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Reply to "2nd Gear Grind"

Cap'n, quite a few ZF treansaxles will grind during shifts if the clutch master or slave cylinder (or both) are internally bypassing.
Test: with the engine off and a friend in the drivers seat, have him push the clutch pedal to the floor and hold it. At the bellhousing access hole on the top-left side, you should be able to get a 0.040" feeler gauge between the clutch plate and the flywheel. If not, there's a hydraulic or mechanical problem preventing full disengagement.
Under these circumstances, all ZFs will grind, especially into 2nd gear. If it turns out to be the slave cylinder, I recommend a long-throw stainless steel style replacement to maximize the disengaement distance & reduce corrosion damage. After everthing's fixed, when shifting remember to mat the clutch pedal before pulling on the gearshift. Your expensive ZF synchros will live longer.
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