My newly purchased 5 speed manulrover lightly grinds when I shift from 1st to 2nd, or when I downshift from 3rd to 2nd. The other gears are fine. Any idea what could be causing this? Clutch feels almost new.

Thanks!

 

I would start with clutch adjustment, then I would look at a bad gearsyncronizer.
I do not know if LR uses self adjusting clutches or not.

 

Sounds like a second gear syncro. I know nothing about LR manuals, but 2nd gear is usually tough on syncros. Changing the fluid might help some, but probably not.

 

When I first bought my 5spd, 1st to 2nd was a challenge. Now it's only a problem when I rush the shift. So I shift a bit slower and use two fingers to get a lighter touch and avoid forcing 2nd. I also replaced the fluid (which was in a horrible state) with ATF Dexron IID and then Mobil 1 synthetic after 400 miles.

 

"DITTO"
Quit driving it till you get this resolved, especialy the downshifting, or you will be buying many hard parts.

 

That's a great point, downshifting can beespecially tough on the clutch, gears, engine,etc... especially ifdone wrong.I used to do it all the time until I realized that slowing downis what the brakes are for and they are easillyreplaceable and cheap. Leave the downshifting to the big rigs and long hills, I think.

 

Definitely sounds like a bad synchro. If you have to drive the vehicle before you can have it repaired, when you shift from first to second, pause in neutral long enough for your rpms to drop about 400 then go into second. On your downshifts, use the accelerator to bring your rpm up until the engine and transmission speeds match. It's usually 400 - 500 rpm difference between gears. If you come out of third gear at 1000 rpm to downshift rev the engine to 1500 rpm and it should go in pretty smooth. I drive a tractor trailer for a living and we use nothing but unsynchronized transmissions and have to shift this way. I also drive all manual transmissions this same way because it's natural to me and I forget to push in the clutch.