[Bret Brinkmann]

First I would try giving Kormex a call and explaining things to them. They have been willing to help people in the past but not if it sounds like they under attack. Your post does sound a little agressive towards them.

But anyway, you sound give the tranny about 500 miles of normal driving (like your grandma would shift) before you go slapping through the gears. This will give your rings a chance to develope a wear pattern (or brake in) and sinse I am pretty sure that tranny never saw BG synchroshift fluid before, it will take a while before the fluids full benifits can be realized. It it is still a little chilly in your area, your shifting may be a little bit notchy untill the fluid warms up. This usually takes about 15 minutes of driving on a cold day.

Still, a newly rebuilt tranny should not clunk when shifted. It could be a dragging clutch. Here is how to test for that. With the car idleing and the parking brake on, put the tranny in neutral with your foot off of the clutch pedal for a few seconds. Then hold down the clutch pedal while shifting back and forth between 1st and reverse (do not let the clutch pedal up, keep it held down). You may hear a cluck the first one or two times which is normal. It if clunks EVERY TIME, then your clutch is dragging. A dragging clutch is usually due to installation error. These trannys can be a pain to install some times and if handled to roughly, the input shaft of the tranny beats on the clutch disk perminately warping it. By far the easyest and safest way to install the tranny is to hook it up to a cherry picker at the holds for the shift cable bracket and lift it into postion. You will have to turn it and twist it a little to clear the sub-frame but it nothing that is difficult.

Other things to check are the cable adjustment under your shift boot in the car, the shift shaft on top of the tranny to make sure the arm that the cable attatches to doesn't have any play on the shaft, the shift lever (L shaped lever next to the shift shaft) doesn't have any more than about 1/8 inch left to right play, and that the rectangular plastic block between the shift shaft and the shift lever is still there and doesn't have more than about 1/8 inch play in it. The rubber bushings on the tranny side of the shift cables could be worn out also. If all of these things check out, then and only then, would I say it is internal.