After swapping the Si 5th into the ZC tranny and was put back together, I've had some trouble. First of all, I broke the top bearing on the countershaft by tightening down on the C-Clamp that wasn't opened properly. I replaced the bearing and tried again. Sucess. Finally got the c-clamp to 'snap' around the bearing the two cases mated together fine. Now here's the problem. I can only spin the mainshaft by hand in 4th and neutral (I believe). Should I be able to spin the mainshaft by hand in all gears? I would think so. I've had so much trouble with this tranny, I could swear I'll never look at one again. What could be my problem. I'll just have to take it back apart (again) for the fifth time now...

 

make sure the countershaft is locked in........

Lay tranny in normal position and install the interlock bolt, last item installed!

Did you happen to install the interlock bolt before locking in the countershaft?

After all that, can you select all 6 gears? Sometime you need to spin the mainshaft to get the gears to engage.

#3 phillips screwdriver fits the bitch pin hole to make bench shifting easy.

Remember, "odd" numbered gears (1-3-5) = pulling out on the shift shaft.

Pics always help, email them if needed.

 

Well, I figured it out. Somehow or another the syncro sleeve got out of alignment and was completely crushed. I took everything apart and saw brass shavings laying everywhere... almost laughed, but not quite. Anyway, I replaced everything, put all bolts back in and then installed the interlock bolt last. I can now select all gears and spin the mainshaft by hand... woohooo. Everything has to be so precise. I should take some pics of the destruction I've caused... it's pretty bad. I didn't know it was possible to make one of those bearings explode. The whole thing turned out to be ok... I'm glad I understand how it all works in there now. Good to know I can work on it if need be. Can't wait to have those lovely highway-crusing RPM's.

 

been there, did it 2-3 times, part of the learning curve!!!!!!

You need a synchro to replace it? Kill the little ring also??

3-4 or 5th?

I have spares if needed