I just got this thing and decided to split it open to give it a once over, and saw that twisted piece of metal. I don't know if it was a snap ring or something, but I grabbed it and it came right out. As for that big bearing race on the back. Is it supposed to be so loose that it more or less falls out of the case? I guess the tail case is what keeps it pressed in. The rest of it looks pretty good, and when I hold that race in place, it feels fine as well. I bought a set of rebuild videos, but I'd like to know if this is going to be a big deal.

 

So one of the keys on that 5th gear slider was gone, and It allowed that spring clip to migrate. I found the key inside the case, as well as remnants of the broken spring. They were both against the case magnet. I also found the bolt behind 5th gear, ground down by 5th gear, and the bearing retainer locks were not bent over the bolt head. I'm wondering if there is a thrust washer that's missing. the back of the gear is shined up from the bolt, but the gear teeth itself is untouched. I hope this is salvageable. it was supposedly in running condition before I got it.

 

That mangled piece is one of the synchro key retaining springs. And you're correct about the bearing race. It just sits there and the tailshaft holds it in place. As long as none of the teeth on the gears are chipped or gouged badly, I see no reason why you couldn't rebuild it and use it.

 

Theres a very small knick here and there but nothing major. None of the gears appear to be filed down or chunked. It sounds fine when it all moves together. But what's causing 5th gear to sit on those bolts?

 

Countershaft bearing endplay / pre-load is set with the retainer bolted to the back of the case. I think (don't quote me this time) that if it is set up too loose, the gear could kiss those bolts like you see. Disassemble the 5th synchronizer and gear, set your bearing pre-load to 0.002". Then, you can worry about whether your 5th speed gear is touching bolts. There's a billet retainer available aftermarket FYI.

Mainshaft bearing endplay / pre-load is set with the front facing bearing retainer. The rear race you are finding loose is supported by the front of the tailhousing as 92RS_Ttop said. So during assembly, the tailhousing is done first, then the front bearing retainer.

 

Right now, just sliding 5th gear onto the countershaft has it contacting the bolts. I have the slider and everything disassembled.

 

It's been a while since I had my T5 open, but I remember the gear being close to the bolt heads. Are you sure the 5th gearset wasn't installed backwards by the PO?

 

I checked the orientation and it's correct. I pulled the shaft and installed new bearings. There is zero end play with one shim installed, as it was before. I now have about .003 clearance between the gear and the bolt heads. Does this seem right? Perhaps the old bearings were not pressed on far enough.