If I drive around normally this tranny shifts smooth as silk - no chattering or hanging or anything. If I pull real hard through 1st (5000+ rpm) it WILL NOT go into gear. Period. I've tried pumping the clutch up and all sorts of stuff. I just have to let the revs drop for it to let me pull 2nd. Ideas?

Is this a synchro issue in the tranny?

 

From what I have been told, the TKO trans has to be dissassembled and have a new input shaft installed to make this trans fit our cars. Apparently the length of the input shaft for Ford applications is different (TKOs are actually loosely based on the old Ford Toploader) so when you buy a thirdgen specific trans they have to install a new input shaft. I would guess there is some sort of issue when it was reassembled. I have had mine for 2 years now and have put over 20,000 miles on it. The only issue I have is I have to double clutch it and rev match to go from 5th to 3rd gear to pass someone, if I dont it will grind. other than that its worked fine for me.

 

Right, this was a Forte unit so I assume that's precicely what was done (as far as the input shaft). I guess what I'm wondering is what part might be at fault given these symptoms. Is it a synchro? is it a collar? is it something in my clutch? is it some other part in the tranny?

My understanding is that if it's a synchro I should be grinding rather than being blocked out of the gear. I'm certainly no expert on manuals

 

well normally if a trans doesn't want to come out of gear it is because there is still a load on the trans, like the clutch is not disengaging all the way. But you say that it only happens at high rpm and only on the 1-2 so it is not likely the clutch. Not sure what else to say. I have never rebuilt a manual trans so I really dont know how they work.

 

Right, it comes out of 1st just fine, but pulling into 2nd is like hitting a brick wall. Will not go in period. VERY frustrating when trying to impress your buddies, or make a decent run down the track....

 

I'm bringing this back because it happens to me a lot... It's like the RPM is too high to let it shift in !?!
Just clutch issue, or a synchro type of thing?

 

sounds like the clutch isnt letting go of the flywheel.. what kind of clutch? a centerforce Dual Friction will do it to you.. i took the weights off mine and i shifted like butter.. until my dad popped the slave when it was off the bellhousing..

 

This also could be of bad oil in the tranny I guess.

In mine, I use Dexron II + additive (Lubisyl for transmission it's a hyper lubricant). It shift smooth at any RPM/load condition.
I change tranny oil every 40000 km (25000 miles).

try this first especially if you never changed the oil after breakin period.
It could help!

 

How's your pilot bearing? Did you have any trouble installing it?