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Sounds like the problem was there before, stiff change may wear the forks. I think I would strip the gearbox again & make sure the various parts are size matched. By that I mean diameter clearance, assembly, roundness etc etc. Im trying to remember whether it is possible to put the synchro pawls in backwards? Dont forget a bent shift rod would cause the problem. Incorrect shims on the gears would place them in the wrong place on the shaft. etc etc. Dont forget no 2 boxes are the same & interchangability of semi worn parts can be a problem in itself.
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Regards Keith, GTJ Twin Spark
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