It's been my experience that it's the condition of the synchro cone that
causes this. While the gear may be in good shape, it's almost impossible to
see a bad cone: this is the part that the synchro fingers engage with. If
this isn't a smooth take up it will cause hard shifting. So far the only way
I can tell if the synchro is going to work well is by trial fitting the
synchro to the cone and seeing if it will rotate or lock up. Again, it's just
my experience, but unless the synchro itself isn't made well (a real
possibility) so far the only solution I've found is to replace the otherwise
good gear with a new one. It seems that if the synchro ring will rotate with
light pressure applied (no lube) it will work fine. If the synchro ring binds
it won't.
Steve & Janet Hedke
1957 TR3 "Scrappy"
Great Race #45
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