I have adjusted the clutch and it makes no difference in how it shifts. It is adjusted exactly the way it should be and is sitting dead nuts to specified parameters. It was off a little for petal play and distance but after adjustment it made no difference in the way it shifts.

5 things of note:

1, this tranny was completely torn down when it was 1st installed 10 years ago and it was done by a tranny shop and there was no mention of any gear issues or synchronizer gear issues in the main body of the tranny. I would think they would have saw it or at least I would hope they would have

2, There was no mention of any gear issues or synchronizers issues the 2nd time they tore it down do to not shifting properly. My dad was pissed that they returned it shifting worse than the old one did and he saw the tranny on the table completely torn down both times.

3, The tranny after the 2nd tear down shifted the same as the old one did except the new one would not popped out of gear like the old one but it still would grind the gears exactly the same way.

4,They never had the transfer case torn down.

5, There is not a spec of metal in the transmission oil.

Question: If it has been grinding for 10 years and over 25,000 miles there would be some sign of metal in the oil right?

Question: Why isn't there any trace of metal in the tranny oil with it grinding this badly?

Question: Does this tranny have a transmission oil filter in it under the tranny pan?

Question: Why can I feel the gears thunking and clicking and rattling and grinding right under the shifter in my hand as I shift it? You can very gently try to down shift it and push the shifter over real slowly and super carefully going into 1st and you start to feel the gear grinding its teeth right up thru the shifter like its happening directly under the shifter. It will also cause the shifter to bounce or move or bump in your hand a little when you do this very gently on down shift into 1st gear when the truck is still rolling real slow and the clutch is depressed Why?

If the issue is in the tranny how come it makes the shifter bounce and grinding in your hand? Its hard to explain it but hopefully that tells you more.

When I do this the sensation and sound is coming from under the shifter and not forward up by the tranny pan where the gears are. Why?

Question: If one of the hubs was staying partially or completely engaged when out of 4x4 could that cause a grinding issue when shifting?

I do not believe I had a engaged hub problem until very recently but its worth mentioning.

Also the truck has "never" been able to get better than 15 MPG no matter how easy you drive it and it has had carb issues in the past. You might get 15.5 MPG if you drive it down hill all the time and in neutral. Is this mileage typical? I have read that many people with the truck I have get abut 19 to 20 MPG on the E-way??

Mine is a 89 Mighty Max SPX macro cab 4x4 5 speed with the 2.6L motor and it gets 15 MPG tops and has never been better than that since my family owned it. I have no idea of the gear ratio. Manufacturer specs say 19/21 for fuel economy for my exact truck