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Discussion Starter #1
First post bear with me. So I've got an '01 TJ 4.0 Sport with a NV3550 and Dana 44. I seem to have lost fifth and reverse - I can put the shifter in position, but it feels like neutral and nothing is there. No grinding, no noises whatsoever. My thought is that either the shift fork is busted, one of the pins for the shift rod is busted, or something else. I've established that this is not a linkage issue and I've already pulled the trans and began disassembly.

Has anybody encountered this issue before? I also discovered a broken pin in my fluid during the draining process. I've found people that have also found the same pin in their fluid as described here.
(look for pictures from user "Iplumb")

Another link to broken pin here.

(I believe this is not the same pin - can't tell because image links seem to be broken)
What's weird is that these people don't have the gear problems that I have, so I think it may be an unrelated problem, does anybody know about this?

The most pressing issue, however, is that the trans rebuild process details a fixture called the 6747 Fixture. Its used to keep the different shafts aligned for both disassembly and reassembly. I found a dude on Youtube that built his own fixture
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But it is not the most illuminating video I've seen. Does anybody know where I can find the dimensions of this fixture? I can't find one for sale anywhere and I know that parts for this trans are hard to come by in general. If nobody knows I'll probably just measure and get and estimate myself. I'll post my build on this thread for lost souls in the future.

TLDR; NV3550 lost reverse and fifth gear - any known causes? Fixture 6747 outlined in manual - known dimensions for a DIY?
 

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Discussion Starter #3
So the manual calls for Remover 6858 to be used to remove the shift shaft roller pin that connects the shift tower to the trans. I was unable to punch this sucker out with a hammer. Instead of buying the $90 tool, I've elected to build my own remover. Using some known lengths, I was able to reverse engineer the dimensions for the 6858 remover. Below I've listed the dimensions I used to estimate the dimensions for the remover:

Shift Fork Roll Pin - MFG # 8672316
Approximately 32mm x 6.75mm = 1.25" x 0.25"

Images used to construct ratios for drawing:
remover front.jpg
remover profile.jpg

With the help of an online pixel ruler and the known diameter of the shift fork roll pin, I constructed and approximation of the 6858 remover. Here is the resultant drawing. I hope this is useful for somebody in the future.
Remover 6858-1.jpg

Contact me for higher res drawings and/or solidworks parts! I plan on building a mockup of this and I'll post the results here as well. If nobody has the dimensions for the 6747 Fixture I alluded to in my first post I'll be making that as well and posting the drawing and mockup here.
 
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