2G Need help with 96 tsi FWD 5 speed

[gfritz25]

You must be logged in to view this image or video.

Alright, new member here, and newbie to the DSM world. Buying a 96 Talon TSI fwd, that needs a little trans work. 5 speed manual. Trans was supposedly built, by Jack's Transmissions. Car came from Colorado, buying it from my cousin. The transmission grinds into second gear. We're both thinking it's the synchros, and possibly the gear is bad because of the grinding. Now I know my way around a car, just never had a DSM before. Haven't had a chance to look at the transmission ID number yet, but I'm thinking it's a f5m33, does that sound right? Anyways, I am either looking for a shop that will build this transmission to handle the power from the mods that have been done... 16g turbo pushing 26 lbs boost, intercooler, BOV, setup to run E85, tuned, supposedly built trans, ect... He has a dyno sheet of the car pushing around 385, in Colorado, so with the tune and lower altitude here, he says it should be around 400. Long story short, I am having a hard time finding a shop that will take on this build. Can anyone either point me in the direction of a shop that can build this transmission, or parts so I can do it? I realize that it will involve seperating the gear cluster, and I am fairly confident that I could do it properly with a FSM. I could get the necessary tools most likely. As far as I know, only second gear needs done, synchros and possibly the gear itself because it's been grinding. Also, just incase I am spewing complete nonsense, someone please correct me... I would rather have someone tell me than make myself look like a fool, as I am a noob in the DSM world. Thanks in advance

 

[luv2rallye]

Since we, like 99% of all cars have a syncromesh tranny, it's unlikely the gear itself is bad since all gears are constantly engaged at all times. However the 2nd gear syncro is probably it (also possibly the hub, slider, bearings {if bearings good at least check bearing preloads}) assuming your clutch is adjusted properly. Yes it's a F5M33. To do yourself you'll need the FSM, a press, bearing separator, lots of patience to not rush (which most people fail at) and do it right.

Here's a test for a bad syncro: http://www.dsmtuners.com/threads/2g...d-second-gear-problems.406668/#post-152697045

Here's great rebuild article (awd but good for fwd too): http://web.archive.org/web/20100627174759/http://www.twingles.com/ideck/rebuild3/dretranny.htm

And some tips:
http://www.dsmtuners.com/threads/f5m33-rebuild-dsm-fwd-transmission.317077/#post-151757065
http://www.dsmtuners.com/threads/wont-shift-into-1st-gear-picture.463935/#post-153268895

 

[gfritz25]

Since we, like 99% of all cars have a syncromesh tranny, it's unlikely the gear itself is bad since all gears are constantly engaged at all times. However the 2nd gear syncro is probably it (also possibly the hub, slider, bearings {if bearings good at least check bearing preloads}) assuming your clutch is adjusted properly. Yes it's a F5M33. To do yourself you'll need the FSM, a press, bearing separator, lots of patience to not rush (which most people fail at) and do it right.

Here's a test for a bad syncro: http://www.dsmtuners.com/threads/2g...d-second-gear-problems.406668/#post-152697045

Here's great rebuild article (awd but good for fwd too): http://web.archive.org/web/20100627174759/http://www.twingles.com/ideck/rebuild3/dretranny.htm

And some tips:
http://www.dsmtuners.com/threads/f5m33-rebuild-dsm-fwd-transmission.317077/#post-151757065
http://www.dsmtuners.com/threads/wont-shift-into-1st-gear-picture.463935/#post-153268895

Thank you for the info. Any recommendations on where to get a good quality synchro that will last?

 

[luv2rallye]

If you have a stock factory tranny, try
https://www.jnztuning.com/oempartscat.html or
wiseman Twicks69

 

[gfritz25]

I was told the transmission was built, but I am not sure. As far as I know the gear ratios are stock, as are all the gears, ect. I just don't want to have to pull it again if I do it, so I want to find good quality parts. Thank you again.

 

[gfritz25]

Is it possible to modify a AWD EVO III gear cluster to drop in a f5m33?

 

[gfritz25]

So, after spending about 45 minutes on the phone with Jon from TRE, I think I'm gonna have them build my transmission. It just so happens to be a plus that I live only 2 hours from their shop. Save me on some shipping costs. Now, I was looking at the South Bend stage 3 endurance, as that looks like my best bet for the torque range I'll be in once I get the other block built. He advised me to not go with a light flywheel, and explained why, and I have to say I agree with the logic. So, would I be able to run this clutch with a stock flywheel?