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Gears Wont Engage On Countershaft

2K views 25 replies 4 participants last post by  transzex 
#1 ·
Assembling my CS, the slider(new hardened from Synchrotech) wont engage 1st ( new 3.08.) or second gear. The synchros, springs, and dampers are also new.

The parts are all burr free, and everything slides when disassembled. Is this because they are new and tight?



 
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#2 ·
No oil, improper clearances, synchros jammed…..

.1 mm on the second gear bearing race can make a difference. Are you using the first gear shim and not need it? Correct new roller bearing?
 
#4 ·
4.9 GearX fd. I used the correct roller bearing. I will try it lubed lol trying to not make a huge mess. Taking me a few tries. I plan on sending you my next one lol
 
#6 ·
The dampers are correct. The little tangs line up in the notches.

I havent tried too much force on them. Figured they would move with some resistance, but didnt want to try to force anything. Rather error on the side of caution, too much time and money going into this project lol

Appreciate the help, thanks!
 
#7 ·
It will shift nice into both gears, without the round synchro "springs". They seem to be blocking the teeth on the slider from going into the dogs on the gears. Ive even swapped the new ones for the old worn ones.

Is that normal? Or am I overthinking this?
 
#9 ·
Well, I e decided to go ahead and reassemble the stack, hopefully in the morning. Then I will lube generously! And see if she slides. Thanks again
 
#11 ·
Thats gotta be a pain. I assemble motors pretty regular, but this is my first trans, with synchros lol Ive got a few spares, I may rebuild them as well just for some more experience.
 
#13 ·
I had the slider mis-aligned in the hub, 1/2.

Now the cases dont fit together lol .... gotta figure out where I messed up with that. I can r/r the shifter linkage, and CS pretty quickly now. Learn by repetition




Also had to remove a fair amount to clear the 4.9

 
#16 ·
This is correct. Im going to pull the main shaft 5th hub off to ensure its installed correctly. And go back thru the MS completely.

Im 99% sure the CS is all together correctly lol
 
#17 ·
Here is the direction the 5th hub was installed.



These are the two sides of that hub, seems the side with the flat surfaces would go against the gear.


 
#22 ·
Still no luck. Made sure the bearing fits inside the case, while it was off.

Does it matter what gear it is in? I have it in neutral.

Only thing I can verify is the 3.08 first.
 
#24 ·
Yup. And the interlock mech is lined up in the shift forks. Interlock guide bolt not installed yet. The one that goes in from the clutch housing side. Tried with it installed and not.

Im going to remove reverse tomorrow and see if it goes together.
 
#25 ·
Well, the problem ended up being a miss matched set of 5th gears. Purchased a .702 5th from a EX trans to replace the .750 Si 5th in mine. I was sent only the countershaft side, so I installed it. The gears where close enuff to go together, but Mr Bone found, they where far enuff apart that they where keeping the shafts spread apart enuff to not let bearings to fit into the upper case.
 
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