[orangefj45]

Originally Posted by fgr55

Case#256 4:1

Popping out of high and low any speed any gear . Installed new shift rail, ball, spring and brass set screw. Seems to have helped the popping out of low but still popping out of high. Donor case was a freshly rebuilt 4spd. Georg at Valley Hybrids built the orion for me. No new cut washer. Right now I am really frustrated with this set up. I hope I can iron it out. Any input and help would be greatly appreciated.

Anyway when I installed the new shift rail and associated parts I noticed that the shift fork didn't seem to seat all the way down onto the synchro shaft sleeve.

Anyone ever experienced this?

Thanks for reading

Josh

yup, i built that case amongst others. it is an early case. i reused the synchro slider (collar) and shaft since they were in great shape. the freeplay between the high and low gears was well within specs. i don't recall the exact measurements.
the last case i built was #357 and it came with the cut washers. i was not bale to use them because they ended up with no freeplay at all and the gears bottomed out on each other, causing them to bind.
i'm waiting for pics from josh to see what's going on with the shift fork and collar. i do not think it's the problem. i think the case might have to be updated to the cut gear and possibly the washers depending on the clearance.......

either way, i will stay in contact and make sure this gets resolved even though the case was not purchased thru me or from me. it was one of the main prizes at rubithon a couple of years ago. gark aka mudrak donated it to the raffle!