After disassembling the Borg Warner Super T-10, I could not see anything amiss so I installed new bearings and synchros and put it all back together again.

It still jumped out of 2nd gear, so I pulled the engine/transmission again and took the transmission to a transmission shop for them to go through it.  After puzzling over it for a week, he asked another shop to take a look at it and they finally realized that the sleeve under the 1/2 gear set was not pressed on all the way.

While the engine was out this time, I decided to replace the camshaft.  It was starting to wear and I wanted a bit more power (who doesn't!).  After getting it all back together again, I drove it about 10 miles and the camshaft destroyed itself.  I've build many engines over the years but never had an issue like this.

Since the engine was now full of metal from the camshaft and lifters, I took it to a machine shop to be tank cleaned and checked out.  I showed them the camshaft, and the first question asked was "Did you add zinc additive to the oil?"  Since 1980 this and other additives were removed from the oil because of the catalytic converters.  I did not know this and there were no instructions with the camshaft.

The machine shop found that the crankshaft needed to be turned and the cylinders needed to be bored.  So I put flat-top pistons in to gain a little compression (I get about 180 PSI and it should be about 10:1 compression ratio).  I also got a Comp Cams camshaft which came with about 10 pages of instructions on oil/additive to use and break-in procedure.

After putting the engine back in for the 3rd time and starting it, it made an awful racket.  It sounded like valve-train, but I could not pin it down.  So back came the engine again (this time I left the transmission in place, thinking it would save some time).  I took the heads to the machine shop and they found the valve springs were very weak.  So they replace these and used the new style valve seals.

Back in whet the engine for the 4th time, but we could not get it to line up with the 4-speed transmission in place, so we pulled the transmission and put the engine/transmission in together.

It now runs great, and sounds a lot more powerful -- which is what I was really looking for in the new camshaft.

So a simple rebuild of the transmission turned into a complete overhaul of the engine.  And guess what -- the transmission still jumps out of 2nd gear!

  

73shark said: I thought all camshaft manufacturers supplied a bottle of Break In Lube to pour over the lifters and bearings during installation. Sounds like you need to get a Muncie 4-speed and drop in it. ;)

The Comp Cams camshaft instructions said that a bottle was included, but it was not.

I used a high-pressure graphite break-in assembly lube, along with break-in oil for the 2nd camshaft and that seemed to work fine.

I also will add zinc additive to the next oil changes just to be sure.

When I was a teanager I bought a Muncie 4-speed for $100.00 but they are a bit more now. . .

  

 Dang Bill......

Iffin you weren't so far away, I'd suggest sending the trans down to Texas...I can fix it for ya. Chances are there is simply too much end-play in it, and most places won't take the time to actually check stuff like that.

73shark said: I remember a co-worker with a 73 Coupe with a 4-speed that actually removed his transmission in his apartment's parking lot during the winter. So it can be done without removing the engine.

I also have heard that some cut the cross member to make it removable, but that would also require removing the exhaust pipes -- not an easy job laying on your back under tight quarters.

  

Adams' Apple said:

The people in this forum have been lifesavers many times over with answers to issues that I have run into.  Thanks to all!  Hope to see many of you in Canada this summer.

  

Norsky said: My, my - you have been a BUSY fellow...!!!  

  

persico said:

I know it sounds ridiculous but my 72 kept popping out of 4th gear under load.  Turned out not to be a tranny issue at all - the reverse lock out cable was interfering with the shift linkage. I guess it wasn’t fully engaging 4th gear.