I have a 2005 Ranger 4.0 4x4 with M5OD, about 120,000 miles. The tranny has a really strange noise that has me stumped. It makes this noise whenever the tranny is turning (ie clutch engaged). If I push the clutch in I can hear the noise fade for 2-3 seconds as the tranny "spins down". The noise sounds like dry metal on metal rub with just a little rattle mixed in. It doesn't seem to change with RPM. Here is the weird part:

When I am in neutral/3/4 gears, the noise is there but not very loud, just a bit louder than normal gear noise that I have heard in any other ranger. However when I push the stick over to the drivers side (ie to shift into 1/2 gear) the noise gets much louder and sounds pretty unhealthy. It doesnt matter if I shift into gear or not, it is the side/side motion of the stick that changes the volume of the noise. If I push the stick to the passenger side or shift into 5th gear, the noise disappears completely.

Noise has been there since I bought the truck, persisted through a fill of Mercon and a fill of Royal Purple. So it is not fluid type/fluid level related. Anyone have any ideas besides turn the radio up? Thanks.

 

Side to side shifter movement is just sliding the shift "shovel" along the 3 shift forks "teeth".
Outside of a noise being transfer up the shifter's metal rod I can't see it causing more noise.

The 1-2 shift fork could be worn and vibrating, when shifter touches it you hear it more.

Next clutch change I would pull the top of transmission off and have a look at the forks.

On some models you could pull the carpet and there is an inspection plate that can be removed to get to trans top cover, not sure '05

 

Thanks for the help, I appreciate it. When the weather warms up a bit I will take a look at the shift forks.

 

Wasn't there an issue with the syncros? I could be wrong but gm trans fluid helped quiet it down.

Wait for others or search on here.