Quote:
Originally Posted by john walker's workshop
the installed, outside diameter of all the new syncro rings needs to be measured with calipers and be within spec. the inside of the pressed on dog teeth can wear oversize from the rough surface of the syncro rubbing on it during it's lifetime, and even though the teeth look nice and sharp still, they often need to be replaced if they allow the the new syncro to expand too much. the shift sleeve has trouble passing over a "fat" syncro. use a standard gear oil like kendall 80/90 GL-5 and hike the short shifter.
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I have an additional comment about dog teeth. In recent years the replacement dog teeth that have been available in the aftermarket, including those through OEM sources, have frequently been a tad too tight right out of the box. Back in the old days the factory put a slight backcut on the teeth allowing the synchro-ring to properly seat within the dog. What we have seen is that this backcut is not being done. It's something we do on all of our teeth at the point of manufacturing the gears. It's something many rebuilders know to do with a dremel at the point of assembling the gearbox with the new teeth.
However, if they just pressed the dog teeth on the gears, installed the synchros, and put the thing back together assuming all the new parts measure within spec, then the synchro in this freshly rebuilt gearbox may be getting pinched too tight and isn't getting enough friction from it's engagement with the slider on certain gears.
Just something for the OP to consider if this problem persists and none of the other suggestions in this thread remedy the issue.