[kramsallad]

I have a '93 GT with the T5. I pulled the trans out to replace the throwout bearing and retainer. I also changed the trans fluid while it was out. After putting everything back together, it pops out of 2nd and 4th as soon as you let out the clutch.

It has a Steeda short-throw shifter. I though it might be backwards, but it seems to be correct. The bushing that the shifter ball fits into is okay as well.

Any ideas?

 

[YLDPONY]

I have a '93 GT with the T5. I pulled the trans out to replace the throwout bearing and retainer. I also changed the trans fluid while it was out. After putting everything back together, it pops out of 2nd and 4th as soon as you let out the clutch.

It has a Steeda short-throw shifter. I though it might be backwards, but it seems to be correct. The bushing that the shifter ball fits into is okay as well.

Any ideas?

Sounds like the stops are not adjusted properly. If I were you, I'd loosen up the stops to the point where they don't touch the handle and see if it still pops out.

 

[kramsallad]

Sounds like the stops are not adjusted properly. If I were you, I'd loosen up the stops to the point where they don't touch the handle and see if it still pops out.

Yeah, I tried that, too. Sorry, forgot to mention that.

 

[kramsallad]

It would make sense if it was on the same rod, like 1st and 2nd. But since it is 2nd and 4th (both on the bottom), it would seem to be a shifter issue. I can't find anything wrong with the shifter.

Are there any other places to make adjustments?

 

[YLDPONY]

Not that I know of...
Do you still have your stock shifter? It's a little bit of a shot in the dark, but it would rule out one thing.

 

[kramsallad]

Do you still have your stock shifter?

No, but that is a good idea. I'm going to check out the shifter offset block this afternoon and see if I can see anything obviously wrong.

 

[kramsallad]

I can put it in gear using the shift offset block, but it just comes right back out. I guess the shift fork is the only thing left.

How could two forks have been damged pulling the trans out? How easy is it to get to?

I guess I'm pulling it out again. The first time I had a lift and it only took like 30 minutes. Now I gotta do it with jackstands.

 

[kramsallad]

What is the deal with the shift fork pads? Could they have come off? Can they be replaced without tearing the trans down? Is it better to just replace the entire fork?

 

[YLDPONY]

I'm not going to tell you to pull the trans just because you or I can't think of anything off the tops of our heads
But.....
you seem pretty comfortable with with getting the trans out (like me). I would probably do it and take a look at the internals.
It isn't that hard to get to the shift forks. You do have to pull the tail shaft housing and then the top cover, but it isn't that labor intensive. Maybe a visual inspection will be a revelation?
When it comes time to assemble it again, I use Permatex Ultra Black to seal the tail shaft back to the case. This seems to work very well.

 

[kramsallad]

Oh, heck no... I'm dreading taking it out. I'd love to hear ANY suggestions from anyone. I just don't know what else could possibly be wrong.

 

[kramsallad]

Okay. Trans is out and (partially) disassembled. I don't see anything obviously wrong internally. The shift forks dont look bent. The fork bushings were in place. There was some very minor scoring on one. All the fork selector mechanisms look okay to my untrained eye.

When I took it out (before disassembly) there was a lot of play in the input and output shafts. I could jiggle them up and down a good bit. There was a TON of metal in the fluid. Big flakes of metal.

 

[YLDPONY]

That actually looks really good to me. But again, I am no expert. There is usually a bunch of metal collected on that magnet at the bottom, but I might be concerned about big chunks.

So verify the timeline...
The trans shifted fine until you replaced the bearing retainer. (?)

 

[moeny_man]

The way I see it is, if you got metal in the oil either start looking for a transmission or get ready to rebuild. metal should not be there, only way for it to get there is for something to be letting go. Also if you haven't found where the metal came from yet you're going to have to keep tearing it apart til you find out what it was, don't want to have to drop it a third time.:nono:

 

[kramsallad]

So verify the timeline...
The trans shifted fine until you replaced the bearing retainer. (?)

Shifted fine. No trans problems. Took it out to replace the throwout bearing. Put it back in. Immediately had problems. Would not stay in 2 or 4. I had to drive it about 90 miles to get home that night. Then I took it out.

 

[YLDPONY]

Shifted fine. No trans problems. Took it out to replace the throwout bearing. Put it back in. Immediately had problems. Would not stay in 2 or 4. I had to drive it about 90 miles to get home that night. Then I took it out.

Did you pull off the bearing retainer? And did you pull off the shifter? I mean the first time you had it apart.

I was just thinking, is the bushing that goes between the shifter ball and that block possibly missing?

 

[kramsallad]

Alright. Mystery solved!
When I removed the old throwout bearing retainer, the collar from the input shaft bearing came with it. I did not realize it, and put the new one on without it. That left the front bearing with play in it. It ate up the front bearing and the inside of the new retainer (see pictures).

The question now is: Can I replace the bearing & retainer and be okay? I don't think that the gears ate into the case, but I will have to inspect closely.

 

[YLDPONY]

I am glad that this is solved!!!

You didn't mention you had a Cobra transmission....?

If you replace the bad parts (bearing, race, retainer it looks like) and clean the case out well you should be golden :bigthumbsup