Hi all, I am likely 5-speed swapping in the moderate-term future and was getting my ducks aligned ahead of time. I'm not sure I'll need to replace my synchros as the transmission I pulled ran and drove before the demise of its donor car (cabin fire that did not reach under the car or into the engine bay) and it goes into gear, but I wanted to figure this out:
In the RealOEM diagram for the transmission as appropriate for my car the same synchro part - 23231228097 - is listed three times under diagram 138, and also under once under 145. I have found a machine shop in Australia making new brass G260 synchros (gearbox-parts-australia on ebay - I'm not Aussie but still far cheaper than OEM and they look to be well-made and well-finished), albeit for -8097. They don't appear to make ones of 23231228096 at the moment, which is listed once each in those diagrams for a total of two. If I am properly understanding the diagrams, would I need four of -8097 and two of -8096 to have a complete set of synchros, or am I being a dummy and misreading them somehow? If I tore down the transmission to replace them is there anything else I should address? No matter what I'm replacing all the exterior seals and every bushing even if I end up not doing a full rebuild, but I'm a relative novice so I don't want to ruin a functional G260. Thing is I might not have the scratch for a full professional rebuild right now given how pricey some stuff is, but I was hoping for some advice on best practices as I accumulate parts for the swap. I have found some excellent videos and articles on G260 service on youtube but understanding the theory and execution can often have a gap for me, to be frank. Think I could get away with seals and shoving in the swap or am I really, really best served by shelling out for a rebuild first?
If it may benefit anyone in the future with a similar question, here's some stuff I found:
In the RealOEM diagram for the transmission as appropriate for my car the same synchro part - 23231228097 - is listed three times under diagram 138, and also under once under 145. I have found a machine shop in Australia making new brass G260 synchros (gearbox-parts-australia on ebay - I'm not Aussie but still far cheaper than OEM and they look to be well-made and well-finished), albeit for -8097. They don't appear to make ones of 23231228096 at the moment, which is listed once each in those diagrams for a total of two. If I am properly understanding the diagrams, would I need four of -8097 and two of -8096 to have a complete set of synchros, or am I being a dummy and misreading them somehow? If I tore down the transmission to replace them is there anything else I should address? No matter what I'm replacing all the exterior seals and every bushing even if I end up not doing a full rebuild, but I'm a relative novice so I don't want to ruin a functional G260. Thing is I might not have the scratch for a full professional rebuild right now given how pricey some stuff is, but I was hoping for some advice on best practices as I accumulate parts for the swap. I have found some excellent videos and articles on G260 service on youtube but understanding the theory and execution can often have a gap for me, to be frank. Think I could get away with seals and shoving in the swap or am I really, really best served by shelling out for a rebuild first?
If it may benefit anyone in the future with a similar question, here's some stuff I found:
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