Hi Moses. So cnyncrvr and I have been working on this transmission, as he said, for quite a while. And as he said, we ran into many re-assembly issues. So after basically losing 4th gear with barely 10 miles on the fresh rebuild, I finally removed it from the jeep again and have done a partial tear down on it, meaning I have split the case again but have left the assembly intact in the intermediate for the time being. I will be attaching some photos too to hopefully shed more light on this mess. The first thing I noticed was when I drained the case. The gear oil came out clear amber in color for about 1-2 seconds then became black and clumpy. I found a lot of metal shavings in the bucket I drained it into, some from the synchros and some from other sources, hopefully the new cage roller bearing in the input shaft. I didn't notice any excessive wear on any of the gears so I'm slightly hopeful there.
As far as the main shaft goes, there is a ton of play in the input shaft. It moves up and down, side to side and forward and backward a lot more than I would think it should. The 3rd gear synchro seems to be doing it's job correctly, but the 4th gear synchro will not engage at all and the entire assembly seems to bind up now in neutral, where it use to spin freely and fairly easily when it was first re-assembled. Hopefully the photos I'm including will explain things a little better than I have. I know I am going to have to remove the input shaft and likely have to replace the caged bearing again but I want to check for the wear you talked about on the nose, but don't have another shaft to compare it too and can only find the clearance for 1st, 2nd and 3rd gear bearing surface diameters. Nothing on the actual nose surface, but I'll keep digging. Well. As I said, hopefully the pictures will help.
