Just a little note on my experience with repro sychro cones for a BN4
The first lot I got from AH4H looked to be well made so I
dutifully assembled the transmission with them. A quick test on the dyno stand
showed they have almost no baulking action at all so I stripped down the trans
again to find out why. The issue is the lack of care when machining the
braking face which mates to the cone shape on the gear.
Pic one is the AH4H
supplied synchro after lapping it on the gear for about half an hour then
colouring it black with a permanent marker pen and rubbing it a few times on
the mating gear.
Pic two is a 'Welch' CGBS140 synchro after the marker pen
treatment but with no lapping.
Pic three is the original 55 year old cone.
You can plainly see the differences- the cheapy replacement ones have very
little contact area (light colour = contact) due to poor machining when
compared to the original and properly made reproduction. They are going
straight back to AH4H
Conclusion: avoid reproduction synchro cones like the
plague unless they are properly made. If you are about to assemble a gearbox
with repro cones, colour in the brake face and see how much contact it makes
with the mating gear.
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