Quote:
Originally Posted by Ken/Alabama
Did you check the clearance between the 2nd gear and the thrust washer behind 2nd gear with a feeler gauge ?
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This basically checks the 'stack-up' clearances of the main shaft. You have to assemble the 2nd gear on the shaft (with the thrust washers), along with the synchro hub and put the snap-ring in to lock it down. Then you check the clearance. The closer you are to .004 the better.
On a lot of my setups, I try to get down to about .0025 to .003 (under the spec). This tends to help prevent the infamous "popping out of second" issue that so many of these transmissions seem to have.