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Hi Everybody, My transmission recently got stuck in 4th gear. It is a 3 piece design, I believe one of the earlier "type a" designs: http://www.zcarz.us/TechnicalInformationPageTransmission.htm I dropped it out of the car this weekend and tore it down. I think I found the source of the problem, but I don't know what the solution is. Any help would be appreciated. I took a video I took talking and showing what I think the problem is: https://drive.google.com/file/d/0B5N_fYOaC113bFZRVDRjN0s4VDA/view?usp=sharing It seems like there might be a few problems. The input shaft with 4th gear on it can slide in and out a few mm, but I think that would be solved when it is back in the case and the c clip is locking the main input bearing in place. The bigger problem seems to be that the coupling sleeve (#10) is going too far forward, allowing the "Shifting insert" (#11) and "Spread spring" (#12) to pop up behind the coupling sleeve and get stuck (See attached diagram). The only way I can get it out of 4th after that happens is to push the 3 shifting inserts down under the coupling sleeve manually, and then pull it back. Does anyone have any idea what could be causing this? Do the shifting inserts need something to keep them from popping out? Or does the sleeve and fork have a mechanism to prevent it from going so far forward that needs to be fixed? It also might be worth mentioning that all of the detent balls and springs are removed. Here is a different video I took showing the stuck inserts as I try to get it out of 4th. https://drive.google.com/file/d/0B5N_fYOaC113b05YUnI5SWlzejA/view?usp=sharing Any help would be appreciated. Thanks!
