2nd Gear Grinding/Clunking

[Rural]

My truck has always been difficult to shift into second gear without "clunking" into place or even grinding occasionally. I'm not sure, but it doesn't seem to do this unless the truck is in motion. So I've began accelerating in 2nd gear when possible. I'm sure that the problem only occurs when the truck is on the cold side. As it warms up, it begins to shift smoothly. The other gears aren't bad (although reverse and 1st may be doing a minor version of this, but I'm still on the fence on that).

I just changed the lubricant in my transaxle and hoped that would help. It didn't.

Any guess as to what the problem could be? Synchro? Any suggestions?

[TRAX and HORNS]

try adjusting your clutch. should be able to adjust @ the arm coming out of bell housing.
what kind of truck? how many miles? did it just start doing it one day or has it taken some time to do what its doing?

[Timetripper]

Rural, What kind of oil did you put in there?

[Rural]

I'm sorry. It's a 1991 Subaru Sambar naturally aspirated 4WD.

The oil I used was 75W90 GL4. I wanted to get 2.2 litres into it, but was only able to get about 1.8 litres into it before it over-flowed the fill opening. This may be because I had it blocked up in back (so I could fit under it).

[Timetripper]

I use 3rd gear [marked 2nd on stick] 99% of the time to start off in.
Just use 2nd [marked 1st on stick] once in a blue moon or if loaded to start in.

I think that the 2~3 shift isn't as smooth as it could be due to tranny design.

If you start having more problems as the temp drops in your area I reccomend going to a synthetic like the Redline as I out lined in other posts - worth the $$ IMO

How much oil you get in it depends on which model tranny you have.

It is marked on tranny right above where the clutch sits.
Where tranny bolts to engine block.

[rayallen]

Rural.....My hijet does not shift as easy with that oil in it either. The oil that came in it was clear as water. If mine gets worse as the temp falls I am going to use atf fluid in mine.ray allen

[LostBoyScout]

I have the exact same issue in my SC 4WD. Even if I shift really slow, it clunks and complains. The 4th and 5th shifts are the only ones that are 100% smooth. I was hoping it was a shifter linkage adjustment..

[boosted mitsu]

just came across this post.
you could try using BG synchroshift oil. this has worked out for us in performance cars where the synchros start to wear down. its a little more expensive than redline and other brands but shows actual results.
its not a fix if the sychros are worn but it will work.

[Timetripper]

The Redline shows "Actual" results as well - I wouldn't be saying to use it if it didn't
just so you don't get the wrong impression from the post above.

[confuzed]

hey rural. i have a hard time doing the same shift but once tranny warms up it lessens but is still a hard shift no grinding tho feels like a stiff linkage i want to climb under and see if there are lube points on it as i had a nissan that did the same thing and some lube helped it out

[Timetripper]

Another thing to consider is the fact that if starting out in 1st [on stick, actually 2nd gear] it is 4.090
and the next gear is 2.470 [2.352 S/C] which is quite a jump for the syncro's to take up.
Above assuming 4wd tranny, 2wd use different tranny.