Hi Guys and gals,

I had a similar problem years ago.  The forks were worn to where they would not push the syncro's far enough.  Two new forks and it worked fine.

The broken keys are more likely from the 1-2 synchro assembly, since you have to sometimes man-handle it into 1st, and it falls out of 2nd on deceleration. The grind on the 3-2 shift is most likely just normal wear/tear on the brass rings. There is probably some wear on both forks, for sure.....there almost always is. Regardless, the trans will need to be removed and repaired. While it's out, might as well go ahead and do a complete rebuild, with new bearings/brass/seals, plus whatever worn/damaged parts that need replacing.
I wouldn't recommend doing much more driving with known broken synchro keys....you could do a lot of damage if even a small piece of one gets in between two gearsets....ouch! Those keys also help keep the brass(synchro rings) from spinning on the hubs/gears. If the brass starts spinning like that, it can damage the hubs....more $$$$, not to mention the grinds while shifting will wear the synchro teeth off of the speed gears rather quickly.

|UPDATED|9/14/2016 9:43:26 AM (AZT)|/UPDATED|

Hi Joel, I don't quite have to manhandle it into 1st just a little extra pressure and it goes in, I suspect this is more likely to be selector fork worn which would also explain the jumping out of 2nd, something I experienced many years ago on a Ford, it was only when i got the new forks I realised how badly worn they were( I thought they were machined that way!)
It's 2-3 or 4-3 where I get the crunch which leads me to suspect that's where the broken keys came from, obviously when it's out I'll do a full overhaul replacing any worn or broken parts, new bearings and seals, etc.not a job I'm particularly looking forward to but certainly not a job i want to do more than once
More importantly I'm looking for a source of good quality parts at fair prices, any suggestions anyone?

Thanks
Graham

Does nobody do their own repairs any more? unfortunately I don't have the luxury of exchange reconditioned units in the UK so I have to do it myself, I've done gearboxes myself in the past so not phased at all but would like some help as to where to obtain good quality parts as once it goes back in the car I don't want to be pulling it out again a few months down the road.

I bought my rebuild kit for my Muncie 20 from Paul Cangialosi at Medatronics Corp in Tequesta, Fl.  Phone # (561) 743-5600.  I rebuild the Muncie myself - my first attempt and it isn't that difficult.  I bought Paul's book on Muncie 4-speeds - How to rebuild and modify and just followed his very detailed instructions.  His web site is www.5speeds.com  He also rebuilds Muncie's.

Hi Bob, thanks for the recommend I'll have a look at their site.
Regards
Graham

I do mine, Graham. I also build transmissions for a living. I haven't given any suggestions on where to get parts because of your location. I've shipped trans parts over to that side of the pond for another C3VR member....and it turned into a big "hurry up and wait" situation with customs.
The best place(imho) in the states to get whatever you need for it is Kajun Jon's . Don't know if he ships overseas or not, but you can certainly contact him once you find out what all you need. 

That would be my recommendation as well, if you go to web site or you tube you will find some good videos. Muncie's aren't too bad to work on but the gears are made outside of the USA now.

Thanks guys, that's the kind of info i nee, I understand the problems of getting parts delivered and the often high additional costs of shipping and duty.
I've managed to make contact with the Italian manufacturer, Antonio Masiero, that a lot of the US parts suppliers are using and come highly recommended with users and am hoping they can supply via a European agent if not direct, they initially pointed me to Autogear in the US as their exclusive agents.
Thanks
Graham