By Charles (152.91.9.10) on Sunday, July 22, 2001 - 07:36 pm:

Anyone had problems with 5th gear? I had a box sitting here with no 5th, opened it up and the dog ring would not go over the syncro, everything in good condition though. Pulled out the gear, lined up the syncro (you know big nothches in the hole etc etc) refitted it anbingo, worked a treat. Stuck the box in the car hooked it up and tried the gears, yep all working. Started the car, drove it in gear, whoops 5th no longer selects. I am going to try another syncro as I think the energiser ring on the syncro is the problem. I know it is not detent balls and the gear and syncro appear in perfect condition. Has anyone had this problem.

By Mike S (202.12.144.21) on Monday, July 23, 2001 - 12:56 am:

Charles, Assuming the Synchro sleeve and hub are correctly aligned (deep splines in the deep slots - not the void) then the only thing I could suggest would be a bent selector rod. I had this problem a few years ago. When the box was cold, everything worked OK. When it was hot (after a rally stage or a few laps of Calder)I could not select 5th. After it cooled down (a few km of gentle running) 5th would engage again. When I pulled the box down I found a very slight bend in the selector rod for 5th/reverse. Presumably when it got hot, either the bend became worse, or differential expansion between the rod and the alloy casing made it jam. Hope this helps.

By Charles (152.91.9.10) on Monday, July 23, 2001 - 03:38 pm:

I will pull off the end cover while it is "in car" and check. It does not engage at all, I think the selector rod is OK but I may have stuck the deep splines in the void (like the lower gears are supposed to do). Thanks Mike. Are the deep slots halfway between the voids or just beside them (the deeper slots and taller splines are not that easy to pick on 5th). Cheers

By Mike S (202.12.144.21) on Monday, July 23, 2001 - 04:06 pm:

The deep slots are halfway between the voids. With the end off the box, you should be able to remove the hub (keeping the synchro sleeve and shift fork in place) and turn it 60 degrees then re-intall.