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Discussion Starter · #1 ·
First, I would like to thank everyone for the valuable info posted on this site. I have come across literally hundreds of tips and tricks and through each others experiences have learned a great deal. With that here's my problem and my questions.

Went to start the Boss for a brief ride before the snow arrives later today. Started up normally. Had to feather the throttle a few times to keep it from stalling (502, no choke). Felt the normal lurch in neutral when starting, particularly as it was pretty cold. Backed down the driveway (coasted) dropped it in gear and nothing. Would not budge. Got it back in the garage checked the fluid level and it appeared to be fine. Dropped the trans pan and was met with a “pile” of clutch material. The usual dust was also present but I found one small shard of metal, about the size of a “large” pencil point, looks like half a tooth. Further inspection revealed the entire filter about two times its normal size covered with clutch fiber. Any ideas on what this might be? Part of the converter or planetary coming apart? Last ride was two weeks ago and seemed fine. I have about 6500 mi on this trans. I change the fluid religously every 2000 miles. So, looks like a tear down is coming. With that, would like to get some other Hoss owner’s opinions and input on options or upgrades as part of the rebuild.

I have read a number of comments on the Converter upgrades being either the # 7 or the Coan. Most of the postings appear to be using the #7 in small blocks with high regards. Has anyone done this upgrade on a big block? Other options?

Clutch Plates – anyone using anything different than the standard plates? Anyone using Kevlar? How about Marv’s clutch plates?

I have read of late we cannot order directly from the factory any longer and must utilize the dealer network. That’s OK I guess but are we able to deal with Nesco directly for trans rebuilds? I believe I read awhile back contact with Jim at Nesco was discouraged but not sure if this is still an issue. Any info or opinions would be appreciated. Thanks in advance!

JMAN
 

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Jman,
I'm not going to be any help on the tranny rebuild info since I haven't been there yet, but I do have a quick question.

I saw you were from Southeast PA. Do you know a guy from the Philly area, I think, named Steve who rides a 350 Boss? I think it is around a 1997-1999 model. His Boss broke down right in front of me two years ago in Daytona and I trailered him to the factory for some help. He was a really cool guy. Just wanted to say Hi again.

Bill Taylor
 

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Jman,

I am by no means an expert here but I did have to pull my tranny last spring for a rebuild. My situation was similiar in that my 502 would not budge either. I had some debris that was holding the check valve open and was allowing the fluid to blow right through.

At that time I dealt directly with NESCO so I don't know if you have to go through a delaer now or not.

I did the frame splitting and pulled the tranny all by myself which was very intimidating but wound up not being that bad. I went with the upgraded componets from NESCO which included a heavier cluth pack and maybe bands I forget. I decided to go with the COAN. I am very satisfied with the COAN but can't knock the #7 as I've never tried it.

I know Elliot has pulled the trannies a gazillion times and he along with a bunch of others have lots of experience.

Chris
 

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JMAN,

I believe they use a #5 NESCO for the 502. Lower stall speed to match the torque/power band of the motor. Either Marv or NESCO would have the answer. I think either the Coan or the NESCO would probably do your bidding.

I understand you can still call NESO direct for the transmission issues, as the warranty from the factory is off on most of the bikes (none on 502) and so you're not skipping the system.

Personally, I would flush the trans, refill and see what gives.

Tim
 

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GRUMPY said:
JMAN,

I believe they use a #5 NESCO for the 502. Lower stall speed to match the torque/power band of the motor. Either Marv or NESCO would have the answer. I think either the Coan or the NESCO would probably do your bidding.

I understand you can still call NESO direct for the transmission issues, as the warranty from the factory is off on most of the bikes (none on 502) and so you're not skipping the system.

Personally, I would flush the trans, refill and see what gives.

Tim

You might call Curtis at TBH as he has seen it all on the tranny issues! Talked to Curtis could be a planatary issue or a low pump pressure and depending on the transmission (B) type it could possibly be upgraded without tear down. You are correct that you cannot go direct to Jim anymore!
 

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Bill Taylor said:
Jman,
I'm not going to be any help on the tranny rebuild info since I haven't been there yet, but I do have a quick question.

I saw you were from Southeast PA. Do you know a guy from the Philly area, I think, named Steve who rides a 350 Boss? I think it is around a 1997-1999 model. His Boss broke down right in front of me two years ago in Daytona and I trailered him to the factory for some help. He was a really cool guy. Just wanted to say Hi again.

Bill Taylor
Bill, just saw your signature. Didn't knew you have such a nice bike, wooow! :shock:

Nice paint job, brother!

Loaf
 

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J-man...Im' on my third tranny which is a heavy duty Nesco upgrade and run a Coan converter. Has been excellent for about 11,000 miles and is running great. I change the fluid every 5000 miles and find very little debris each time. Some fine particles at most and the filter hardly has to be cleaned. At this point I really just open one pan bolt and if it looks clean and fairly clear, I don't even drop the pan and just change the fluid. I assume you are using Mobile MX4T synthetic oil. Have you been rough on the trans?
What I'm saying is that I certainly don't think what you found in the fluid and filter is normal. The metal shard you describe would worry me and I'd be worried about the planetaries as well. I had similar clutch material in my oil with the first two trannies but not anymore.
Call Nesco and describe but sounds to me like a rebuild is coming.....Joe. What year bike and tranny and small or big block? The early two speeds were certainly more prone to self-destruct than the newer versions.
 

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Thanks Loaf!

The paint is getting a little tired after four years and 27,000+ miles, but I still daydream about riding it and the excited "new-bike" feelings haven't gone away yet.

We ride amazing machines!!!!!!!!!!

Bill
 

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Discussion Starter · #9 ·
Guys, thanks to each of you for comments and input. Much appreciated. I spoke to Tom at MBH and he is pretty sure it is/was the planetary letting loose. I did an overnight drain and cleaned up as much clutch material as possible. For self-satisfaction, I reassembled and refilled. Put the bike up on a set of jackstands and started up. The rear wheel began to spin at idle but slowly came to a stop. Tried reverse and there was nothing. No need to drain again. So it’s off to Mountain for the fix.

Bill – Yes, you rescued Steve Koban. Steve lives in the area but I do not see him riding much. As a matter of fact, I believe he bought a nearly new 606 from Mountain almost a year ago and sold the 350. If I run into him I will certainly tell him you were asking for him

Chris – we met at Marvs trailer last year in Myrtle Beach. Hope all is well. Thanks for your info. I thought about pulling the trans at a friends shop but I am going to have Mountain perform some updates and upgrades. Looking to experiment with the Kevlar clutch pack. Tom has installed a few to date with pretty decent feedback. Again, these are recent installs and only time will tell.

Grumpy/Joe/Dave – I have been running the MX4T for approx 6500 miles and I would be lying if I said I babied it. It has seen its share of smoke shows but always trying to be cautious on the shift points and the use of reverse only when appropriate. It is an 01 Big Block that has been rebuilt once a couple of years back. Tom mentioned there are upgrades that are not present in what I have today.

Here’s the kicker, squirreled enough change aside over the last several months to buy a complete set of new body work and it is currently being custom painted. Probably pick it up in a few weeks. Shortly after that, I’ll be picking up my bike with a trans bill that I was not anticipating. Oh well, that’s the way it goes.
 

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tranny

if you take the right side cover off remove the snap rings the cluth pac will slip out that the large snap ring out of the basket and steel & fiber plates come out. mine are FORD AOD any trans shop will have them about $ 35.00 trans filter is a 3/8 in line trans filter sold at any parts store about $ 18.00 blow out any and all ports and lines then put back together fill with dex III run 30 or 50 miles and change fluid and filter drop pan to check for trash if it looks good fill with new fluid{i use ATF+4} good luck mj
 
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