Dodge First Gen Cummins G360 Removal and Rebuild

So my transmission had an incident a few months back where the oil drained out going down the road after a bolt vibrated out. Of course this resulted in overheating the transmission and burning out a syncronizer. After that I knew it likely had a short time to live so a few thousand miles later it started knocking so it is tear down time. Follow along as I show how I remove the G360 transmission and tear it down to assess the carnage. The gear that got the hottest lost all its teeth!

[@paulcooper2897]

Speaking of planting gear teeth and growing them .... I think your Steel Wool Shrub needs trimming! Thanks for sharing 🇨🇦

[@bcbloc02]

Its like a chia pet!

[@mattthescrapwhisperer]

I love tailgate rebuilds. It's always real world on this channel!

[@sallybrokaw6124]

Or on the floor!😊

[@VultureTransport]

I am putting an NV 4500 HD in it.

[@Hoaxer51]

As a bonus for replacing the input shaft, you get a free clutch alignment tool! 🎉

[@bcbloc02]

Woo hoo! :-)

[@johnsenecal2732]

As a mechanic in the 80s we use to pull the quad box transmission out of the older Mack’s and AutoCars cement mixers. Those we’re almost as big as your truck engine bay. As we start being a mechanic first it’s a dirt mechanic. Then you move up to being a asphalt mechanic. Then if you get lucky you move up to working in a shop. Always like how you just get it done. Thanks

[@lewiemcneely9143]

10-4 on the quads!

[@bcbloc02]

Appreciate the praise! :-)

[@lewiemcneely9143]

@@bcbloc02 Thou art worthy!

[@bobs1345]

The Getrag G360 transmission was a marginally rated transmission when used behind the Cummins 6BT. I believe it's maximum torque rating capacity was right at the stock torque of the Cummins engine. Chrysler engineers specified the transmissions supplied shall be built to the "tighter clearance specifications" which made the situation worse. The general fix for longer life expectancy was to rebuild the transmission to the looser end specs and increase lubrication by using the top bolt hole on the PTO cover as the increased fill level check point. Gear oils have also improved over the last thirty years which also improves life expectancy. Hope this helps.

[@bcbloc02]

I probably tow heavier than anybody with one and put a good deal of horsepower thru it as I am about 400hp and 1000ft-lbs I imagine. The physical gears and syncros in the g360 are bigger than the nv4500. The countershaft is the weak link which is why I run 3.07 gears so I can tow in direct and avoid loading the countershaft. If it hadn't lost oil I doubt I would have had to work on it. In the end I want to put a FSO series Eaton in it if I ever find one priced right.

[@haroldphipps3457]

@@bcbloc02 or an RTO6610

[@bcbloc02]

@@haroldphipps3457 Twin countershaft transmissions are too wide to fit the trans tunnel without serious modification and I have big feet so I don't want to loose foot space.

[@elroyelblander6277]

@@bcbloc02 🤣🤣

[@elroyelblander6277]

Is/was Getrag a German company??... Thought I read that some place... doesn't matter..👊

[@edsmachine93]

Well the carnage and destruction was pretty bad. About 45 to 50 years ago I use to build truck transmissions and diffentials. Mainly Farm trucks. Alot of the 5 speeds in them days were Clark 280, 282 and 285's. New Process 540's and that series. I liked those transmissions. Plus a whole lot more. Many Eaton 2 speeds, GM Corp 2 speeds. Was all very interesting work. My Dad taught me the business. Built driveshafts. Mainly grain trucks for farm use. I always liked gear work. Once you got everything cleaned up and had your parts it was good clean work. Can't beat bench work. Brian you working on this brought back alot of good memories. Check your shift forks. Thanks for sharing the process. Take care, Ed.

[@bcbloc02]

Guess I could have robbed the 540 out of my grain truck to fix this job but I sure would not have wanted to loose my overdrive. I would far rather rebuild the trans than take it out or put it in the truck.

[@edsmachine93]

@@bcbloc02 HI Brian, I believe a 542 is a .80 overdrive. You could get an old Brownie and make it a twin stick. I know a guy did that with a Ford 1 ton with a 460. T98 4 speed with a 3 speed brownie. I always like gears. I can twin stick big trucks. 5x4's. Been along time, but was fun. Take care, Ed.

[@edsmachine93]

@@bcbloc02 Brian, what about a G56 6 speed? I had a 2005 2500 Laramie. Bought it new. Trans always worked great. I have a 2015 3500 now with and automatic. I miss my 6 speed manual. Just an idea. Take care, Ed.

[@BleuJurassic]

instant total rear rust proofing at speed from the bolt falling out good job

[@KG-yn9qi]

Well if the bearing race pocket bad!, at least you know a guy that can build it back up and recut it! 👍🏻

[@stacy6014]

Up here in Michigan you could have done most of the bolt removal from the cab because the floorboards would be rusted away. Joe

[@acmemachining]

Hope your luck changes, 1st the barn blew down then the trans blows up. Great video.

[@outsidescrewball]

My knees were screaming watching you in the back of the truck……looking forward to the rebuild….koko

[@MegaRiffraff]

My brother-in-law bought one of these new in 1990 , I bought one in 1992 , he had lots of trouble with his 5 speed , but he pulled heavy loads a-lot , while under warranty they replaced the trans 2 times , at least once more on his dime after the warranty, he still has the truck it stays hooked to a 30 ft, cattle trailer now ,

[@bcbloc02]

I tow heavy with mine too and have more hosepower than most so I figure it comes with the territory. Still I ran it over 40000miles no issues until it lost the oil. I really would have liked to have changed it for something better but can't currently find anything and I need my truck so I figure throwing $500 at it to get it on down the road some more miles is a good investment.

[@jimpritz4169]

The chassis on your truck looks great if you lived in NY it would have been all eaten up by salt and road chemicals. Can't wait for the new parts and gettin that baby back "On The Road Again".

[@bcbloc02]

I try not to ever drive it if there is salt on the roads. I really only use my truck for hauling so at least half its miles are pulling my goosneck hauling loads and most of the rest are hauling stuff in the bed.

[@forestgremlinfpv7732]

Always hoped you would do a video on the ol getrag. I run one in mine. It was perfect until the truck went through a flood. I threw bearings in it have probably put 20k miles on it towing, so far so good. I set it to the middle spec for the bearing preload at .007

[@TheAyrCaveShop]

Dang that's a lot of bad luck hitting at once... hope the repairs go smoothly. ATB....Dean

[@lewiemcneely9143]

A bigger hammer usually sets the stage for the NEXT event in the series and maybe a little Delo to help the teeth produce younguns. BLESSINGS!

[@WatchWesWork]

I don't know why I thought you were just kidding about the "tailgate rebuild".

[@bcbloc02]

I have to feed the trolls from time to time. They are some of my most loyal viewers! 🤣 lmao

[@infoanorexic]

My original might have lasted, but trying a rush delivery of a NASCAR participant's new trailer to Sanford, FL proved fatal. It just proves that these trucks are work horses, not race horses. For yours to have lasted this long, it's obvious that you knew that it had to be driven different under load. I did the 4500 HD upgrade. Probably the only task I paid for someone else to do on my pickup, other than tires and exhaust work. I figured it was cheaper and less painful/inconvenient than having my chiropractor straighten me out after doing the work myself. 20 years later, that transmission is still as he put it. He said I'd forget all about that Getrag before I got home. He was right. The only additional thing I've considered was a GearVendors unit so I could keep the engine in the torque curve easier. 2-3 is still a bit tall in some conditions.

[@TrPrecisionMachining]

good video brian

[@nschelling6420]

Ugh. I might be doing the same thing to my ’99 Cummins (NV4500). Same reason. Gearbox oil escaped, only difference is i’m not exactly sure how it got out. Now it has a whine in every gear except 4. I’m sufficiently disgusted with the overly large ratio jump between gears 3 and 4 that if a good G56 came along I would be sorely tempted to go that way. I would prefer to swap a 10 speed in but I don’t want a project of that magnitude now.

[@bcbloc02]

Yep that noise is a probably a death cry. Not going to be long for this world.

[@dans_Learning_Curve]

Will be going through the transfer case and front differential on my '00 Jeep Grand Cherokee this summer. Just so you don't feel alone with the gearbox rebuild!

[@jdmccorful]

You do like working in "confined" spaces. Laughed real hard when you tossed the destroyed teeth, comenting "see if they grow". Nice work! Thanks for the look and your time.

[@SuperBowser87]

Without going into detail I’mll probably dig them up someday.

[@somebodyelse6673]

@@SuperBowser87 - If I lived around there I'd be sorely tempted to half bury some gears on that spot.

[@Fatamus]

A Hot 🔥 low oil transmission 🥺 makes for a cloudy day. Even on a good day. thanks for the video 👍

[@428eliminator3]

Hold the main shaft while drinking a bud light ...it will turn into an Allison.

[@bcbloc02]

Not sure I could handle that! lol

[@AmateurRedneckWorkshop]

Think how much more fun an ottomatic would be. Thanks for the video keep on keeping on.

[@bcbloc02]

I never particularly liked the Chrysler automatics for towing I don't feel like the gear spacing works the best. i could always throw an Allison in it but those cost a lot of money to build. Actually I could not have even bought the torque converter for any auto for what i spent fixing this trans so if it holds up it definieltly seems the way to go.

[@diamondpressco2673]

funny i had a customer yesterday see you playing on the screen and said, " no way is that brian block" i said ya i watch him all the time, he said he used to live out ur way and you were the first one to get 300 hp out of a cummins or somthing i couldnt remember exactly what he said

[@bcbloc02]

Probably from when I was the first to make over 300rwhp on a VE Cummins. Many in the industry said it could not be done. I was also the first to 450+ and 480+rwhp. I wasn't the first to do over 600 at an event but it was my injection pump that did it then I did the most horsepower and torque fuel only uncorrected I believe a record that still stands. I have been told I need to go to Firepunks this fall and defend my title. :-)

[@forestgremlinfpv7732]

​@@bcbloc02 do it

[@Randysshop]

I have done a few of those transmissions in the past. the easy part is getting them out of the truck,and almost 3 man job to put it back in.

[@bcbloc02]

Yeah putting it back didn't go easy for just me but I got it wrestled in eventually.

[@lewiemcneely9143]

@@bcbloc02 You always do.

[@davidrobinson7493]

😅

[@paulhammond7489]

I would take odds that many of your subscribers have fought a mystery snap ring at some point in time during a teardown :)

[@elroyelblander6277]

Nothing lives too long without oil in the end I suppose,but anyway 👍👍

[@10swatkins]

"Cab Interior? We don need no stinkin Cab Interior!"

[@reinholdhummler2459]

Great Job🤞

[@SuperBowser87]

Only 400,000 miles? Don’t make them like they use to do they ? 😂 Brings back memories of all the transmissions I pulled laying on my back.

[@bcbloc02]

Well it looks like somebody had been there before so maybe they need attention every 200k or so. lol

[@elroyelblander6277]

@@bcbloc02 my heavy foot and tendency to add fuel and air like you,they only lasted maybe 50,000??.. idk...the first getrag I had ,only lasted 6 months after I bought the truck... countershaft bearings took a shit...fuel, air,big tires,3:54 gears,and a 19 year old kid probably did em in🤣🤣

[@donmadere4237]

Got to love to old simple stuff! Never gonna sell my old 2001 2500. Bought a new Ram 2016 only got 65k already replaced the transmission now the turbo position actuator has crapped out! New trucks junk!!!

[@wilmamcdermott3065]

Do a delete put a real turbo on it

[@richardandrews6754]

well that ant good, at least you will not have to rust proof the chassis now I guess.

[@bcbloc02]

It is well lubed between the frame rails anyway!

[@Hoaxer51]

It’s ready to drive In Ohio in the winter now! Lol

[@elroyelblander6277]

👍👍 grenaded a couple of those from adding fuel and air...too much torque I suppose..the bearing's didn't like it...and had a couple other issues...I learned to like and repair the auto's eventually... does a NV4500,5600,or g56 hold up better?.. perhaps the 360 can b upgraded... idk.. thanks for another video 👊

[@bcbloc02]

I personally think a nv4500 is worse than a g360. The getrag has bigger gears and syncros and does not suffer from the 5th gear backing off mess the nv4500 does. The 5600 and g56 are much better units but still have their issues. That is why I want to find an FSO eaton to upgrade too. In all reality I should get the d600 project done and use that to pull trailers with and just drive my crew cab but never know how that will play out.

[@elroyelblander6277]

@@bcbloc02 👍👍yup ,that's true man👊

[@elroyelblander6277]

@@bcbloc02 Right on 👍👍

[@guubagaaba8391]

i hope you'll be making the gears !!!!!!!!!!

[@johnlee8231]

Jobs like this a four post lift would be a nice fit for your wish llist. Not that you need it but it sure be nice

[@sallybrokaw6124]

Watch Wes Work would say (There's your problem lady!) AL B.

[@WilliamTMusil]

Hiya Brian

[@sawz5]

I think maybe you better make a cradle to fit the jack and the trans.

[@bcbloc02]

I don't plan to be doing this job again for a long time.

[@ron827]

We should take up a collection and buy Brian a workbench but then where would he put it? :-)

[@gwharton68]

You could weld some new teeth on that gear and remachine it. It would be good as new. Sure like your work bench.

[@bcbloc02]

Sure could be lucky for me the Taiwanese make one for $80. :-)

[@neffk]

tight quarters

[@jamesupton143]

It looks like someone had been in it before.

[@bcbloc02]

Yes I am sure by the marks where somebody cut the bearing off the top shaft it had been into before.

[@bigun447]

One big problem. That is the guy who owns the truck has to pay the repair bill. Do you give him a sweetheart deal on labor? Ain't it a be-itch when your own stuff breaks.

[@dennissheridan1550]

Now is when you wish you had a lift, it's so much easier to stand under the rig and do the work than laying on you back with not much room to wiggle.😆👍

[@Hoaxer51]

He’s on concrete so better than working on stone. But yea, a lift would be nice.

[@bcbloc02]

At least I remembered to run it up on the ramps first this time since last time I found out the trans would not come out from under the frame rails and running boards without jacking the truck up.

[@elroyelblander6277]

@@bcbloc02 I hate when that happens..🤣🤣🤣🤣👍👍

[@elroyelblander6277]

And yeah that shifter is a pain in the ass...f@#$ that thing...

[@bcbloc02]

Certainly a design that could have been done WAY better.

[@Hoaxer51]

Once you get it out and on the bench it doesn’t look to bad to work on. Plenty of room with the whole top off, I’ve worked on some old ford top loaders that were a pain to work on. They gave you just enough room to get the gears in and out, they must have forgot you have to fit your hands in there too! Lol

[@elroyelblander6277]

@@bcbloc02 u said they changed it??.. they hadn't by 1993..was the last one I did...I believe getrag is/was a German outfit.. surprised they didn't design that one a little better...idk.but anyway 👍👊

[@bcbloc02]

Never changed it on the g360 it was the Nv4500 they finally put bolt on shift towers on.

[@placerman9498]

Had to rebearing my Getrag 360 at 140,000 miles countershaft bearings are to small for the load , only haul heavy loads in 4th gear now . What oil do run in yours Brian ?

[@bcbloc02]

I used Deere Hy-gard in this one and the one in old yellow. I put over 200k on that one myself but it has never towed anything.

[@ianmorris2527]

I reckon that you would have gotten it apart a lot easier with it on a work bench rather than the tailgate Just sayin is all 😂

[@VultureTransport]

I have two G360 for parts.

[@bcbloc02]

Good to have spares!

[@jeffreydevillez7433]

I'm having a T90 flashback. 88 needle bearings if I remember. I know that's not a T90