I had a 6 speed gearbox with problems changing from 1st gear to 2nd, it would crunch and feel notchy, I decided to change to a 5 speed gearbox, mainly because I thought the gearbox was damaged and also for the stronger gearbox.

Since then I have opened the 6 speed to find that it is perfect inside no syncro damage or any other damage.

I am now having trouble with my 5 speed gearbox, same issue 1st to 2nd is notchy, does not feel correct. This leads me to believe it is something on the car and not the gearbox.

I have bled my clutch line and also adjusted my pedal for maximum stroke. The slave cylinder is not leaking.

I have also checked my syncros through the bottom inspection hatch and they are in good condition, I have watched them work as someone has moved the gear stick. Also I have checked the selector forks are not bent.

The clutch cable mounting bracket is brand new and not bent.

I feel like my clutch is dragging, other than removing the box is there anything else other than the usual “change gearbox oil, Shim the fork lever, syncros are damaged, slave cylinder is leaking, adjust the pedal, selector forks are bent, selector mechanism is damaged, ” that anyone can think of to check.

One thing somebody mentioned was the wrong slave cylinder could be fitted, preventing the clutch from fully disengaging but I am not sure without trying another one.

I do have an aftermarket short shifter installed.

Any help is greatly appreciated

Regards Shaun

 

Post pics of the synchros in the 6 speed.

 

to go 5 speed conversion... you gotta replace all that ... correct
isnt everything different? even the clutch?

 

Disk is different that's it. 5 speed swap requires shifter base/shifter, center console, cables, and clutch disk. That's it IIRC.

 

I don't think this is always the case guys. The ACT 5 speed clutch disk installed fine on my 6 speed transmission. More than 2k miles so far and no catastrophic failure.

 

I've had the same experience with the ACT HDSS.


OP, have you checked the white bushing that goes underneath the shift linkage? Mine was really worn out and loose, and when I replaced it with a RossSport delrin bushing the notchiness in the shifting went away.

 

My 2003 Evo got a new from Mitsubishi transmission about a year ago. On this new transmission the bracket that locates the "white bushing" had holes that were slotted. The transmission the car came with had round holes in the bracket. I dunno when they made the change but I'm supposing the slotted holes are there to allow some adjustment if the car isn't shifting quite right.

 

I will get one from ross and see what difference it makes thankyou thankyou