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Transmission has demons - T5 wont shift when in Jeep

Transmission has demons - T5 wont shift when in Jeep

FourIsWaltz

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Location
Ohio
Vehicle(s)
'86 CJ 258ci, Borg Warner T5, Dana 300, D30/AMC20
I've searched the world for this one, and come up empty.

I just rebuilt my T-5 , with the help of Paul Cangialosi's videos and a few books (that all had slightly different parts, even the AMC service manuals). I admit I was in way over my head, but I puzzled it together with plenty of before and after pictures. When it's on the bench, I can run through the gears and they feel great.

Then I put it in the CJ7 .

It glides into first gear like sliding into a warm feather bed. SECOND GRINDS LIKE I'M MAKING COFFEE IN HELL. Won't engage. Third through fifth, even reverse, perfectly smooth. I can't get it into 2nd even when it's not running.

Pull it, and with the Transmission back on the bench it's engaging without any resistance, everything is fine.

The CJ has a lift so the clutch bell crank is at a slight angle. The only other thing I can think of is that there's a snap ring that goes into the Mustang version of the T-5 that didn't get used in this one.

ANY ideas of where to start? Anyone have any experience with anything like this?
 
How much clutch pedal free play do you have?
You want 1-1 1/4" inch at the most.
What oil are you using?
LG
 
Did you use new synchronizers in the rebuild?
It may be a worn synchro or debris under one causing drag so second won’t match up
 

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