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Popping out of 5th after LSD install

1170 Views 34 Replies 6 Participants Last post by  rgm_93si
I installed an MFactory LSD, a Synchrotech carbon synchro kit as well as various OEM bearings and any items that were not included in the kit in my 93 Si hatch with a D16Z6. I referenced the service manual and several videos. The installation went smooth as well as the first test drive where I went through all the gears keeping it under 50mph. However, on the highway it pops out of 5th between 55 and 65mph. The transmission was not making any noises or grinding and shifted smoothly. I drained the fluid and checked to make sure the snap ring was on the counter shaft bearing which it was. I pulled the transmission again and opened it up and there is no sign of an issue. The car has new Hasport motor mounts, energy suspension bushings on the shift rods and a K-tuned shifter. I’ve had no prior issues with the transmission which has less than 150k miles.
The first thought was that 5th gear may be bad so I am attaching some pictures. To me it looks fine, but maybe there is an expert out there that can verify. At this point I am stumped, the only other thing I can think of is to take it to a tranny shop and have them look for any issue. If anyone knows of anything else I should be checking, I would appreciate their input.

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drive that tiny roll pin in on the shift shaft and slowly slide it out, covering the shaft opening and the ball opening as parts will go flying.

Reverse side of the 88-91 5th fork has some wear, but nothing to worry about, also I see you have it right side (Beveled) up.

4th gear side of 3-4 fork is showing some wear on one tip....would have to see the three others.

PS. I love the wrong answers posted that the OP had to correct people on.
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second pic of the 1-2 fork, the left (short) side has noticeable wear., like 6.25mm-6.30mm, new is 6.50mm and 6.45mm is as thin as I've tried and documented.

generally popping out of 5th is lack of lube via the shafts, which is why I say to always cleaned them out.
I love watching bone work
Careful, I might drop in some time. DIL's BFF who I walked with in Son's wedding, now lives near Busch Gardens and working for city of Tampa.
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how did the roller bearings and oil ports in the mainshaft look?
detent springs? condition, age, etc..
detent springs are captured in the shifter fork assembly.

You mentioned OK and 4 hours from home, what is your general location?

You did put the little rod back in for 5th fork right? That is part of the lockout system.

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I could see the 5-R slider being an issue, but it would have to be really screwed up to be popping out of gear.
I doubt anyone will find something that I cannot.

That said, another random text today, another transmission customer referred to me.
I'm about 10 months behind right now.....I've only built two trans. since July 4th or so. Covid took me down for about two months then I've lost 6 weeks so far since my crash.
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