It ain't no secret that I've hated the way my transmission has shifted since day one. Mainly a super notchy 2nd gear that has improved a little over time but not enough to make me happy. A TKO 600 just isn't a worthy race transmission in stock form. Down ****ing is like sticking your prick in a virgin.
There are a few shops that modify these things to make them shift up to 7-7500 rpm reliably. Liberty in Michigan and American Powertrain in Tennessee. Liberty wants about $750 plus freight both ways and American powertrain is around $1250 but they harden the parts to make them more durable. From my understanding, they only add upgraded synchros to 2nd, 3rd, and 4th gear. Neither price includes a new shifter.
Since I do all kinds of racing with this thing, I'm replacing the brass synchros with carbon fiber empregnated synchros in 1-5. I've downshifted into 1st 2-3 times running misc. autocross events. See paragraph one. I figure while I have it apart, I may as well do them all. The carbon fiber synchros are $50 a piece.
I was hoping to find a red flag tearing this thing apart. I did find a broken spring retainer in the shifter but seriously doubt that's affecting anything. I ran it through the gears with the inspection cover removed. I noticed that second required the shift sleeve and synchro to move much farther to mesh than any other gear. These carbon fiber synchros are supposed to slow down the shaft more aggressively than the brass and aid in making the synchro and sleeve mesh faster. Everything is in excellent shape so far.
It really wasn't that difficult to dissasemble. I went out after dinner and had it out and apart in about 3 hours. You need to be careful because it's a needle bearing nightmare.(Especially in the 5th gear race) There are misc. shims beind bearing races that you need to be careful with. The front plug for the lower gear shaft is known to leak when they sit and mine did as well. It sets the preload on the bearing on that end and it will get glued back in to stop the leak. I am going to add a Pro 5.0 shifter with adjustable stops....
I'll be into this deal about $600 including synchros, shifter, gear oil, and sealer.