First off..the T5 WC is in 95 S10 2.2 pickup (70,000 miles). Guess they put the WC in the 94-95 models.

When letting the clutch out in first (sometimes 2nd) I hear a very brief grinding sound then it goes away. If you are rolling or let the clutch up fast...it doesn't make the noise.

Took it apart and noticed that the pilot shaft bushing is enlarged and far from where it should be. The front taper bearing cup and bearing have too much clearance. There is distinct travel when pushing and pulling the input shaft. Not an expert..but it is excessive in my opinion.

Is it possible that the excessive front play is affecting the 1-2 syncros?

The tranny looks great inside, very clean. "All of the gears" have sharp edges "except for the 1-2 slider"...the edges on both side of that gear look like they were intentionally champered (See picture below)?

Anyone have a picture of what the 1-2 should look like?

Also..any one have a picture of bad or good syncros?

What you've highlighted is the Reverse slider. It's intentionally champered as it has to engage both the driven gear and idler gear at the same time, all straight cut.

If the shafts weren't shimmed properly, it can cause all sorts of noise and engagement issues.

85MikeTPI

Thanks..just checked a Mustang T5 site and learned that the slider gear is supposed to look like that. I don't see any damage to the syncros and suspect that the grinding (vibrating) noise is probably the bearings up front "briefly" vibrating a result of the loose front bearing and bad pilot bearing??