Here is how i would do the 2nd gear syncro replacement. It from memory and a bit long. If anyone finds a step i missed or has a better way to to a task feel free to speak up. Remove shift remote(4 bolts),Remove rear flange and seal,Remove tin plate and interlock,Unbolt tail piece-be sure shift lever clears shift rods at the interlocker-rear bearing is a interference fit on the mainshaft so a large hammer and 2x4 wood block will help remove the tail piece,Remove the 1'long spacer from the mainshaft and speedo drive gear.(be sure the key is still there when reinstalling the speedo drive gear!)Take a sharp chisel and mark the center bearing holder to case location (this helps when reassembling),Remove the side cover and remove the bolts and lock washers from the shift forks,Remove the 2 bolts that hold the shift rod block to the rear of the main case.(i have a 7/16 box wrench i ground down to fit this job.The block can break if you pry on the thinner areas so be carefull!,Remove the 3 rods with the block,Remove the brass shift forks,Remove the bolt that holds the reverse gear shaft,Slide the shaft out to the rear and remove reverse gear,Remove the release fork and the front cover,Remove the layshaft and let the laygear and thrust washers drop into the case,With a long brass drift i tap out the input shaft and bearing(be sure its clear of the laygear),Needle bearings will drop into the case to be collected later,From the front of the box carefully tap the mainshaft with a hammer and block of wood to remove it from the case.You will have to slide off the sliding hub assembly along with 3rd and 4th gear syncros to remove the main shaft from the case. Be sure to note which is front on the sliding hub assembly!,Then lift out the laygear and front and rear thrusts washers,Now collect the 3/4"long needles bearings from the bottom of the case.Next step is to put the main shaft straight up in a good vise.There is a pin and spring just visable.You have to depress the pin into the mainshaft and rotate to collar to remove it.I use 2 small picks or probes to do this.Once you rotate it it takes some wiggling with the picks to remove it,Slide off brass parts and then 2nd gear to access the syncro.I have not found a easy way to remove the "C" clips inside the laygear.I put the laygear in a vise protected with wood strips and use two small picks to remove the clips.Have you pot of coffee on and be sure small children are not where they can hear you. When assembling i install the laygear and thrust washers into the case and run a small wire thru to hold the thrust washers from dropping out of place, Reassemble in reverse order,Grease the inside of the input shaft to hold the needle bearings in place while assembling. When bringing the laygear back into position i stand the gearbox on its tail and insert a long screwdriver thru where the thin wire is.Remove the wire and try to align the layshaft and thrusts with the holes in the case.Install the layshaft with the notched end toward the front.Also when you put the mainshaft back into the case the chisel marks will correctly locate the rear bearing housing so the gasket and tail piece will align. I hope this helps and thanks to AlanT (who posts here)i am able to assist others with syncro changes. Bob
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