Noisy gearboxes

[Ian Williams]

The synchro cone is loose on the ist morion shaft, probably as a result of being fitted cold, if you put is back together without dealing that you will have further problems. The difficulty that you now have is that the toothed bore of the cone is now stretched, some may suggest staking it onto the gear but in my experience this is often unsuccessful, I usually replace them with one from another box. The lay shaft appears to be not badly scored, provided there is not excessive play in the bronze bearings all should be well there.
I have just looked back through your pictures before posting, the cone is not loose on the ist motion shaft but on the main shaft 3rd gear. I also suggest that the box has had an alternative ratio fitted, the layshaft has been altered with a larger constant mesh gear, quite the opposite to what I would expect???