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Well I finally got my car back home from winter storage at my moms. So, that's at least a start......

When I had mine rebuilt the guy Machined some oil grooves and added a drain plug..Just something to think about if you have not allready.

Al

The new syncros have machined oil slots, not sure if the originals do or not. I will see when I take it apart. I assume that's where your mechanic machined the grooves?

On the main shaft he machines oil grooves into the main shaft for better lubrication to the gears..This process is done it the milling machine with a carbide ball end mill..

It was part of the rebuild process ..

Al

BTW my invoice shows $35.00 this procedure..

Al

Ok, well since I am doing the rebuild myself I won't be able to perform that operation but since the trans has lasted this long I guess it will be ok. I have read a lot about rebuilding these but never heard anything about that operation. I just want it to shift into gear smoothly. So what promted you to rebuild the trans? Were you having any issues?

I figured I am allready into this car for so much may as well do it now.. .he did replace my second gear though so something was up.

Al

Got the car up on the lifts and removed the torque arm and driveshaft....that's it for tonight. I am getting too old for this

Is it normal for oil to come out when you you pull the dirveshaft or was it from a bead seal??
just wondering if i should fill the transmission before I install mine.

Al

It is normal for some oil to leak if the yoke is removed, especially if it is tipped. I would not put oil into the trans until after it was installed.

Well, the trans is out and on the bench. Once again, I am getting too old for this. Seems to be more work than than I remember

Well, surprise, surprise. I think i found the cause of my shifting issues. Keep in mind I have had this problem since new and over 75,000 miles. This is my 1st/2nd slider assembly. This is where I thought the problem was (already purchased a NOS one) but I was not expecting to see this.

Could you see it was broke before removing the shaft from the trans casing or did you have to remove the outer part of the slider to see it?

No, I could not tell until I took it apart. It's the inner part of the slider hub that was broke so the outer part was actually holding the whole thing together. Once I separated the two pieces then I saw what was happened. Funny thing is as I continued to work on it tonight another section (there are 3 sections) was cracked! I can't believe the trans still functioned at all and held up for as long as it did. The fact that I had this problem since the car was new is absolutely baffling, we are talking 75,000 miles. Oh well, I have the mainshaft completely disassembled, still have to remove the cluster gears and get everything cleaned up before assembly. It will be a few weeks before I get it all back together but I am thrilled that I actually found what was wrong. Now I just have to take my time and get it put back together correctly as I do not want to do this again. Here's the new slider assembly put together and then just the inner hub, that is the part that is broke.

Well, slow progress but the trans is now completely disassembled and everything cleaned that I am reusing. Next will be to start reassembly. I can honestly say I have learned a lot about manual transmissions from this experience. I won't claim complete victory until it is done and I am driving it but it's been enlightening.