rgpressler@suddenlink.net

Moses Just got the transmission with the new third gear and synchro sleeve installed. Took a test drive and the transmission worked beautifully. When shifting in to third gear I could actually feel it locking into place. With all of the replacement parts I put in it should be good for another 200000 miles. Thanks for all of your help and direction. All I can say after 4 tries is YAHOO!!!! Thanks Bob

Moses, Your right, I have learned a lot about transmissions but don't really want to be an expert. I have never been a "gear jammer" but now I know what happens to transmissions for those that do. I think I can get along with out the video extension since the procedure is now burned in to my memory. Thanks Bob

Moses, Third gear cost is $137 and the synchro sleeve is $79. I am going to order both just to be safe. I had already put in the new hub because it was damaged. Pulling this transmission and tearing it down 4 times is really wearing me down!! I will let you know when I get it all back together hoping this will fix the problem. Thanks for all your help. Bob

Another picture of my syncro sleeve. Bob

Moses, The dog teeth on third gear look worn to me after comparing them to the forth gear dog teeth. I am sending several pictures of third, forth gears and syncro sleeve. If you think the third gear needs replaced, should the syncro sleeve also be replaced at the same time??? Bob

Moses, I couldn't really tell if it had been rebuilt before or not. The previous owner had put in a new clutch but the transmission was a mess. Third-fourth synchro keys were in the bottom of the case in pieces and the brass syncros were chewed up. Probably why he replaced the clutch. It just wouldn't shift with out grinding. Thanks, Bob

Moses, I forgot to mention that my video rental will end this week. I hope I won't need it but , just in case - a one week extension might help. Thank You Bob

Moses, I'm Back. I have done a lot of measurements and checking. The first thing, I put the shift housing and shift lever on, held together with clamps. I supported the gear assemblies and observed the operation of the shift forks and synchronizer sleeve. In forth gear the sleeve engages all but 1/16th inch of the cogs and when in 3rd gear the sleeve engages all but 3/32nds inch of the cogs. At that point the 3&4 shift rail snap ring is up against the intermediate plate. The shift fork-to-sleeve clearance for 1&2 and 3&4 are both 0.020". I disassembled the gear assembly and took measurements of the shaft. First gear surface 1.534, second gear 1.848, third gear 1.495, the pilot surface 0.983 and the flange is 0.198. All surfaces smooth, no ripples or indentations. The input shaft bore is 1.456 and its pilot surface 0.590, and also both smooth. The syncro ring to gear of all the new syncros is 0.030. I inspected the first, second and third gear bearings, they looked OK but the cage edges felt sharp. So I ordered all three bearings, should be here Friday. I inspected the new keys and springs and found that my placement of the 3&4 insert springs were not as shown in the video, so I corrected the positioning. I tried to measure 3rd gear wobble by putting pressure on the top and bottom of the gear and measuring clearance. I got 0.005 one way and 0.008 the other way. The 3rd gear to flange is 0.008 while holding 3rd gear straight back from the flange. All of the inner gear bores are smooth. I hope the new bearings will take up the wobble.? Oh yea, I installed a new clutch pilot bearing and checked the shifter clearance through the floor board, no problem there. Are there any other things to check before Friday when my parts arrive? Thanks Bob

I want to first thank you for your extensive reply. I am going to double check my shifter clearance and replace the crank shaft pilot bearing (neglected to do). My kit came with front and rear seals, main bearings, syncro rings and input shaft pilot bearing. The pictures are of the old 1&2, 3&4 and the kit 3&4 syncros. The last tear down I replaced the kit 3&4 syncros with ones that matched the old 3&4 snycros. The clearances I speak of are the clearances between first gear thrust washer .005 second gear & flange .006 and third gear & flange .007. The pictures of the gear assembly are of different angles as I was comparing them with the video pictures. I think the syncro sleeve and hub are on correct?? I will be checking all the things you mentioned when I pull the transmission out and tear it apart again. Starting today. Thanks Bob

Moses, I have read all posts on ax15 transmission rebuild, problems and rented the video. I have pulled the tyranny 3 times replacing seals, bearings, syncros , keys and springs. I replaced the 3rd and 4th syncros which came in my rebuild kit with the straight as opposed to the angled syncros. I am stumped as to why it will not stay in 3rd gear. 1st, 2nd, 4th, 5th and reverse all work fine and can now down shift when I couldn't before. The tranny will go into 3rd gear but as soon as any torque is applied it pops out and I am unable to even hold it in gear. I would greatly appreciate any thing you might suggest before I pull the tranny out again. All my gear clearances are with in spec. Thanks, Bob