With the transaxle completely disassembled, David set about to check all the parts to tray and find the smoking gun for my 3->2 downshift problem. While there was nothing obviously wrong, he did find a few things that didn't help the issue.
"There was non-typical wear with the 2/3 synchro cluster. Specifically, the 2nd gear synchro 'cocks' on the gear. As both parts are (supposed to be) conical, this is an oddity. This is a critical dimension for the synchro to operate correctly. When I swap the second and third gear synchros, the fit (on second gear) is markedly better. The force to engage (lock up) the syncho is very low. Although the blocker springs are intact, they will be replaced. The pins that push the blockers into the synchro sliders show considerable wear. Those too will be replaced. The slider, which locks the gear to the shaft has seen a rough life"
Hopefully, after some new parts, my shifting will be smooth.
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