Hi,
I'll put in $.02 worth here.
If you checked the clutch out and that is all okay, then the next logical
conclusion is that your synchro rings or the cones are worn beyond spec.
To check this (with the shifter cover off of the TRansmission):
1. put the transmission in neutral.
2. locate all the synchros. 4th is toward the bell housing, 1st is toward
the tail of the transmission.
3. Make up a feeler guage of the appropriate thickness, something like .040.
4. Try to fit the guage between the brass "little teeth" and the matching
"little teeth" of the gear itself.
5. If it don't fit, the synchro is worn beyond spec.
I'll bet that you'll have to pry the synchro rings from the gears because
they are too worn.
You don't need to spend $800 to fix this problem, if you are really on a
tight budget, you can replace just the synchros, but you'll have to
replace the seals at the same time. And you really do need to tear the
whole unit down in order to replace the synchros.
Any competent transmission mechanic should be able to replace the
synchros in a couple of hours, probably $100 worth. The parts (synchros,
seals and the "circlip from hell") shouldn't cost more than $100, so
you're looking at $200 unless you do it yourself, then it'll be less money.
IMHO, if you go to all the effort of taking the unit out and tearing it
down, you should probably go ahead and do a real rebuild and replace the
bearings and thrust whashers and stuff while you are in there. It makes
sense from the perspective that you won't have to do it again (at least
you won't if you do it right!
Now back to your regularly scheduled programming.
rml
p.s. Try this URL:
http://www.mit.edu:8001/afs/athena.mit.edu/user/z/i/zimerman/www/Documents/tr6/
It is my epic of TRansmission rebuilding.
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Quote: You'll have to talk to my attorney about that topic...
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