Successful Syncho Installation!!

["Dave Ewing" <rabbit16v@prodigy.net>]

Well, finally finished the synchro install.  I had some problems with my
motor and had to pull the crank.  While the trans was out, and I had time
while the crank was at the crank shop (for you NW lister, Custom Crankshaft
in Tacoma does an INCREDIBLE job for cheap!!!!) so I ordered the seal/gasket
kit for the AGB and the 2nd gear synchro.  Once I got it all apart (if you
do this yourself you do need two special tools which you can make pretty
easily) I found the reason for everyones complaints about 2nd gear grinding
when cold!!!! I know some of you know this already, but the synchros have to
have a certain clearance spec.  The ones that grind cold and get better when
the car is hot don't have the right clearances.  The inside of the synchro
(the part that sits on the carrier for the gear) gets worn and once the
trans is warmed up and well lubed and the metal has expanded, the clearances
have changed causing it to shift better.  Anyway, at first glance my 2nd
gear synchro looked fine until you checked the clearances (all I actually
did is install the new one and notice the huge difference in how it sat on
the shaft).  The 020 is actually a pretty simple trans to pull apart and put
back together.  Be careful if anyone does this that the pictures in the
bentley are wrong, but the writing/wording is correct.  Plus, if you can,
remember or even draw the parts on something as you take them off.  You can
replace bearings while you are in there, install a bolt kit, diff, etc. but
I was just after the synchro and the seals.  I replaced all the seals and it
is suggested that you replace the mainshaft seal while it is out!!!  I do
plan on a 4K 6spd with a velocity diff and bolt kit fairly soon though!!
Just wanted to let everyone know that I am back on the road with no grinding
and HAPPY!!!

Dave


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