Posted by Ken on June 01, 2005 at 23:11:23:|
Really common problem. Usually synchro hub or 2nd gear splines worn. If the synchro hub is good and the 2nd gear splines that mate up with the synchro hub are good, odds are you need a thicker snap ring. This is the snap ring that limits the rearward movement of 2nd gear on the mainshaft. The snap rings come in different thicknesses to get the correct clearance. All in the repair manual. I have seen thin wire wrapped around the mainshaft, in behind the snap ring to move 2nd gear forward so the synchro hub gets more 2nd gear spline to hang on to, kind of rube goldberg but it seemed to work, and can be done with the trans in place. I'm not advocating this as a fix but it illustrates the point: if there is enough room to wrap a wire in the snap ring groove, then you know the gear needs to go forward. Hope this makes sense.