broken tooth

The input gear is coupled to the cluster gear all the time. You should be able to hold the clutch in and turn the input gear with a pry bar or big screwdriver to turn the cluster gear. Should not take a lot of force. Maybe wrap the end of the bar in tape or something so as to not mar the gear. Get a helper to hold the clutch pedal down, or figure out a prop of some kind.

 

I have bumped the starter to rotate the gears, looked everywhere, still nothing Having said this I find it hard to believe a rebuild by the po would have been so sloppy as to leave broken parts in the trans. Ultimately, in line with everyone's input, I will have to pull and disassemble the entire unit to prove this out.

 

posting a picture of the tooth you discovered could help identify the source.
and yes, remains have been found in rebuilt units before.
it happens

 

Are all 3 sychronizer plates still in position ?
A completely missing tooth would most likely sound really BAD.

 

I have heard of things like that being left behind during a rebuild.

 

Sorry I can't post a picture but to answer the other questions , all gears run smooth and shift the same , no problem with reverse either. trans is incredibly quiet in all gears

 

" Do ya feel lucky? "

 

As a professional Jeep transmission rebuilder I have to comment. If there was a broken tooth left in the case during a rebuild, the "rebuilder" needs to be shot. If it was truly rebuilt then the case and all other parts should have been thoroughly cleaned and all debris removed. Someone who worked for me did that they would be fired with no recourse...

Not saying someone couldn't have done a poor job of cleaning the case during a rebuild, but it isn't truly a rebuild if bad parts are left in the case.

 

Could the 'tooth' be part of bearing cage that belongs in the bearing at the output of the trany? My cage fell apart and made some interestingly shaped parts in the sump.

 

no.

 

well, end of the line then I guess.
if you can't see anything, and you've checked twice, just run it I guess.
The tooth could have been heavy enough to not have got tossed around and cause more damage.
I think the choices are clear: run it or tear it down for inspection.

 

Well thanks for all the imput, I guess I will just run it till ?