I rebuilt my 98 VLSD tranny about 4000km ago. I replaced all of the syncros and most of the bearings, and made sure of proper preload on all of the shafts.

I installed the tranny and it felt awesome except for a slight "psttt" sound coming from the stick. I did not worry about the sound because I heard it before I did the rebuild. My specualtion on the sound is that the shift forks are just slightly kissing the syncro-sleeve.

Then I was out driving and suddenly my 2nd gear syncro stops working I can still shift into 2nd but there is no syncronization so the gears crash into each other


Anyone have any suggestions on what the problem could be


P.S. I am cleaning my garage so I can fit the car, and I should have the tranny off by sunday

 

*bump*......

 

You already know what the problem is, you lost the 2nd gear syncro. Pull the tranny out and tare it down again. Replace whats gone bad and hopefully you'll be in good shape again.