ok so i just rebuilt my t5 and i put it in and it still grinds second. Even shifting slowy it just grinds away, adjusted the clutch, still grinds. Its fine when sitting still so it not the clutch.

I was going to put in my spare tomorrow so i was just looking to get any feedback on what you "experts" think the problem is before i tear it back apart andgo buy a new second gear.

I was thinking, theres this bolt on the side which i had toback outto get the top cover off when i rebuilt it, when i put it back together i just turned it all the way back in to where i thought it was originally.

Do you think that would affect anything, any input would be great b4 i jack the b**** up and start pullin it again.

 

you shouldnt have had to touch the big torx bolt.

check your inserts and the spring alignment for the 2nd gear synchro hub

 

i figured i shouldnt have touched it but that top cover was being a huge PITA so i just loosened that torx and it top cover came out pretty nicely

so if ijust adjust that back out and test it at different depths do u think that will free second up again

 

what does that torx bolt actually do?

 

when you take it back apart look at the 2nd gear hub and the little teeth that go aroungd the hub..they should be pointed and shaped sort of like a roof top house...if they are flat and mushroomed out...you'll need to replace the gear/hub assembley.

 

shouldn't have to replace the gear just the outter syncro ring... the ring is made softer than the gear so that it wears instead of the gear... either you did something wrong (more than likely what adder said) or the syncro ring is worn