transmission rebuild question

[timspider]

I'm just about to get my transmission out after a very long extraction process. I've got the new clutch components I need (I hope) but I've got a question on the tranny.
The transmission was pretty smooth when I got this car a year ago with 85,000 miles on it. I've since put anther 10,000 on it and new just in the last weeks once the clutch started to fail is that 4th gear starting popping out. And it was stuck in 4th and very difficult to get out once I was in. Other gears seem ok.
So my question, wouldn't this be a good time for a rebuild?
Or just get 4th gear fixed (sounds like may be a worn fork from something I read?
I don't have the budget for it right now, but with cold weather coming, I have time.
And with the major pain this is to remove, it feels like a good time to breath some life into this 95,000 tranny before re installing.
Given that scenario, what would you do?
thanks again.

[wizard124]

Yes, now is the time.

Look here: http://fiatspider.com/f08/viewtopic.php?f=9&t=26031 Photos and tips to inspire you

So, once you have it apart, the question is what to look for? This is only my second transmission job but I offer these tips.
1) Get a new input shaft needle bearing (cheapest one in the transmission). Inspect the other bearings carefully, use a magnifier to look for scoring and pitting. Rotate them and ensure they spin smoothly. Some get pricey but when in doubt replace it.
2) Compare the thickness of each syncro and cone to the others using calipers or micrometer. You know which of your gears is trouble free so start with that one. You may not need to buy new for each gear.
3) Do the same for each gear fork. You will see wear on the sides of the fork. You suspect 3/4 fork is bad, worn or bent.
4) Look for chipped teeth on the gears and sliding sleeves (see photos in reference thread).

I'll repeat it again here for emphasis. Be very methodical in laying out the parts as you dis-assemble the transmission and take many digital photos for future reference. Clean and inspect the various sub-sets of the tranny one at a time; then lay them back in their rightful spot in the dis-assembly line. You DON'T want to take everything and dump them in the parts washer all at once.

A bench vise is a must.

[vandor]

If I open up a transmission, it gets at least all new synchro rings and springs (1-4 gears) and the shift forks get replaced if they show any wear.
Sounds like there may be a new input shaft (4th gear) in your future as well. Grinding gears wear their engagement teeth very quickly and they start jumping out of gear.

[timspider]

sounds like I'll be throwing some stuff in my auto ricambi cart soon.
Resigning myself to this being a winter project.
Thanks for the help

[SLOSpider]

).

I'll repeat it again here for emphasis. Be very methodical in laying out the parts as you dis-assemble the transmission and take many digital photos for future reference. Clean and inspect the various sub-sets of the tranny one at a time; then lay them back in their rightful spot in the dis-assembly line. You DON'T want to take everything and dump them in the parts washer all at once.

A bench vise is a must.

Explain methodical to me? Bench vise?