When a TKO transmission is shipped there are a few things that can happen…
Before trying to diagnose a potential problem… remove the shipping plug from the rear of the transmission. Remove the shipping plug by pulling with pliers. Pull a little on one side, then the other.
Be careful not to accidentally grab the lip of the output shaft seal.
Once the seal is removed, rotate the input shaft counter-clockwise. It should spin easily. Push the shift stub forward into 3rd gear. Rotate the input shaft counter-clockwise. It should spin easily. Push the stub into 4th gear. Rotate the input shaft counter-clockwise. It should spin easily.
Move the shift stub into 2nd or 1st gear. Rotate the input shaft counter-clockwise. It should spin easily.
If you find the stub will not shift into any gear (try them all, usually with a lever installed for ease) then one of the shift rails has moved from the neutral position during shipping.
To confirm this the lever will only detent left or right and not move forward or backward.
Remove the 5-sided plate and inspect the shift-lug positions. They should all be straight across from each other. If one of them is out of position use a screwdriver to re-position. It should click into position. And then repeat the above counter-clockwise process.
The other issue is a stuck blocking ring. A stuck blocking ring will only allow you to rotate the input shaft in neutral and a single gear. If more than one blocking ring is stuck, the input shaft will not turn in neutral or any gear.
If only one blocking ring is stuck, you determine which one by shifting into each gear and rotating the input shaft. The input shaft will turn in the gear that has the stuck blocking ring.
This simple problem can be fixed a couple ways. With a shift lever installed temporarily for ease… move the lever in and out of all the gears you can, multiple times. Usually this frees up the stuck ring or rings. For a single stuck blocking ring, focus on shifting in and out of this gear multiple times.
Another way to free-up stuck blocking rings is to shift the transmission into a gear the input shaft will not rotate in. Install the clutch disk on the splines and rotate back and forth to shock-load the gears. The blocking rings should pop loose.
Only once did we have a transmission with a blocking ring so stuck did we get the transmission back for a fix. It was too simple. We removed the two forward covers, popped the stuck ring and done.
Use this procedure to eliminate any frustrations. These are shipping issues and cannot be overcome.
As always, we’re here to help and can guide you thru the above process and any other related parts and installation issues. Hours are 8-5 Mountain Time, M-F. You can find this article and other tech help information on our web site moderndriveline.com