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Old 08-28-2002, 12:40 PM   #4
SlowGT
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Join Date: Jun 1999
Location: Columbia Co, PA
Posts: 303
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Once the teeth on the slider assembly get too worn, it'll start kicking it out of gear. You'll be able to hold it in for a while until the teeth are completely gone. Then you'll be able to hold the shifter in the appropriate position but since there's no teeth to engage, it'll just sound like it's gonna fly apart & continue to wear the slider smooth. It could be a bent shift fork, but the T5 forks are so hard that they'll usually snap before bending.

The grinding into second is probably the inner rings on your synchro wearing away. The synchro normally rides a certain distance from the gear and the inner rings maintain that spacing. Once they go away, the synchro ends up jamming against the gear and they fail to perform their duty.

Call Bob Hanlon and ask for some troubleshooting help from them. www.hanlonmotorsports.com

If you have another vehicle, you might try replacing the slider and synchros yourself. TTC has an awesome service manual you can download for free. www.ttcautomotive.com . Since my stang isn't my daily driver anymore, I've been practicing power shifting my 3550 on a regular basis. Consequently, I've been replacing 2nd & 3rd synchros regularly also. I've just started keeping the extra pieces on hand. The more expensive stuff I can pickup from Hanlon as needed.

A good aftermarket shifter with positive shifter stops will help your synchros last longer after the rebuild. I've got a Pro 5.0 and I wouldn't have any others.

As for a clutch. I would not recommend the King Cobra either. That's what I've got and I hate it. My next clutch will be a Super Connector '49' series from Hays with a Hays lightweight pressure plate. Not normally sold as a kit. It's right around $400 for the pair + TOB.

Good luck dude.
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