I recently swapped out my T5 for a Ford T19 with a Novak adapter. When installing the new transmission I also put in a new flywheel, clutch and bell housing as well as replaced all the clutch linkage.
Initially everything seems great when you bring it out -- shifts like butter through all the gears. The problem is that after it has been running for a while (maybe 6 or 7 miles) it starts to have trouble when shifting from 2nd to 3rd gear. Sometimes it feels "notchy" going into 3rd, other times it will actually crunch going into 3rd. 1st and 2nd gear still seem to shift fine.
I am really struggling to figure out what is going on -- I don't know if there is an issue with the clutch dragging or if there is an issue with the transmission.
Things that I have tried:
- Clutch free play adjustment -- I started this at 1" and have tried from 1.25" down to very little free play and it hasn't seemed to make any difference
- Runout -- I brought the Jeep to my mechanic to have him check my work since this is the first time I have done an install on this and he said the runout was OK
- Pilot bushing -- had the mechanic check this as well as I did put a little ding in it when trying to tap it into place, but he said it was ok
The one issue my mechanic did find was that I hadn't notched the skid plate quite enough in the front where the T19 sticks down and he thought this was pushing on it in an odd way. He notched the skid plate back further and added a drop to it as well (previous owner appears to have done a budget lift and there were also drive angle issues). This fixed a different noise I had, but the 2nd to 3rd gear shifting issue is still occurring.
I'm not sure what to do next -- what could cause it to start out working fine but then have trouble after it has warmed up? Appreciate any ideas people might have.