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Discussion Starter · #1 ·
A while back I had asked some questions about rebuilding a T-5.
I went ahead and tried it. Turns out my 3rd to 4th synchro exploded. Ordered a rebuild kit on ebay and an entire new synchro assembly from quadratec.
But on reassembly everything works but this new synchro assembly from quadratec. I saved up some money and took the tranny to cottman transmissions and their tech (real good guy, pressed in all the new bearings for free during rebuild)is taking a look at it right now but cant seem to figure it out.
Is it possible to get a bad synchro assembly or is something else the problem?
 

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Discussion Starter · #3 ·
i havent actually tried to put it back on the jeep cause i cant get it to work manually on the bench. but i read somewhere that you're supposed to petroleum jelly.
 

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If you haven't put it back in the Jeep how do you know it's not working? It's perfectly normal for a transmission to be very stiff and hard to shift on the bench, but work fine when it's installed. More details and symptoms please.
 

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Discussion Starter · #5 ·
The sliding hub on the 3-4 synchro wont engage the brass synchro rings.
There are two retaining springs that hook into 3 keys inside the hub, without these springs it works, but with the springs the hub just wont engage at all. Is it supposed to be like this on the bench? The other 2 synchro assemblies engage easily.
I talked to the guy at Cottman's who is rebuilding the tranny for me today, he ordered a new assembly that hopefully will work.
 

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I can't say about the T5 specifically, but I've had such things happen with Borg Warner T10 and Muncie 4-speeds, and Moss boxes in MGs. I can't recall ever having one refuse to shift in the car under power. It might have happened, but I don't remember it. And it was fairly common to have one not want to shift right on the bench. That's in maybe a dozen rebuilds I've done over the years.
 

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Keep in mind that there are 20+ versions of the T-5. It could be posible that it is a syncro for a different type. Does it look the same as the pieces of the old one. Also check the Detent plates under the sycro sometimes they get out of position and will not let it shift.
 

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[ QUOTE ]
Guess I should have tried it out before calling it a lost cause.

[/ QUOTE ]

In view of the amount of work to R & R a Jeep transmission, that's not necessarily so, especially in light of Bandhmo2's comment about the number of variations. I think you did the right thing.
 

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Check the bump on the top of the clips. Sometimes that bump is too straight up and down to let it feel normal. Compare with an old one. Sometimes they get a burr on them. Drag a file lightly on an angle to ramp them better.

Also on the new hub's inner surface, new ones sometimes have a machining burr on the edge. Knock the burrs off.

Are the springs positioned right?
 
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