4 speed getting stuck in 2nd gear outside of car

yellow rose said

Doing it on the bench with no shifter may have been the issue

You need to turn the output shaft sometimes to get it in gear while its sitting still and has no parts moving in the trans from the clutch.

When the clutch is out and the engine idling the input, cluster and main shaft are all turning.

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I would agree. I own 13 or so 4/5/6 speed cars and have been through almost every trans in some way. This is the first one that ever that did this. The interlock system should keep it from over throwing. A good known cover and forks did the same. This was the first time with brand new full snychro assemblies.

I think maybe the 2nd gear snychro ring had to seat/wear some onto 2nd gear cone. As you move the slider the 3 tabs push with the outside slider, contact the brass ring which forces onto 2nd gear slowing it down. Then the outside slider continues to push to engage the gear and the tabs come out the back some. If the ring was back even that 1/16 of and inch was just enough to over push the 3 selector tabs that much further. If you take an 833 with no side cover off and select 2nd gear there is nothing stopping it and will allow the tabs to almost come out. Same way 833 od will do it on 4th