NV3550 transmission turmoil

[BigForumGuy]

I've had my 03 TJ for about 70,000 miles (9 years) and am dealing with my second transmission swap.
First one came after a deployment where she sat in a lot for 8 months. There would be a high pitched whirring sound that I believe went with the RPMs then eventually, shifting into 5th on the interstate, there was a very loud click, thunk, boom and I only had 4th gear. Input and counter shaft were bare upon inspection, bought a new one from a yard, installed it, and life went on without a clue as to how that happened.

The problem I have now is a very loud click, clearly coming right below the shifter, and obviously increaes with the RPMs. It goes away when the clutch is disengaged, and quietest in 4th but still audible. It sounds nasty. I dropped the trans a week ago to check it out and the throwout bearing was in 2 pieces, split like a bagel around the circumference. I replaced the clutch, throwout bearing, and CPS because I forgot it was connected when I dropped the trans.

So does anyone have any ideas what this sound is or what causes it? I've never rebuilt a transmission, does this sound worth it or should I just find a new nv3500? How does a throwout bearing split like that?

Videos are usually poor quality but I'm attaching one, first one is 3rd to 4th, never got over 2500

 

[machoheadgames]

I don't know what the cause of your problem is nor what the sounds are but I really like the AX15 and they are available new still, for about $1700 which is often cheaper than paying a shop to remove and rebuild and reinstall. It is basically a direct swap for the NV3550 with the exception of the backup light switch needing some very easy rewiring and I think you need to get the shifter assembly for the AX. Otherwise it should be a bolt in affair to get you a much quieter, very good reputation 5 speed that has very slightly different gear ratios and overall has a better reputation for longevity. Put some Redline MT90 in it and it'll go a long time. Plus, I like to recommend this option as it will help keep that brand new transmission market going hopefully as long as possible for the manual guys to benefit from.

The original parts used to build and rebuild the NV are long gone, so rebuild kits are at the mercy of foreign, arguable quality parts. Just doesn't seem worth the work to rebuild it to me considering the circumstances.