1st and 5th grind

lccynmbr13 · 11-05-2009, 11:32 AM

I just bought a '93 GSX for my new daily driver. Before I bought it I test drove it but never got up to feeway speeds and never got to 5th gear. 1st gear grinds every time you pop it in from a stop unless you put it into 2nd first. I seem to be able to put it into first when deceling around 10mph though which is pretty normal. 5th gear grinds every time I shift into it regardless of speed, double clutch, rpm match, whatever. I've never torn into a tranny before this is new water for me I'm thinking it could be one of the big nuts coming loose. I'm not thinking synchros since they only effect downshifting (am I correct?). Any advice or ideas would be great. Also I've searched all over this forum looking for a how to or write up on how to tear down/ put back together a tranny or even just a write up on synchro replacement with no luck. If anyone could point me in the direction that'd be great.

twicks69 · 11-05-2009, 12:06 PM

Quote:

Originally Posted by lccynmbr13

I just bought a '93 GSX for my new daily driver. Before I bought it I test drove it but never got up to feeway speeds and never got to 5th gear. 1st gear grinds every time you pop it in from a stop unless you put it into 2nd first. I seem to be able to put it into first when deceling around 10mph though which is pretty normal. 5th gear grinds every time I shift into it regardless of speed, double clutch, rpm match, whatever. I've never torn into a tranny before this is new water for me I'm thinking it could be one of the big nuts coming loose. I'm not thinking synchros since they only effect downshifting (am I correct?). Any advice or ideas would be great. Also I've searched all over this forum looking for a how to or write up on how to tear down/ put back together a tranny or even just a write up on synchro replacement with no luck. If anyone could point me in the direction that'd be great.

Here is an oldskool VFAQ thread on a 2G transmission rebuild:
2G Transmission Rebuild - www.VFAQ.com - Drivetrain

As for the issues you are facing, it could easily require a transmission rebuild, or it has loose end shaft nuts, or you have a bent or loose shift cable or bracket.

Pop the hood, and thoroughly inspect the shift cables and their bracketry attaching them to the transmission, along with circlips that hold the shift cables in place, the bolts and rubber-lined washers that attach the bracket to the transmission bellhousing, and the shift shaft is free to move (make sure that it is not hitting anything that would cause it to not fully engage 1st or 5th. Make sure that the shift shaft and shift linkage area on the transmission is clear of intercooler piping, intake piping, and the lower radiator hose, etc.

Start here before pulling off the 5th gear cover to do an end-shaft nut check/tightening.

lccynmbr13 · 11-05-2009, 01:50 PM

Thanks for the information twicks your replies are always helpful. Is dissassembly of the 1st gen trans the same as the 2nd gen? I'm going to pull the ride into the garage and check all the easy things in a minute I'll post my findings shortly.

twicks69 · 11-05-2009, 02:51 PM

They are very similar, and have the same teardown processes.

lccynmbr13 · 11-08-2009, 11:22 PM

After a thorough lookover I'm pleased to say it totally slipped my mind that the clutch is WAY out of adjustment. Its adjusted (as purchased) with the rod all the way out with it riding the hell out of the throwout bearing. I adjusted it to the way it should be and not to my surprise found that every gear grinds with slight pedal play. I'm starting to think this is a clutch issue not the tranny itself. On Wednesday I'm going to pull the trans and check that the teeth on the pressure plate aren't bent and that the cheater washer behind the ball is there (feels like an ACT2900). If all of that is good I'm going to swap the flywheel for my flywheel off my down racecar since I'm sure it's machined correctly. Hope this is a cheap fix

Mindslayer · 11-09-2009, 05:29 AM

Before you do that, try to adjust your master clutch cynlinder a few turns. vfaq.com shows you how.

TimG · 11-09-2009, 07:38 AM

It doesn't take much to take off the end case and crank down (110 ft-lbs) on the nuts. It's about a half hour job. Just make sure you RTV the case before you put it back on.

lccynmbr13 · 11-09-2009, 12:40 PM

Quote:

Originally Posted by Mindslayer

Before you do that, try to adjust your master clutch cynlinder a few turns. vfaq.com shows you how.

The rod is already adjusted to the maximum amount of travel.

TimG I guess I might as well tighten those up as long as only the first layer of the case has to come off.