Hi Bill, next time you have the box apart, grab hold of that big second gear and rotate it. See how much faster the BIG 5th on the cluster has to be spun up? This requires effort from the synchros. Take some serious mass out of the faces of 5th & 4th, this will help. Change the 'economy' bearing under the small 5th for the earlier needle roller type.Bill-Sims said:Different folks have different results and therefore different opinions. It's not in a 115 car, but in an Milano-- but is still the same gearset--that I have lightened 1st and 2nd gears. The car is used strictly for autocross, and I couldn't tell a bit of difference. In fact, my synchros lasted about 6 autocrosses and no highway miles.
For comparison purposes, my OEM synchros with unlightened gears lasted 180K highway miles and about 20 autocrosses before I started getting 2nd gear crunch.
I'll put the transaxle out soon and replace the 2nd gear synchro. Doing it myself this time because seems this is a "consumable" for me!
Also, make sure the points on the engagement dog teeth are good, otherwise they tend to skip and crunch. I press off slightly blunted ones from 2nd & 3rd before they get too bad and swap them up to 4th/ 5th. I figure this makes most economical use of what you have.