05-10-2020, 08:57 AM
On your first question, I can't profess to have built enough boxes to know all the answers - but I do remember considering precisely this point on a box I re-built some years ago. I elected to assemble it on an unworn section. The result was extremely 'notchy' at first and didn't feel great at all. After a little time it "bedded itself in".
I'm not sure exactly what your situation is - did you strip the box because the balls have popped out? In that case you will want to look very carefully at end play, perhaps synchro cone wear and give it all a good clean up. And hereafter change gear a bit more gingerly... This happened to me after a fairly abrupt shift from reverse to first. Oh yes, and use the correct oil (engine oil).
Finally I'd be deeply worried if I couldn't find all the ball bearings. Are you sure they are not stuck down in their respective holes?
I'm not sure exactly what your situation is - did you strip the box because the balls have popped out? In that case you will want to look very carefully at end play, perhaps synchro cone wear and give it all a good clean up. And hereafter change gear a bit more gingerly... This happened to me after a fairly abrupt shift from reverse to first. Oh yes, and use the correct oil (engine oil).
Finally I'd be deeply worried if I couldn't find all the ball bearings. Are you sure they are not stuck down in their respective holes?