Synchro Sleeve Stuck Forward.

Here's the long of the short of it:

I rebuilt my t90, put it in the jeep, found out I had a stripped bolt, took off the TC. When I removed the TC, the mainshaft shifted and caused the synchro sleeve to move forward past the dawgs. Didn't realize it until after the TC was back on and I went to shift the trans.




SO...

What are the fewest steps needed to fix this?

Am I able to just drop the Trans and TC, remove the front bearing retainer, shift the input shaft forward enough to get the synchro off? Or does it need to be torn completely down again in order to fix this?

I am really frustrated this morning, need more coffee..

 

Also, I tried pushing the dawgs back in.. no bueno.

 

I think the sleeve will go back if you have 3 hands inside a case designed for only 1.......
If you can compress the springs all at the same time.....it will go back.

 

Big tie-wrap around the hub? A little piece of something under the tie-wrap and on each shift plate. Tighten the tie wrap, slide the sleeve back ... just an idea.

 

hmm maybe a good idea

 

I had the same problem, I got it all back together somehow, now the Trans comes out of second gear on deceleration. If I am paying attention when I shift and push it into second it will stay in second, but if I just push it in second easily and not click it, it will slide out on decel. If I push it in second I can ride around in second as much as I need to. The speed limit at the club I belong to is 20 mph, so I ride around in second a lot. I think I may have damaged my synchronizers , and may have a burr on one, I keep hoping it will heal itself. Good Luck

 

I seem to recall doing that a couple times. Just push it back on and bolt the shift tower back on. I seem to remember wrapping my hand around the assemble to push them in a bit an pulling back on the synchro.

 

Regarding Rick's problem, did the transmission pop out of second before you rebuilt it? Did you replace 2nd gear?

If the 2nd gear bushing is ok, I suspect you accidentally released one of the springs on the shift plates. Now the shift plates do not properly detent the synchro sleeve when in 2nd. If the 2nd gear bushing is a little worn, it will skew on the shaft on decellerating. This pushes the sleeve away fron the gear, and it comes out of 2nd. Maybe not worn enough to come out if the shift plates were working right ... or maybe this combination of parts accentuates a worn 2nd gear.

 

I only have synchros on 2nd gear. X_x Was hoping that the puke-sludge that I drained out of the gearbox had them jammed up, but after a week of fresh gear oil it still rakes bad going into 1st and 3rd. :/ I guess I will have to tear into that thing one of these days before I rake the teeth off, lol.

I don't have any trouble driving the unsynchronized Rangemaster gearboxes in the dump trucks and such, but that ol' Jeep wants to rake pretty bad no matter how perfectly I let it spin down upshifting or double-clutch downshifting.

Anyway, all I really wanted to say was "good luck getting yours fixed." I am NOT looking forward to taking mine apart, lol.... Although at least it's a 3-speed instead of a 4- or 5-speed, I reckon.

 

I replaced all bearings and shafts, no gears, all were in good shape. The synchronizers were like new, sharp points and no damage. The Trans worked fine until I pulled the transfer case. I pulled the transfer case put an all new kit in it, I let the main shaft slip back and the synchronizers popped up, not out. I managed to get them all back in and everything seemed OK. Like I said it works good if I pay attention and shift it right, if I don't, it doesn't pop out of second, it slides out of second on deceleration. My column shift would pop out of second, before I changed it to a floor shift transmission. I don't plan to pull the Trans again, unless it gets worse.