GSX 3rd gear incorrect subgear. need rebuilder's help

[ed1380]

I had problems with the trans popping out of 3rd gear. I took it apart, and the only thing that looks like it could be causing the problem is this weird spacer/shim/whatever, that has couple less teeth than the actual gear. It can spin separately from the main gear, but it's very hard.



EDIT: have a possible cause

3rd driving gear-26 teeth
weird subgear- 25 teeth

4th driven gear- 25 teeth

Looking through the service manual, the FWD transmission has a subgear on 4th driven gear. The AWD tranny has a subgear on 3rd driving gear. The clutch has been replaced and syncro's are very good for 150k miles. so the tranny might have been rebuilt, but they accidentally used the wrong subgear. Is that possible?




heres a video showing it.
YouTube - ‪Eclipse gsx weird 3rd gear shim?‬‏

heres's the whole gearset

 

[pneumo]

There's nothing wrong with your subgear. It's supposed to have one less tooth than 3rd gear. It's built like that to reduce gear chatter noise.

Usually when it pops out of gear it's either the shift cable adjustment, shift cable bracket is loose, shift fork is worn thin, or the teeth on the side gear are wearing down.

 

[ed1380]

you beat me to it just found this http://www.dsmtuners.com/forums/151785273-post8.html

1st and 5th are fine, so I doubt it's the cables. it doesnt really "pop" out of gear. it refuses to stay in when you release the clutch.

I have more symptoms here http://www.dsmtuners.com/forums/maintenance-repairs/398484-2g-awd-pops-out-third.html