[tempest1964]

New synchros can be out of round. They need to be checked for fit. There is an excellent video on this by a guy named Paul Cangualosi at 5speeds.com. The video explains it a lot better than me. Good luck!

[AMX guy]

Before I take it to someone I'm wondering if I should check the bellhousing alignment. could it be messes up enough to cause that synchro to bind on the hub? that would explain a lot. I could use one of the alignment tools in the future anyway.

the input fits in the pilot bushing easy and it bolts up no problem. but I don't know if that means anything. also, I did something kind of dumb , I put some silicone over the spot where the countershaft pin goes just to insure it didn't leak. about the thickness of 4 sheets of paper, I wonder it that may have had any effect on the alignment?

[mgarblik]

I would watch those gear box videos on Youtube. They are excellent. It's likely one or more brass rings are bent or warped. I do the Sharpie test he describes on all the gears and synchronizer rings now based on the video. About 1 out of three new ones are bad and can not be used. Junk parts make life tough on us. I bet you can fix this yourself. You just need a pair of really good heavy duty snap ring pliers and basic hand tools to take a Muncie apart. Very simple transmission. If you don't want to tackle it your self, PM me. I am doing 1 right now, a M22 for a guy from Indianapolis. I am in Dayton, OH.