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M41 rebuild snag - 3rd gear syncro sleeve not engaging? 140-160

posted by  Tfrasca on  Thu Mar 3 20:25 CST 2016
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I just got my M41 together, but I'm pushing the shift dogs around and something doesn't seem right. 1st and 2nd gear engage perfectly, and the selector sleeve slides all the way over the syncro until it butts against the gear itself.

The 3rd gear shift is harder to engage and when it does, the selector sleeve just barely covers the syncro and there's still about a 4-5mm gap between the sleeve and the gear. Surely this isn't right, and the 3/4th selector should butt against the gear, just like it does on the 1/2nd sleeve and gears - right?

Hs anyone run into this issue before? I'm sure I put something back together incorrectly, but I'm not sure what it could be. The syncro dogs on the 3/4 sleeve are symmetrical, so those can't be backwards. Any thoughts?

Thanks,

Tyler








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    M41 rebuild snag - 3rd gear syncro sleeve not engaging? 140-160

    posted by  Phil S. on  Fri Mar 4 17:57 CST 2016
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    last visit: Fri Oct 24 13:18 CST 2014
    [RELATED]

    Probably one of the synchro rings is out of alignment with the dogs. It's picky to keep them lined up during assembly.








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    M41 rebuild snag - 3rd gear syncro sleeve not engaging? 140-160

    posted by  Duck on  Fri Mar 4 12:54 CST 2016
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    last visit: Wed Apr 30 21:00 CST 2014
    [RELATED]

    Did you replace 3rd gear ? Most have 22 tooth gear while a few have 23 teeth. This could cause a snag.








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    M41 rebuild snag - 3rd gear syncro sleeve not engaging? 140-160

    posted by  Chris Mullet on  Fri Mar 4 12:07 CST 2016
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    last visit: Fri Oct 24 09:08 CST 2014
    [RELATED]

    Is the shift fork bent? I had that problem once and it inhibited full engagement.
    --
    Current rides: 2005 Volvo S80 2.5T, 2003 Volvo V70 2.4NA, 1973 Volvo 1800ES (getting ever closer to road worthiness)







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