I have ACT and don't have this problem. In fact it shifts totally smooth now. I think it's the fact that I had them put in GM Synchromesh fluid. I can't believe how positive and smooth the shifts are now. Sometimes I'll just sit at a stoplight and shift through all the gears in complete amazement now. 2nd gear used to be the worst, with a "notch-notch-notch-click". Now it's just one quick click and it's in gear. Like a bolt-action rifle.

 

maybe it's your clutch line. I heard from someone they had the same notchness and figured out that the clutch line isn't properly installed.

 

Synchros, stock evo gear box sucks almost as bad as the clutch and transfer case.

 

are you sure you're not talking about the restrictor? I think restrictor makes the syncro not engage fast enough so not to shock the tranny.

I do shift a lot smoother when rev matching tho.

I've never heard anything about syncros going bad on any cars that's driven well.

 

Hate to say it, but he's probably right. Sounds like the synchro is taking too much time to get everything aligned right.

- Jason