The 1st-2nd syncro hub won't slide all the way down the new countershaft. Should I force it? Should it be able to slide freely on the countershaft? It's only 1/4" - 1/2" from being all the way down, I just didn't know if I should force it.

 

What does the Helms say?

 

The FSM doesn't say anything, it just says "reassemble the countershaft", but neither the FSM or Helms is going to apply directly to the ITR FD since the countershaft/1st gear are different. The FSM doesn't mention needing to press anything on until 4th and 5th gear... It seems like the hub slid off the original countershaft without to much trouble.

Has anyone else who has done a FD swap ran into this? What did you do?

 

Put some elbow grease into it. If it won't go all the way, press it on.

 

I was worried that pressing it on would cause interference with first gear; maybe causing it to drag if it was too tight against the syncro hub, but I think I figured it out. The JDM first gear ride inside a collar that slips down on the countershaft instead of directly on the countershaft like the USDM one. I think if I press the 1st-2nd sycro hub down onto the shaft it will actually sit ontop of the collar and not interfere with the first gear...

 

Won't interfere even with the USDM 1st. Hub splines only go so far.