Gearbox: Worn synchro hub and slider (Experts chime in please)

[HIKAR1]

 

I am currently rebuilding a R34 GTT gearbox that has a problem getting stuck in 4^th gear and unable to down shift from 5^th to 3^rd even if you rev match (block out condition). Sometimes you have to jerk the shifter to get it to pop out of 4^th, but funny enough, all the gears goes in like butter even on full song.

All the gears can be selected in/out with the car running, clutch-in whilst on the brakes (i.e. the main shaft not rotating) indicating that it is not clutch drag related.

Information on previous rebuild:

• New bearings and synchros

• 3^rd/4^th synchro key popped out, one was found in the drain plug

Inspections on tear down during current rebuild:

• Input shaft end play was checked and within specs

• Countershaft end play was checked and within specs

• Synchro gap and grab was checked and within specs (all gears)

• Synchro teeth condition was good (all gears)

• 1^st/2^nd and 3^rd/4^th synchro keys and spring was in place

• All bearing condition was good

• All shift forks had slight wear on where the brass lining were but as expected. No cracks.

• It was found that 3^rd/4^th synchro hub and the slider felt loose and was able to rock when assembled compared to the 1^st/2^nd synchro hub

As all the issues are apparent in the 3^rd/4^th cluster, an educated assumption is that when the 3^rd/4^th synchro key popped out as per previous rebuild due to play in the hub and slider, more kilometres gave it additional wear that made it so severe that the engaging the slider caused it to be twisted off centre and jam into place, unable to get out of 4^th. Is the above a reasonable conclusion to the problem?

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TIA

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