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I know this transmission has some issues, a rebuild is planned for next winter. A new one occurred last night. Decelerating in 2nd down a mild hill it popped out of gear and ground alot going back in. My guess is the synchro's are pretty worn. Wondering if it could also be a linkage problem?
The grinding is a bad sign. Could be linkage. Put it in second, get under the car, unbolt the rod from the 1/2 gear lever, see if the lever moves any farther forward.
But popping out of gear is usually a worn slider. When you rebuild, be sure to get new sliders as well as synchros, bearings, seals, etc.
I'm going to go out on a limb CaptKen, and say that only replacing the brass synchros will not cure your problems. I don't know how many folks I've seen spin the mainshaft while looking at those big gear teeth and proclaim, "Looks good!" Busted big teeth will only occur as a result of catastrophic failure.
The small teeth transmit the power. If they are rounded or chipped it's prudent to replace the gear and the corresponding synchro. This pic is of Muncie high (4th) gear. The Hurst Competition Plus linkage was adjusted properly yet it would pop out of gear...never under power, but always on coast.
Look close and see the chipped small teeth. Probable cause was speed shifting without using the clutch as my car was drag raced before I bought it.
Thanks, next time it's on jack stands I'll check the linkage....but I'm pretty sure this tranny has been abused. It will get a complete rebuild when I do it.