Originally Posted by
Buddy 5th gear pop out is from worn synchro's,Wrong. Sure, it can happen, but 99% of the time it's caused by the flex in the entire transmission casing and linkage. The synchros will be perfectly fine and you'll still get 5th gear pop-out. The flexing causes the selector fork to move the selector ring/collar up and away from the point of engagement. It pulls it away to the point where very little of the dog teeth are meshed and eventually the stress is too much for them and there's so little engagement that the gear "pops out" usually chipping away at the tips of the dog teeth while that happens. Repeat this cycle and maybe 1,000 miles later you'll be unable to engage 5th gear because so much of the dog teeth have been chipped away.
The fix for this is the new 5th gear with deeper/longer dog teeth. With the new gear the flexing isn't enough to create this problem and your 5th gear should last 300k+ miles no problem.
Originally Posted by
Buddy yes you can tell by popping the case apart and looking at the brass looking rings between the gear sets, look at the second pic #4 of this link and you should understand what im talking about, if its bad the synchro teeth will be rounded causing a pop outYou're right about the teeth being ground down, but it won't be on the synchro, it will be on the 5th gear dog teeth and the selector ring dog teeth. The synchro will probably look (and should be) pristine.