T5 Main Shaft Repair

Hello. Tore apart my transmission and found some concerning things.
Here is my 1-2 slider (be ware)
This is one of the most chewed up sliders I've seen. I don't even know how this got this way... Synchro was fine. Probably because previous owner beat the hell out of it. Other side (1st gear) looks new.

Speaking of synchros... Here is my third gear synchro. This is the main reason that I rebuilt this thing. Absolutely NO action from this synchro. Again, likley due to this gearbox being beat hard.



Here is my second gear. This is a 30 tooth second gear which seems to be harder to find and more expensive. My question to you guys is will is be OK using this? The picture makes it look worse than in real life. There is still a small amount of point definition left on the upper part of the teeth. I just spent a lot of money on a kit and the slider for this thing, I really don't feel like spending another $80 on it. If I do decide to use this, what will be the consequences? Long term effects?

On more question. My main shaft has a small amount pitting/damage, causing the notorious T5 whine. So if I choose to not buy another main shaft or repair this one, am I screwed? I think it was due to improper preload on the shafts. If I stop the source of the damage, will it continue to wear? Keep in mind, my engine is not much more powerful than stock and I don't beat on my transmissions. Thanks.

ThinBlue502 said:

I’m not an expert, but how pissed would you be if you put it all back together without replacing the main shaft and something was wrong? All that work, the money you invested, isn’t it worth it when you weigh the whole thing versus just the cost of a main shaft? That’s always my line of thinking though. In for a penny, in for a pound.

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That's what I was afraid of. Oh well, guess I'll fix it. Thanks.

So I'm having a hard time deciding on what do to about my damaged main shaft. I'm in the process of rebuilding my T5 and on top of the main issues, it has that notorious T5 whine. The main shaft is galled. I've heard that there are a few ways to remedy this, like sleeves or complete replacement. I'm already spending WAY more than I expected as there were multiple gears that needed replacing, so I'm hesitant on spending all the money on an entirely new shaft. So that leaves me with either repairing or leaving it alone. What methods are there to repair this shaft? I think I've also heard about someone taking it to a machine shop where they welded over it, then re-machined it? Also, just curious, what are the consequences of leaving it alone and having the old "out of sight out of mind" mentality about it?

Thanks.

First off I THOUGHT this was a 3.97 1st 4cyl transmission, but upon further inspection I discovered it has the 3.35 cluster (second gear was stamped 1352-080-060, which is the part number for the 2nd gear on the 3.35 ratio cluster) my counter shaft has 1352-077-938-B27 stamped in it, so it gave me no information as to what it was. My id tag was missing as well.

Now, here is where my real confusion comes in. I have heard that you need a special pilot bearing for 4cyl t5s to go into the v8s, BUT my input shaft is part number 1352-085-025. I believe that this is the v8 input which can be used with the normal pilot bushing. Can someone please confirm this for me? I can't seem to find out.

Secondly, I am having my main shaft turned and getting a hardened sleeve being pressed over it. Can someone please give me the exact specs for this part of the shaft so I can give it to the machine stop?

Finally, my transmission has the notorious T5 whine which damaged the input shaft (input gear teeth worn to knife-like edges, fortunately the counter gear remained undamaged) and main shaft (classic case of the galled/pitted surface). I am purchasing another identical input shaft and repairing my main shaft. My question is, what can I do in order to prevent this from happening again?? I am spend a ridiculous amount of money on this thing and I don't want to have it fail in another 5000 miles. So what steps can I take to ensure this galling/pitting problem will never happen again?

Thanks.