Tranny Trouble Please Input Needed

[Mike1992]

This Auto to Manual swap has led me to where I am now just got a little q/a for yall. I am going NUTS!

what i've replaced and fixed:
pedal assembly, clutch master, ss clutch line, slave cyl., clutch kit(Disk,TOB,PP), shimmed pivot ball,(fork sitting center), BG Syncroshift, Symborski Shifter Plate Bushings. Under the Hood Cable Bushings, Taboo's Extended Slave Cylinder Rod

My Problem:
Going into first sometimes it feels like the shifter is like putting your finger into a fan blade but goes in. Then while driving down the road i get the same feeling when shifting in every gear (Only tried up to 3rd so far) I've drivng the car maybe 2 miles, at only 3-15 minute trials.(Too scared)

Tranny is used came from a 90 eclipse at 140k, the flywheel looked fine, but maybe this is the problem I didnt get it resurfaced. Should have I?

Transmission will only allow me to put about 1.7 quarts of gear oil in, which seems odd when its suppose to hold 2.3qts.

The cables are set up perfect I can hit ever gear and feel it fall in, when car is off. Clutch Master is almost maxed out so I know its not a hydrolic issue.

Tuners I am lost and about ready to give it the dealer so they can figure out the problem, but help beforehand would be excellent

 

[Mike1992]

Only conclusion I have come to is the ALL the Syncro's are bad OR the flywheels needs to be resurfaced

 

[Morphius]

What you describe sounds like poor or worn syncros. With 140K on the tranny, it's probably never been apart and in need of a rebuild.

Are you sure you have the clutch pedal/master,etc set up correctly for good disengagement? Did you weld the pedal assembly BEFORE you installed it? I see you put a higher clamp load clutch in which will only aggrevate a worn pedal assembly.

If the flywheel surface was bad it would slip.

-DaimlerChyrsler Engineer

 

[Mike1992]

Remember this is a Non-Turbo car.

This info is from an Auto to Manual Swap in which I just completed.

The pedal assembly was found to have a missing a bushing or 2 and some little washer, I since then replaced all that from new dealer parts. The pedal and arm that attaches to the Clutch Master is tight and functioning great. Everything is now there.

The clutch Kit was an Exedy Kit which I beleive to be a stock replacement.

EDIT: I thought maybe it was a hydrolic issue at first also. So i replaced all those parts. Then the car wouldnt disengage unless I have the clutch master maxed out. Now I even added the Taboo 1/4" Longer Rod and still seems the same and still maxed out I dunno WTF here Either.

Is it poosible to have ALL worn syncro's that just seems odd to me, I guess its possibly just very unlikely.

 

[Mike1992]

I was just talking to a friend of mine which said the fork sounds to be bent. The first time I put this tranny in I had to pull it back out to shim the pivot ball because according to RRE's website the fork needs to be positioned center or somewhat a little towards the drivers side, and mine was wayyy over the passenger side, so i shimmed it, and now its positioned 1/2" off center to the drivers side. This then allowed me to be able to shift with my small grinds that I am bitc$ing about.

Does all this info sound like a bent clutch fork?

Edit: Before the shimming I couldnt get it into ANY gear, it would grind like maddd