Drivetrain - Troubleshooting trans gear grind | Ford Escort Owners Association (FEOA)
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Drivetrain Troubleshooting trans gear grind

Discussion in 'ZX2 1998-2004 2.0L DOHC' started by mimino, Feb 8, 2020.

  1. mimino

    mimino New Member

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    Long-time member of tzx2 (rip).

    I've recently rebuilt my trans (bearings, synchros) due to what I thought was a shot 3rd gear synchro (it would grind on both the up and down shifts). At first everything appeared to be fine, but the grind came back only on the 2-3 upshift (down is perfect). Before anyone mentions synchros, i'll repeat that it was rebuilt and there is no 4-3 grind even at 6k+ rpm. I've had the 3-4 fork replaced with an upgraded one that folks recommend. I'll include a picture of the old fork that shows damage to the 3rd gear selector below.

    The damage appears to be from the selector tooth (or whatever it's called) misalignment. I actually ended up breaking this tooth prior to the rebuild (the new fork was too strong for it lol). There is also no problem with how I shift. I made sure to pause in neutral during the 2-3 shift to rule that out. Double-clutching on the upshift makes zero impact (rules out the synchro issue). I can be sitting in neutral, bring the rpm up, clutch in and try to shift into third - grrind. With the wheels off the ground and in neutral, I can shift it into every gear without using the clutch without a grind, except for third. However, if I shift it into fourth and then back into third (without a clutch), no grind...

    I've performed all kinds of diagnostics (clutch engagement, hydraulics, linkage, etc.) to no avail. My mounts do appear to be shot. I'm actually waiting on a delivery today to swap them out, but it'll most likely have to come down again. I do have a donor trans that appears to be in good shape.

    old 3-4 fork with damage to third gear side of it:

    [​IMG]

    broken "selector tooth":

    [​IMG]

    how it should look:

    [​IMG]
  2. pextor

    pextor Moderator Staff Member

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    What fluid do you run in the transmission?
  3. mimino

    mimino New Member

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    i broke her in with some synthetic atf and then went amsoil. it started grinding and i switched back to atf for now.
  4. pextor

    pextor Moderator Staff Member

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    I had some trouble with the transmission in my old S/R so I put in synchromesh and it seemed to help. Just a thought.

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