quote:The ONLY way to measure it is with an NEW syncro.
Not true. I have a table of detailed measurements of all my cones that clearly show the degradation of the second gear cone (the dimensions of the top and the bottom of the cone, and the deltas).
quote:The second gear fix in the future HAS TO BE, that the new syncro must contain those grooves and the gear must be machined smooth.
While that may be a better design, that is the opposite of every -2 ZF that have ever been built. (UPDATE: OK, every ZF that I have seen - which is exactly one of them in the flesh, and about 5 of them on the interwebs!) Would you then go in and modify all your other gears too - while you are in there?
quote:Sleeving the gear compromises it's structural integrity and you have modified the design to power of an unknown. This is like a friction weld solution as well.
I suppose it won't hurt anything anyway. If it comes apart it will just spin.
I agree - the worst that can happen is I start to get a second gear grind if the cone comes loose from the gear. BUT........ It is not like this is a direct linkage for all engine power. It is only braking the rotating mass of the ZF internals, and clutch disk.
quote:Anyway it's a done deal
Agree here too.
There are two ZFs fixed by CRM that I know of. Quella has done a bunch of "laser cone welds" for other customers. I have not heard of any of the Quella repairs flying apart, and if they were, respectable ZF builders wouldn't keep going back to him. The basic fix is the same (new cone on old gear).
I will track things as I can, and will report out in 10 years.
The problem is with "armchair quarterbacks" that they have no skin in the game. No amount of $$$ (or schedule) is too much for them to pay to "do it right" - since they aren't paying.
"You pays your money and you takes your chances". I think I made a good bet.