Well little update:

after spending countless hrs on the web and taking to people I decided to rebuild the tranny ( sorry have it rebuilt )

found a local guy that knew what he was talking about so took it out of dodge and dropped it off with him.. took a few days to get all the bearings, parts ect in but he got it done..

I had flywheel resurfaced, new clutch, throw out bearing etc out it all back together, then put tranny in and np205 back shafts etc.. took it for a drive and the issue I now have is little sticky to get into 1st and 3rd gear.

so I took truck to guy with everything in so he can drive it and feel it and he agrees something is not correct.. so looks like he is now gonna take tranny back out and see what is going on..

thank goodness this is not my daily driver

my guess is syncros are not working correctly for some reason.

what do you guys think? syncro or something else?

 

if the kit had the new style syncro's with the plastic then it's probally them.

i don't think the weight was the issue, we run ours around at 20k combined and have no issues.

 

The PO of my truck that i just bought, Said after he rebuilt the getrag it shifted hard into 3rd for almost 10,000 miles until it finally loosened up.

 

Well after almost 2.5 months of the truck being down, I finally got it back last night and drove it all day today..

flywheel resurfaced, new 13" clutch, all new internals and new shift rails and ball guides for shifter ball.

It was great to drive it again.. and it drove very smooth and much quieter then before.. but guess what; down shifting into 3rd it is tight.. so I guess we will see how it does after a few miles on it

oh and for now I am not selling it.. took the ad down from classifieds

 

I love the getrag but after 3 rebuilds i know 2 people who build them son im doin the soon the 1st time was syncros, input the 2nd time was revers/5th and 3rd gear and 3rd syncro then 3rd and 4th grinds down shifting in both of them so i think it time for a mojor over haul

 

In case you're still in Calgary: I got a rebuilt Getrag in Edmonton at Western Powertrain for under $2000- a few years ago. They stand behind their products and shipped me a replacement prepaid to S.S.Marie (long story, mostly my fault) . So if your clutch is OK then that's your only cost to get on the road, not counting the 5 liters of synthetic engine oil!

 

Just rebuilt mine myself, I now have about 5-600 miles on it. at first I thought I didnt do it right, because it had the same issues with 1st, going into 3-4, and downshifting to 4 and 3.
Really sensitive, if you dont shift at the right moment itll grind. My tranny definately shifted different than before.
But what I noticed because its my Daily driver, is that its getting better the more I drive it...so far hope thats all it is (needs to break in)
been on different forums asking the same thing, and overall the answer on this issue seems to be that it needs time to break in, some trannies more than others