[blykins]

The problem could be something as simple as bellhousing misalignment or a problem in clutch adjustment....

Otherwise, it's most likely just a stacking of manufacturing tolerances. The biggest issue is the surface finish on the gear cones. Next to that is the blocking ring material. And next to that is simple blueprinting and changing the shift finger.

We offer a "Sure Shift" modification on all of our TKO 500/600's, where the transmission is disassembled, all of the above is changed for the good, and then reassembled with the factory warranty.

We also offer two different levels of strength improvement and can offer around another 15% of torque capacity in addition to the 500/600 lb-ft capacities that are offered.