Hopefully someone has experience with this.

I am working on a P2U5 transmission, all of the sleeves/collars seem to move relatively easily past the spring/ring except the one on 5th and reverse. I cant seem to move the 5th/reverse sleeve past the ring. I have tried this on my old gear set and with a set from a M2S4 as well and they all seem to be the same. Is this normal? Maybe they just need more lubrication before they move smoothly? The all move freely past the synchro to the gear when the rings are not installed so its definitely not an issue with the hub/gears/synchros. The testing is using 3 completely separate gearsets with different collars so I don't think its an issue with the collar. Its the same with moving into 5th and reverse. Well I assume the top one is reverse, feel free to let me know if I'm wrong, still learning.

Trying to provide as much info as possible. If I put the synchro and spring into the collar then put the hub in it does fit and move smoothly but once its disengaged it wont go back in. This is all by hand and not using the forks/gear selector. Once the fork is installed its the same thing tho, I have not really tried with the selector yet since I don't want to bend the rings.

 

What brand are the springs? Have you tried fitting the springs inside the sleeve?

 

I assume they are stock springs. I have not purchased anything new. I have tried the springs from 3 separate transmissions and they all seem to be identical. 2x P2U5 and 1xM2S4

As long as they are loose they snap in just fine but when they are sandwiched between the synchro and hub they no longer snap in.

I filled the transmission with fluid and tried shifting it and no change. I can shift easily into 1-4 but 5th and reverse wont get past the rings. I tried to force it in but I don't want to hit it too hard and bend the rings. I would have to assume that things would be better if the transmission was rotating.

I cant seem to get the snap ring in either so that may be the reason I cant spin the transmission. I tried dropping it and prying the top bearing with no luck. Soo frustrating. I guess ill have to rip this thing apart for the like 10th time.

 

Tried loosening the bolts and dropping it and no luck. So I pulled it apart and started troubleshooting from scratch. First thing I found is I couldn't spin the darn thing even in neutral. That was a bit of a new thing. 5th gear syncro was pretty wedged again I'm guessing if the collar was spinning it wouldn't have any issue breaking loose or maybe if It was just warm/hot.

Pulled the reverse gear and shift forks, couldn't get it to spin. I went head and pulled the main and counter shafts and they look fine, they both spin freely. Ill get back to that issue. I decided to test the case install with each shaft individually. Main shaft only spins freely until the bolts on the case have been tightened. Ok... maybe this is the problem. Pulled the top bearing out of the case and started comparing with the one on the M2S4. I cant get the cover off for the mainshaft on that one so I couldn't remove it from the case. After some comparing I noticed one side of the center of the bearing has a taper, when I pulled the bearing initially it had popped apart and I did not assemble it correctly. This may the issue or part of the issue. The tapered part of the outside of the bearing has always been up and correct, just the center was wrong. In the pics below I have already corrected it.




Next issue, when I removed the bearing there is a clip and a plate that sits above the bearing.. I'm not sure what order they install. I'm going to search and see if I can find the answer but it may be one of those things that no one talks about. If you know the answer please let me know.
Not sure what order to install these on the case.

 

it looks like the plate goes in and then the clip. That's what I thought and that's how I was doing it but some time things don't go the way that makes sense.. The picture above is wrong, I just wanted it to be visible.

 

Try shifting it with the shift box.

 

Yea I tried with the box, no go.

I put it back together again and now it spins. I still cant get the darn snap ring all the way in but since it spins now so I feel good about it. 5th and reverse still questionable but with 3 gearsets acting the same.. must just be hard to shift into 5th.