T5 Tailhousing not fitting

I have a 92 Ford T5 that i'm trying to mate with a S10 electric tailhousing. I was reading the "How To" and thought this would be easy.

My 5th gear assembly looks different than what i've seen in the "How To". The sleeve i'm pointing at on the 5th gear assembly is hitting the lip (see finger) where the funnel goes in the tailhouse. it protudes too much. I took measurements and this appears to be causing the problem. See pictures...

Is this assembled correctly? I was thinking i could shave that sleeve down about 3-4 mm to get it to work. Or should i shave the tailhousing lip? Will this cause any problems? Thoughts?

Bryan

 

Often, this type of "problem" is simply the assembler not holding his mouth right...

It really is quite a "fiddly" section of assembly - getting everything to line up perfectly with shafts going into different holes, etc.

First suggestion - make sure you're assembling the trans vertically - input shaft down.. Then just keep trying and wiggling - I've seen trannys that were assembled together not want to go back together!!

 

i'm using the bellhousing to stand the t5 upright and wiggled.

However, i measured, with a framing square, how far the that sleeve i'm pointing at was from the mounting surface of the gearbox. it was 3 1/8". I then measured how deep the tailhousing is from its mounting surface to where the sleeve sits. it was 3". so, the tailhousing is an 1/8" too shallow for the 5th gear assembly (with that sleeve). The original tailhousing was 3 1/8" deep at the same location.

the outer syncho it pretty wobbly so that's why i asked if it was assembled correctly. The transmission was just rebuilt (not by me).

Bryan

 

I'm at a loss to explain the 1/8" difference...