2nd Gear Grinds on New TRE Rebuild, Need Help

[project_tsi]

I just car my car up and running with my new trans rebuild from TRE. Its a 93 trans with 11% taller double syncro 1st, 10% taller 5th, stage 2 rebuild, 4 spider center diff. The clutch setup is a 2900 Pressure plate, and Clutch Net 6 puck sprung disk, and ACT flywheel stepped to .609. The fluid in it is 2 quarts of redline MTL, and 1 quart of Redline heavy shockproof.

The problem is that 2nd gear is grinding, at high or low rpms. However, when accelerating if I come out of 1st, and push in the clutch pedal a few times, and rock the shifter left to right a few times, the car goes into 2nd very well with little to no grinds. But on decel, when trying to downshift into 2nd, that method doesn't help. I have to slide the car into 1st then it will go into 2nd with little to no grinds.

I've been emailing Jon at TRE about it, and he told me to check my shifter cables for wear on the ball/socket. I did that, and from what I told them he told me to change them, and that when the ball/socket wear out, 2nd, 4th, and Reverse suffer, and that kinda what I've been havign.

So I swapped my shifter cables out yesterday out of a lower mileagle 91 laser, same part number on the cables. However, it didn't help.

I've also tried adjusting the side to side adjustment on the cables from under the shifter column, but every setting doesn't help.

What else could I try? Adjusting the pedal? It's releasing pretty good now, but I dunno. Its starting to drive me crazy. And right now, I want my old trans back.

Thanks for the help, Dan

 

[project_tsi]

Yeah guys it only grinds in 2nd. But it doesn't shift like butter in the other gears either like a new trans should.

I went out and did a creep test, it failed, so then I adjusted the master cylinder rod multiple times, in all ways. I adjusted it probably 10 times, always trying a different spot. Nothing helped. It still ground. All it did was change the engagement point, which I found to be very good to start with. Oh an with every adjustment, I did another creep test, every time it failed.

I'm really confused what to think right now and it sucks.

 

[hopwoodp]

I would say to send it back for inspection or have them send you a replacement.
Your a wiseman and if you can't fix it - then its more than likely the tranny.

 

[project_tsi]

I want to explore every option and adjustment first, before pulling the trans out again.

 

[Initial DSM]

i'm having a problem like that but mine doesnt go into 2nd gear at a high rpm if i shift fast.it doesnt grind it just locks me out ..i pretty much gave up

 

[hopwoodp]

Well, lets see what we got here. Does your shifter have alot of play in it? Is your shifter bushings in good shape/did you modify the shifter link cable bushings to the skate board bearing type?

Also, how fresh is the break fluid? Did you put a slave cylinder extension rod in? From your judgement, do you think that your clutch assembly is in proper operating condition, to include your shifter fork, fulcrum ball, T/O bearing?

Now, seeing that you said it doesn't shift like butter, do you think the shifter cables need to be re-adjusted(not replaced in this perspective)? The cables that you just put in, how much use did they have before you installed them?

How old is your master and slave cylinder? How is the condition of you clutch pedal? I mean, you are running a pretty heavy clutch and who knows how well your stock components are holding up to this.

If you need any out of the box ideas let me know.

 

[twicks69]

Dan, it sounds like a clutch adjustment issue. I would also reccomend dumping the MTL and heavyweight out of the tranny, and changing to Lightweight Shockproof (blue).

If you have any other issues, PM me and I will be more than happy to help you out.

 

[snox135]

If it's failing the creep test, I don't see how it could be the tranny. I run 100% heavyweight shockproof in my TRE and never had any problems with it. I have to be easy with it when it is cold. But I don't get on it hard when it's cold anyway.

 

[Siral3x]

HMM...I had the same problem but with an old tranny ...
My short throw shifter didn't had enought side play <---|---> to go right into 2nd gear, it would but I had to force it, and most likely it would end up grinding every time, since it was like not lining up right to go into 2nd.
My cheap trick was putting a bunch of electric tape on the ..hmm... small rod that's pushing this spring thing on the shifter side. Well mine was bent kinda and wasn't pushing the spring all the way causing horrible 2nd gear shifts. Basicaly I made it ticker with electric tape and that fixed it ...till I bought a new shifter.
Hope you are gettin an idea of my problem...an hope it helps.

 

[project_tsi]

Maybe I'll swap the stock shifter back in and see if it helps.

 

[99gst_racer]

FYI to anyone following this thread:

Dan pulled his tranny and brought it to Jon earlier this week.
Forward to today: I picked up Dan's tranny from TRE today and had Jon explain why it was doing what it was doing. Apparently, Dan had damaged the 2nd gear double syncro to the point where it was stressed and hardened and no longer "mobile". That was effectively "locking out" the 1-2 hub sleeve causing it to grind against the 2nd gear's teeth.

The hub sleeve and double syncro have since been replaced and the tranny will be reinstalled today. Hopefully the problem is solved.