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I have a 84 bronco with a NP535. At first I had to realease the clutch a little to engage 1st gear, so I replaced the clutch, pressure plate and bearing. While I had it torn apart I put in a new flywheel. It still has the same problem and now it grinds from 1st to 2nd. I notice when I down shift it will grind at 2500RPM. Is my linkage going bad? I changed the fluid when I replaced the clutch. Whats the deal?
I had the same problem with my NP435. The aluminum second gear synchronizer cone sheared the rivets that held it on it’s mount. This was on a Saturday, no one locally had a new one. A friend of mine at a gear shop used regular pop rivets(!) to put it back together, I was skeptical but I needed to run the truck, I ran it three years this way. A couple of months ago, when I had my engine rebuilt, I installed a rebuild kit that included new syncros, the pop riveted syncro was still holding together but was racking on the rivets a little bit.