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3rd gear notchy after XTD stage 4 clutch swap

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4gfun

Supporting VIP
2,009
55
Dec 10, 2007
Ask Me, Virginia
A few months ago I was driving down the road hard at the top of 3rd gear and all I heard was a grinding noise.

The car was not driveable after that. I took the tranny down and noticed that the PTT Twin Discs had all of the splines missing.

Prior to this incident, the transmission shifted like butter. I have owned many DSMs and have never ever had a tranny as smooth as the one in this GVR-4.

So I decided to put an XTD Stage 4 flywheel, pressure plate, disc and TOB in there. I didn't shim the ball because the fork was in a position that deemed it not necessary according to RRE's site.

I put it all back together and adjusted the clutch properly at the master. I replaced the master and slave and bled the system properly.

I used Coastal GL4 gear oil in there Just like I had in there before.

The transmission is now notchy going into 3rd gear and 3rd gear only.

In unrelated posts, some of you suggested that I need better tranny fluid but that makes no sense since it worked fine before. Still some of me says to put some synchromesh in there just to see if the problem goes away so that I can diagnose the problem and see if it is a tranny problem.

The problem is verifiable like 1 time out of 30 when I put it in gear. It NEVER grinds going in either. It doesn't seem like a bad synchro either because the RPMS fall if I try to put it into 3rd without pressing the clutch (someone suggested this as a test). It really seems more like a 3rd gear lockout if that makes sense.

I have adjusted the shifter cables correctly as well (a real PITA on the GVR4)

What happened? Is there some way that I could have messed up the tranny that night?

Please help

Replaced tranny fluid with straight Pennzoil Synchromesh as a test. Still the same. Spent hours adjusting the cables and it is less notchy but I can still notice it.

Any ideas?
 
Last edited:
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