Hey transmission gurus, got another one for ya. (a bit of back story : I own a 2002 artic blue Rsx Type s. I boosted it and its alot of fun! I blew up my stock k series second gear a little while ago so I have been rebuilding my transmission with a set of MFactory gears and carbon synchros.)

I finished assembling the countershaft, main shaft, and differential and dropped everything into the case with the shift forks all in the correct position. I dry-fitted everything without Honda Bond and closed up the case. I put the shifter mechanism, the detents, the reverse gear bolt, and the shifter mechanism bolt all in place. It spins and shifts through all gears. When I turn the input shaft, it turns nicely, but it makes a grinding noise. I opened the case back up to find that the 5/6 synchro collar is half engaged with the 5th gear synchro, almost as if the shift fork is too heavy, and it drags the collar down onto the synchro. If I take the weight off of the collar by slightly lifting the shift fork with my hand and spinning the input shaft, it sounds normal. When doing the rebuild, I bought the master rebuild kit, which included Synchro collars, but I never changed the Synchro hubs. Could that be a factor? Anyone have any ideas? thanks!

 

here is a video I posted to YouTube of the sound.