Resolved 1G 2nd & 3rd gear grind before and after rebuild

[Anfurnyy]

Car is a 93 Talon, manual (confirmed to have 93+ trans)
Ever since I got this car in 2020 2nd and 3rd have kind of "clunked"/"grinded" into gear.

Last year I refreshed the trans, replacing all synchros (except 5th/reverse), new keys, springs, 1/2 and 3/4 shift forks, new bearings, cleaned out the input and intermediate shafts, upgraded to 300m output shaft, and re shimmed the trans and the same issue persists. When I had it apart, neither the sliders or the dog teeth on the gear looked excessively worn or damaged (see pictures) One thing I'll note is I think I've installed the 3/4 slider on upside down but I'm not sure that would make a big deal or not because 4th is just fine.

-Always ran MT90 fluid only.
-2nd gear usually does it when the trans is colder, when it's warm I don't usually have any issues.
-3rd gear does really consistently though. If I shift slow, it doesn't seem to do it but even any sort of a moderate shift it clunks into gear. At high rpm it definitely seems to grind.
-All other gears are perfectly fine at any rpm.
-Clutch is an ACT 2900 sprung disk (yuck, I know) with an ACT flywheel but this also happened with a OE replacement that was in the car when I bought it.
-Pedal assembly has been welded
-Both Master AND Slave are NEW OEM, not AutoZone or Similar.

Is there a more surefire way to adjust the cables to make sure they are correct other than "put the shift straight up and down and slide the cables on"?
maybe its some sort of clutch disengagement issue still?

Is there other advice anyone can spare to try and get this fixed?

HERE'S a video of me shifting into 3rd pretty casually and you can hear it clunk.

Pictures to show the overall health of the trans while I had it apart.

Any advise is appreciated!

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[Anfurnyy]

That is a shallow 1st synchro, you can run 2x springs on that side of the hub as well then.

Thanks for the confirmation. I'll probably do that.

 

[My93Talon]

Whelp.. im in deep now.
I was rebuilding my 1990 transmission due to a badly worn 2nd gear. I ended up bending my 3-4 hub slider When I was pressing gears on and off it got bound up. Now 3-4 won't engage easly. I still have the trans apart. According to what I'm reading here. Is it correct 1990-1992.6 gearsets are different and I cannot get a hub slider from a different year than that?

 

[pauleyman]

Whelp.. im in deep now.
I was rebuilding my 1990 transmission due to a badly worn 2nd gear. I ended up bending my 3-4 hub slider When I was pressing gears on and off it got bound up. Now 3-4 won't engage easly. I still have the trans apart. According to what I'm reading here. Is it correct 1990-1992.6 gearsets are different and I cannot get a hub slider from a different year than that?

that is correct. earlier sets are smaller diameter. More changes than that but that's the biggie.

 

[Anfurnyy]

I forgot to update this thread after I got everything back together. Replacing the keys fixed the issue. Car shifts fine now.

The 95-96 gear set / input+ intermediate shaft was a complete drop in with 92.6 "HD" 3/4 gears and shift rail, and my 93+ 4 spider center and Quaife LSD front diffs.

Making that info specific so if someone comes looking they can hopefully find this post.

 

[twicks69]

The only little detail that may be a fitment issue is using a 90 style main case oil guide and 5th gear cover as the 3-hole 3/4 shift fork has a different clearance than the 2-hole version. Did you swap those components as well?

 

[Anfurnyy]

The only little detail that may be a fitment issue is using a 90 style main case oil guide and 5th gear cover as the 3-hole 3/4 shift fork has a different clearance than the 2-hole version. Did you swap those components as well?

Late reply once again but my case / oil guide are from 93, with just the 95-96 gear set and late 92 3/4 and compatible 3/4 shift rail and fork.

I don't believe i saw any sort of clearance issues or fitment issues between the early style shift fork and the later oil guide but I guess I didn't specifically look for that. But also didn't see any issues with the oil guide after that same 3/4 exploded after awhile.