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PostPosted: Sun Apr 13, 2014 4:26 pm 
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Joined: Mon Sep 06, 2004 9:04 pm
Posts: 99
Location: Grand Rapids, MI
Hey guys I have a 90 GST trans that I took apart to put a lsd insert in the diff. Everything came apart with ease and went back together just as well until I went to install the end cover. Everything is assembled and torqued and two new shaft locknuts.
Without the end cover on each gear engages fine. With the end cover installed I can't engage fifth gear. I tried reinstalling it with fifth engaged and once installed it is locked in that gear. I'm noticing there is a bit of a gap before tightening down that I feel is more than normal. I'm out of ideas.
Attached are a couple of pictures to explain what i'm seeing. I'm really hoping somebody sees something i'm missing.
Gap before bolting down
Image
Gears with trans in neutral
Image
With fifth engaged
Image

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PostPosted: Sun Apr 13, 2014 7:14 pm 
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Joined: Wed Dec 24, 2003 3:32 pm
Posts: 9524
Location: Ottawa, ON, Canada
Flip the shell for fifth. It might have an off center area for the shifter fork fingers.
Is it possible it's flipped?

The FSM shows a bunch of angles for each gear shell, it looks pretty easy to flip. When the remainder of the fifth gear is installed, it may put things out of alignment. Quick to check, it may be listed on the lilevo site.


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PostPosted: Sun Apr 13, 2014 9:06 pm 
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Joined: Mon Sep 06, 2004 9:04 pm
Posts: 99
Location: Grand Rapids, MI
I made sure and left the fifth gear set exactly as removed so I didn't mix things up. I removed the little dowels and cleaned those up and played with the thin tinny ring that attaches to the cover and sits against the brass synchro ring. Something seemed to help and it feels like it's engaging fully now. Maybe I was just being a wuss and didn't want to force it. We'll see how it goes.

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92 GS sedan, 100mph burnouts = sold


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PostPosted: Mon Apr 14, 2014 6:00 am 
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The Silent Administrator
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Joined: Wed Dec 24, 2003 3:32 pm
Posts: 9524
Location: Ottawa, ON, Canada
You can remove the end case with the trans in the car too.
So, not a big worry that way.


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