Gearbox Rebuild(2nd gear crunching when shifting from 3rd down to 2nd gear)
 

As the title says, i am rebuilding my transmission due too the gears 2nd and 3rd crunching when shifting down. Anyway after striping drive pinion assembly i found that 2nd drive gear was cracked on the inside of the gear and has done some extreme wear on other opponents. also wondered, does the outer baulk ring and synchro cone ment too look like this and how do you separate them. just wondering what would the cost be too replace some of these parts. pics too come soon.

https://cimg6.ibsrv.net/gimg/www.sco...d4cb77e2e8.jpg


https://cimg7.ibsrv.net/gimg/www.sco...75377b30d5.jpg


https://cimg9.ibsrv.net/gimg/www.sco...743321a411.jpg


https://cimg0.ibsrv.net/gimg/www.sco...b29aa5b554.jpg

any gearbox guru's on, too give me any technical info

I assume this is a 5 speed box..

Is it a uk or JDM box.. Looks like the double cone synchro type.

parts not cheap..Think the synchros £120 ish ..plus gear..£100 ish and synchro hub £ ???

Cheaper to get a good used secondhand box for around £ 250.

no probs bud. i have done that anyways get another box. just want too rebuild this one too have a spare.
The box is a 5 speed jdm import

Ok.. good idea..
that's what I did with mine.. I bought another JDM box with a damaged casing for £30 and used the internals to repair mine.
Prob is the gearbox parts from subaru cost a fortune.

the prices aren't too bad.

is there any threads that cover a gearbox being stripped and rebuilt. The workshop manual doesn't give much information.

very basically... remove 4 bolts and tin plate on top of centre diff case.. carefully remove 10mm bolt that holds and locates the selector shaft.. then disengage the linkage selector shaft by twisting/rotating out of engagement from With The selectors on the end of selector rods.
Remove the 14mm bolts holding the transfer case to the main case and pull whole assembly off including the centre diff.
Remove all the bolts going through the main case and it splits in half.
You will need a proper hydraulic press and collars to remove the gears from the shafts.
That's it in a nutshell really.