Got a problem with a 60A trans. This trans was bought used and unknown to me. I should have looked inside but didn't. The problem is the second and third gear synchros are worn, with second being the worst. I gotta double clutch to down shift to second without grinding and I grew up with synchros and I suck at double clutching. I will continue to practice the double-clutch maneuver but in the meantime I need to plan and gather parts for the repairs.

Can I just replace the synchros or do I need to plan for a full rebuild? To get to the second gear synchro set do I have to do a fairly full tear down so that a full rebuild is as easy? Trans feels and sounds real good other than the 2nd gear grind.

Also, any hints and tips for a 60A rebuild/repair to be done in a shed by a dummy with few metric tools?

You can simply replace the synchros. The difference in a "full rebuild" is you would also replace the bearings. Either way it is a complete disassembly. The bearings last fore ever unless it runs low on lube.

32604-H9700 RING-BAULK

Appears to be unique to the 60A

Be awarre that new synchro's don't always fix the problem. What is also quite common is that the tapered journal upon which the ring runs can also wear. If they get too worn, a new ring wont fix the problem. Although the gear and the syncho hub is actually two piece, the hub it'self can not be purchased on it's own. Since these boxes were still being sold new up untill 2007, theres a reasonable chance that new gears might still be available. But you might find that they are spendy.
You wont know till you tear it down if the hubs are worn too or not. ONe time I fixed an out of spec box by fitting the ring from fifth gear to 2nd gear. Since the upshift to fifth takes little effort, the ring had the least wear. (As did the hub itself)

OK, looks like a full rebuild, provided I don't have other problems. Thanks for the help.

This is pretty straight forward; I did the synchro in my gearbox a couple of years ago and the box can be done in a couple of hours. Mine was the 2nd gear synchro, it was just barely out of spec. I have a good bit of experience with Hewland boxes and can go up and down through the box without the clutch......................worn synchros are actually harder because they partially work and are not consistent...........I could just change down to 2nd but it was a pain. I pulled the box and changed the parts in an afternoon.


Tom