This photo shows Petes 1st gear brass snychro teeth sheared off as expected, however if you look closely you'll see zero gap between the brass synchro ring and the lower toothed ring! Factory clearance is 1.2mm and the wear limit is 0.7mm, but this is zero!
Zero clearance means the synchro does not reduce the speed differences between the inner and outer cones and you have effectively a dog box?
We also noticed damage to the mainshaft bearing cage and bearing housing. Suspected spun shim, inadequate clearance or wrong bearings fitted. removing the outer bearing race should confirm this.
To fix it i reckon;
All wear limits need checking and synchros replaced if required,
Detent balls need checking and replaced if required,
Detent springs need replacing,
Synchro spring clips need stiffening or replacing,
Both main shaft bearings need replacing,
Bearing clearances need checking and reshimmed,
All floats need checking and worn parts replaced as required,
At least the gear teeth are fine!
Pete, Im back at work tomorrow and will do that list for you then.
Last edited by Cosmic73 on 17th June 2016, 8:15 pm; edited 1 time in total