I was not happy with my second gear from the beginning of its rebuild and found that although 3rd gear worked well 2nd was not particularly keen to go in without grinding unless I took it very slowly going up to third or double de-clutched going down to second. I also found that the first change into second of the day was the worst and then the rest were semi-ok......
When I rebuilt my transmission I replaced the second gear with a modern repro, I kept the original synchros, input shaft and output shaft the same as they all looked good and had been working before. I thought that the issue after rebuild was due to a poor match between the old synchro and a new repro gear cone, c'est la vie I thought. I have removed the transmission after a thousand miles for rebuild even though the problem was getting better and what I have found is that the second gear bushing has remained stationary on the output shaft whilst the gear has spun around it! No wonder the poor synchro was having a hard time.
I have measured the bushing ID and it is 1.1290 (upper TM limit) for 95% of its width except for a small band at one end which is at 1.1260 (below TM limit), this band can be seen in the photos. It appears to me that this band has been tight enough to hold the bushing stationary and the bushing has been loose enough in the gear to spin that way instead. This is why the first change was the hardest as the gear had to break free on its steel to steel contact.
How do you guys think I should proceed with this repro second gear, surely this is the most stupid transmission rebuild problem ever? I suppose it is my fault for not measuring the new bushing but as the bushing is fine for 95% of its width I must just have pushed it on and thought it was ok and then when it tightened up just pushed a bit harder. Thoughts and comments are appreciated,
cheers
Matt
