Hi Guys
Hoping you can help me......
The problem I am having with the box is that it jumps out of second gear but only when I accelerate hard going up through the box or when using the gear box to help decelerate went braking.
I have had a gear box place look at it and they said it needs a new second gear and second gear selector fork.
Now where is the best place to source the parts if the gear box place was right (Along with a complete rebuild kit, syncro, bearings, seals etc) May as well have the lot done.
This is all bearing in mind the parts are normally quite cheap its Shipping and our British VAT and customs Duties that make it expensive.

Is it possible to rebuild a T5 gear box myself to keep the price down as I have already been quotes £600 ($1000) to do the rebuild and that seams to expensive to me.
I have a PDF file with the disassembly and the assembly instructions on it but isn't to clear if I will need any special tools.

Be grateful of any help you can give.
Cheers Bri

A press, a bearing splitter, lock ring pliers and the usual tools are what you're gonna need. Sometimes you can get by without the press by using various pullers & such but I choose not to. Use Ultra RTV (black is fine.)

I would tear down and inspect 2nd gear and the 1-2 synchro. The fork may not be bad, but it's definitely not a hugely pricey item so it's worth picking up. The key is how the teeth on the gear & synchro appear.

Aren't all parts available throught HanlonMotorsports?

Cheers Guys
With that i may as well have a go at pulling it down and take my chances.
What are the chances of the 2nd gear hub being damaged though?
I cant see why it would. I could belive that the selector fork pad needing replacing but i guess i will see if i strip it down.
Thanks again
Brian

if it's poping out of gear accelerating either your slider is worn or the 2nd gear probably both or broken keys, mine did the same thing except anytime i put it in 2nd it did it, also you could have too much play in the countershaft, is it a world class t5? i swapped mine out for a wc t5

Cheers 86z
Yeah I am already running a World class T5 with B&M Short shifter.
SO far i am going to order a full rebuild kit.
Which part is the slider as i cant find that on the diagrams i have?
Cheers Brian

The outer ring part of the synchronizer. In replacing, you replace the synchro as an assembly (hub+slider) together.