $250 tow bill.

[MILKCARTON]

I have a know good 555 trans in Colorado Springs.. 719-963-9208 Tracey

[TopGunRMNP]

Also, how much power can an OEM clutch hold since I imagine that will be replaced as well.

[shadow88]

I don't think the a-555 is available from mopar any longer. I could be wrong, I never thought to check availability. You should probably look for a used one or an a-520 would be almost the same as far as bolt-in, power capacity, and gear ranges.

Clutch selection??? Tough call... At minivan weight, it's going to have a lower torque capacity than a clutch in an omni. My guess would be about 250 foot pounds of torque in a minivan is about where a stock clutch would be pressed too hard.

[TopGunRMNP]

Update: getting rental car, driving back to CO and getting a truck and dolly then headed up Mon to bring back.

Picking up another a555 or a520 then swap with clutch upgrade kit.

[tryingbe]

This transmission was locked in first.

http://www.thelostartof.net/trans/ddtrans_0237.JPG


My suggest to you would be find a replacement trans swap it in.

[ajakeski]

Notice the broken shift fork shaft boss (Arrow).
When the intermediate shaft lets loose everything gets shoved up into the shift forks putting stress on the shaft. Be sure to inspect this if you decide to rebuild your transmission.
I've bought some cases that looked good in photos, but had cracks at this spot.

[iTurbo]

I have an A523 for cheap in Gillette, WY. You would need to change your shifter and cables for it to work though.

Unfortunately the two A555s I have here need to be rebuilt as well.

[135sohc]

If you mean the one by the pinion gear, I completely agree. Mine did the same thing, but stuck in 2nd. It lasted a very short time until it completely came apart, locked the front wheels solid and left me in the middle of the road.

Yup.


And the good news is that those bearings are NS1 right :(

Yes and no…

The original KOYO roller bearing used in the 520 and 555 has 12 roller elements. That bearing has been gone for years, Chryslers 'solution' was to go back and reuse the lighter duty bearing from the 525 and earlier units. It is slightly narrower and has 13 roller elements. Side by side with the original KOYO 12 element bearing it is noticeably lighter in construction. Industry part number 5707.

Now the bearing and its matching race for the 523/568/543 are both NLA as of earlier this year so yeah it sucks.

[TopGunRMNP]

I think I'm with you Chris, originality is what I want and I like the sharp mechanical gear selection in the 555.

I mean, my other car is an SRT-4 with a pickup truck-like gear throw and wouldn't have it any other way.

I hear and read the 555 is practically the ultimate, but many dislike or have a bad history with them.

The 555 I can get was bought for a CSX as an upgrade but never installed and unknown mileage. I could have the 520 out of the csx, or a 523 but then need to source the other components...

[iTurbo]

Dang, I wish I had something for you. I only have several rebuilt A568s, a used A523, and a couple broken A555s though.

If you are passing thru Gillette and need any help let me know. Big parking lot and lots of help if you need it.