Trans rebuild help

[CJ_]

Hey everyone, so I posted this in my thread but didn't get any responses, so I figured I would start a new thread.

During my trans rebuild, after mating my front diff housing and the middle gear housing, when I would turn the 1-2 gear shaft, it would not spin freely, and made a grinding/ticking noise. After taking it back apart and inspecting everything, this was the only thing I could find that did not seem right. When the shift collar engages the gears, the synchros get stuck halfway up. Is this only going to happen when the shaft is out of the car? Is this anything to worry about? Would this cause the grinding noise when spinning the shaft by hand in the housing?

Summary:
-Mated front dif housing and gear housing
-1-2 shaft did not spin freely
-Took back apart
-Inspected everything
-Noticed 1-2 synchros not snapping back
-Is this a problem?

Video:

[Kenrevo]

That looks like the 1-2 shift collar. Did you install everything right and just write it wrong?

I don't remember exactly how it works but seems like on of the springs isn't in right.

Sent from my SAMSUNG-SM-N910A using Tapatalk

[CJ_]

Ah yes, I meant 1-2 shaft/synchros, my bad. Fixed post

Im like 99% sure all the springs are right, I went back through the JHM video like 3 times and I'm sure everything is installed correctly.

[slow ride]

Springs should return the blocker ring so it has to be something like that.

[Scotty@Advanced]

I'd verify the syncro isn't warped/bent or otherwise damaged. Syncrho rings shouldn't stick like that.

[CJ_]

So I took the 1-2 shaft apart again and found this. The old synchros do not have the problem, but the new one does.. Bad synchro?

First synchro is the old one, second is the new JHM synchro

[erykv1]

can you post any side by side photos of the two synchros?

[armageddon-]

did you replace the collar too?

[CJ_]

did you replace the collar too?

Yes with the JHM updated collar

can you post any side by side photos of the two synchros?

JHM is on the left, its just as flat as the old ones and not bent from what I can tell

[DxC]

just a side note - your trans parts are very dark stained fluid. thats not good, it means things got hot in there and prob ran without fluid. all the ones i rebuilt looked like new with golden/brown fluid

[CJ_]

Hmm.. So do you think I would be okay brake cleaning everything? Trans seemed fine when I last drove the car. Just some minor grinding in 1st to 2nd hence the rebuild. All the gears and bearing surfaces look great

[themadscientist]

Barring any other mechanical issues, it will feel notchy or even stuck when you turn that shaft without having the center diff housing on and that 12 point fastener tightened down. Once it is, the shafts will all be properly aligned and it should all turn freely. Seems to vary trans by trans, but I've encountered it before. I've rebuilt about a dozen 01e's. So slap the rear case on, tighten the fastener, spin the input shaft in neutral and all gears and see how it feels. Also, new synchro's in old collar hubs can be "sticky".

[Scotty@Advanced]

Try polishing the fingers on the syncrho ring. Those fingers slide on the return spring and the casting on those syncrhos has poor surface finish compared to the factory rings.