i have a eg coupe with a d16y8 motor and trans. the car shifted fine through all gears even with some broken motor mounts. i pulled the trans and swapped in zc 1-4 with the y8 5th and used the y8 final. i also modified the 3-4 shift fork to use the older slider. i put the tranny together and shifted it before i put it back into the car, and it shifted through all the gears fine. i installed it back in the car, but i doesn't go into second, it seems like it does, but when i let out the clutch, it grinds and pops out, also third and fifth, i can be driving in fifth on the highway it would just pop out into neutral. i pulled the trans 4 times in the past 3 days and i seem to only find that it seems that the 1-2 slider doesn't seem to sit in the middle of the syncros, it sits more towards 1st. so yesterday when i pulled the trans i found the counter shaft bearing on the case wasn't all the way in, so i tapped that back in flush and installed the gear packs, and everything lined up perfect. so i installed it back in to the car, and it does the same thing, only now it grinds putting it back into 1st when coming to a stop. i need help, and i really don't want to put the other gears back in, thats my last resort, please help me trans god.............

 

You need to keep the Y8 1-2-5, and swap on the ZC 3-4.

88-91 gearstacks are 3mm shorter, causing the offset your seeing.

ZC 4th will need grinding to fit over the 3-4 hub.

 

okay i'll put the y8 1-2 back in, but what do i have to grind on the zc 4th to fit on the hub? I'm using the zc 3-4 syncro set. i did the grinding to the fork and it goes on the slider good. thanks for your help.

 

88-91 4th uses the wide roller bearing, 92-95 uses the narrow bearing, that extra width rubs on the cone of the 92-00 3-4 hub, grind for clearance

I can't find my pics.......

 

I rebuild Trannys all the time and to me it seems you need to look at your syncro springs. They might be bad or not there at all. Also see if your sincros might be discinigrating at all. Do some seem to be smaller than the other? And on the other not your shift fork might not me the right length. Is the fork on the Counter shaft of the Main shaft?

 

fork length is not changeable, the issue is a shorter gearstack in the wrong tranny.

 

i replaced the 1-2 gear set with the y8. ground the cone part of the 3-4 hub so the needle bearings can sit flush, i also had to grind the bearing sleeve also. the sleeve would sit about 2-3mm higher. i made it so the sleeve would be flush with the gear. reassembled the trans, it has a hard time shifting. it shifts into 1,2,5,R. this is with the trans in the car not running, no fluid. it feels like 3-4 has a lock out. need help please, again. i'm hating this gears, and real close to puting the stock gears back in.

 

Use the Y8 3/4 hub and slider, not the ZC.

 

You grind the gear, not the hub. I need to find the pics.....

this gives the idea

 

How Bense did his........

http://bensebuilt.livejournal.com/2007/02/05/