Just rolled back into the house. 8 hours of driving, 2 hours of R&R on the TL, and 4 hours of talking...well listening. That man Dan Williams can tell some stories, and if any of you need a little humility in your life, I know exactly where you can get a whopping dose. First, dont read the instructions which Dan includes with his rebuild kits...which I read at least four times, them show up at his house with a broken transmission.
Turns out, I only made a couple small mistakes, other than that, I had the trans assembled properly. There were a few things Dan didn't like in the shaft fits and shift rail lever fits...most were too tight for his liking. He was happy wth the bearing fits on the main shaft. I followed those instructions and had the shaft poloshed to within .0005 clearance.
So the culprit of my TL failure and undoing of my self confidence...the synchro teeth on the second and third gears were all but destroyed. Which I didn't know. Second being the worst which is why I could not downshift to second. The gear and bronze blocker ring would have never synced. This also led to one of the dogs in the one/two synchro to eject itself into the first gear bronze blocker ring locking the trans into second. When Dan showed me what a new gear looks like, especially the synchro teeth in this case...I understood the failure.
So before you slap your TL back together, inspect all the teeth on every single piece. If you don't know what they are supposed to look like, GTS and educate yourself, or call Dan and ask...just leave yourself plenty of time for the phone call.
I will also add, Dan has to be one of the most giving kind gentlemen I have ever met. He R&R'd my TL free of labor and only charged me for parts. He also gave me a very nice hardback Mustang book. If you ever have the opportunity to drive and meet him, take it. However, don't show up before noon because you will be waiting. He works noon to midnight and beyond.