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Bn2 transmission locked-up

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tontonene

tontonene

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I recently removed the transmission on my BN2 to replace the front seal and gaskets, due to excessive leakage. After re-install, I now cannot shift out of third gear. The only thing that was done to the unit after it was pulled was the removal of the bell housing to replace the input seal and new gasket. The clutch, pressure plate and release bearing were also replaced. Third was the gear the unit was left in when removed. It appears the internal shifting linkage is stuck. The transmission operated fine prior to removal. The car sat all winter with the transmission drained of fluid. I have removed the side plate to inspect. Everything looks clean and nothing loose. Any ideas on how to regain the shifting ability would be much appreciated.
I really do not want to pull the transmission out again if I don't have to. This was quite a "one man job".
thanks,
Kip
 
Verify that the 3rd/4th synchronizer hub hasn't slid too far and allowed the balls & springs to escape, thereby blocking the xmsn into 3rd gear.

You can do this by looking inside while the cover is off.
 
Randy,
I will look at that. When I removed the cover, I was careful not to allow the balls to come out, even though the springs did. I will recheck.
thanks,
Kip
 
Those are different springs/balls; look for the ones referenced above along the mainshaft near the front of the box (right behind the first gear__which is actually 4th/top).

Maybe I can find a picture...

IMG_7288.jpg


IMG_7294.jpg


IMG_7300.jpg


IMG_7351.jpg
 
If it was left in third then the shift rod would have been back into the case.If the front cover is all you had off , something could be blocking the rod from sliding forward into the cover . Check and re-check, thats whats kept me sane !
 
That is a possibility. I should have checked it out before re-install in the car. I will check the items Randy suggested first. I may have to back the unit out and release the bell housing.
thanks,
Kip
 
You know Andrea, it might've been easier to find my pictures on your website than my own :wink:
 
tontonene said:
Andrea,
The BN2 did not use the buffer. <span style="font-weight: bold">There wasn't one when I opened up the unit.</span>
Kip
Click to expand...
Often times there isn't, but without it, it's possible for the selector rod to over-travel allowing the balls/springs of the synchromesh hub to escape...
 
Thanks to everybody who responded. I removed and re-inserted the three shifting rod balls and juggled the shifting rods until I was in neutral. This released the third gear. All is now well.
thanks again!
Kip
 
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