Transmission syncros

Bernie Benz b.benz at
Tue Aug 5 08:04:04 EDT 2003

No BTDT with Audi trannies, much with Lancia 2wds some time ago, but all ZF
designs are about the same in the gear area.  DIY doable but time intensive.
You might find a used one for cheap, AF classified had one a while back.  I
don't know, but parts avail could be a prob.  A used tranny may be no more
exp than a few new bearings, so with parts from two you might be able to
make one good one for cheap.

Lancia ZF syncros had a common problem that they were a little to large for
the cone on which they gripped so would soon bottom out on their axial face
before exerting enough force on the cone interface.  Machining .020 from the
syncro's face solved the problem for good.  Never had to replace a syncro as
they were like new.  You may find that this is your problem.

TO bearings should last the life of the clutch which should last the life of
the car, unless you've tought kids to drive or grag it.  Must have been a
bad install job.

Have fun!


> From: "Reid, Les C." <Les.Reid at>
> Date: Tue, 5 Aug 2003 07:42:25 -0500
> To: <200q20v at>
> Subject: Transmission syncros
> I am considering replacing the syncros in my transmission.  1st gear is
> the worst (car must almost be stopped to engage), 2nd gear is bad as
> well (have to up the rpm when going above 15mph), 3rd-5th are so-so.  I
> have already changed the fluid (no noticeable difference)
> Is there anyone out there with BTDT experience that could give me some
> pointers?
> Is there a way to check if the clutch plate is completely disengaging?
> I also hear a rattle when the clutch is held down while stopped.  Think
> this is the throw-out bearing.
> Clutch/TObearing was replaced 60k ago by previous owner.
> I don't post that much, but I really appreciate you guys, especially
> Bernie.
> Thanks
> Les Reid
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