Reply to "ZF Synchro Repair Discussion"

There is a slight difference between the reapir that Dennis Quella makes and the repair that was performed on Chuck's gear. Dennis presses the entire cone/tooth section off of the splined section of the gear, presses an entirely new part on and has it welded . The original part is pressed on and sometimes will get loose ( enough to fall off when the trans is disassembled).The welding eliminates the possibility of this. It appears that Chuck's gear had only the cone machined off of the toothed portion and a new cone pressed on. I have had Dennis repair at least 50-60 gears for me ( maybe more) and none have given me an issue in over 10 yrs. I'm not saying that there is anything wrong with the method that was used on Chuck's gear. I would have to have additional information before I weighed in on that. It will likely last quite a long time. The " spline " design on his new cone looks like it would last longer than the original version. And BTW, I recently flipped a BMW M1 transaxle for a GT40 customer which had a completely different synchro design on 2nd gear only!
Here's a picture of a gear that I just got back from Dennis.

Ron