Gearbox problem?

Post by **Ollyboy** » 02 Mar 2007, 15:07

Good afternoon!

When cold the gear selection is fine, however, once the gearbox is hot it intermittently sticks in third and fourth gear. Double declutching helps a bit. If you stop when stuck in fourth, and switch off the engine it is still difficult to get into neutral. If you "waggle" the gear stick in neutral when these symptoms are occuring it feels as if there is more of a resistance than normal.

I have been to my local garage and had the hydraulics bled, the gearbox oil level checked, and linkages lubricated. It has been suggested that it might, optimistically, be that the clutch is not disengaging properly, or that the gearbox is failing, perhaps due to selector problems.

It is a 1985 1.9 DG Transporter (Sorry don't have gearbox code, but it's a four speed). Its done 70,000 miles and was owned prior to myself by a very careful elderly driver, so I hope its unlikely to be gearbox wear.

Any ideas as to what is wrong with my 'van would be gratefully recieved!

Cheers

Oliver

Post by **Fox McIntyre** » 02 Mar 2007, 15:11

there is, so I've heard, something to do with the syncro cones cracking for 4th and it then gets jammed in gear, could be your fault starting to accour? My van gets a bit sticky in 4th after a long motorway haul, but it's never properly stuck in gear though

Post by **cumbriankeith** » 02 Mar 2007, 16:11

I'm afraid to have to tell you that these are the exact symptoms for a cracked hub - the one that that serves third and fourth gear. Mine did all that until it jammed in third permanently and the box had to be removed and sorted by a gearbox specialist. It's a common problem on these boxes apparently and just the new part is about £130.

Post by **HarryMann** » 02 Mar 2007, 16:21

Not sure the 4-speed is so prone to this.

You should be able to elimnate the clutch disengagement, because it will either drag when going into first and reverse, and snick, or you will hear the sycnro-hubs having to do all the work (a mild screaming noise)..

You might have an airlock in the slave cylinder - check the whol clutch system out for leaks anyway, under the pedals and a round the slave.

Wjhilst it doesn't sound like the linkages, nevertheless, did the garage really disassemble the whole linkage system and re-grease? Means doing quite a lot of work to to do the middle one and have you checked the front ball-joint in the cab?

Having said all that, if it won't pull out of gear easily (even without the clutch it should) as you ease the lever with no-load either way (between drive and over-run), then sounds like its the box.

Others who've eperienced this may have more specific ideas

Post by **Ollyboy** » 02 Mar 2007, 17:25

Thanks for all the advice so far - the knowledge that is available in this forum is amazing!

The garage hasn't had the linkage apart, they have applied lithium grease to the bushes.

There aren't any leaks in the hydraulic system - I've looked, hoping that there is a number of times!

It does sound like I might need to get a new synchro' hub; How big a job is it to fit a new synchro' hub. Can anybody recommend a specialist garage in the Scottish Borders/Central Region that could takle the job? I don't really want to fit another unknown gearbox when I have a (hopefully) fixable low mileage gearbox!

Cheers

Oliver

Post by **cumbriankeith** » 02 Mar 2007, 19:54

I used this outfit and am happy with their service. A rebuild cost around £400.
Cumbria Transmission
Tel: 01229 586230
North Lonsdale Rd, Ulverston LA12 9EB

I know it's not very near to you but now you have the info anyway!

Post by **HarryMann** » 02 Mar 2007, 22:02

.. or if you want it diagnosing definitively first then Syncro-Nutz at Shotts should do that for you.

http://www.syncro-nutz.co.uk

Post by **Ollyboy** » 05 Mar 2007, 20:32

Evening!

Thanks for the replies Harry and Keith.

I have had the van to work and back, which is 50 miles, and I haven't quite described the symptoms properly - any gear is difficult to select or disengage from when the 'box is hot. I get the impression it is either the linkage and/or clutch but I am not about to lay bets on it!

I had forgotten that there is a good VW garage in Edinburgh - John Forbes. I'm going to seek advice there first as it is nearby and has a good reputation, but will bear in mind the recommendations I have.

I'II keep this thread posted as to what the cause of the problem is, once known

Cheers!

Oliver

Post by **HarryMann** » 05 Mar 2007, 21:51

OK, bear in mind Synro-Nutz, Shotts know these vans inside out (and if you go there you'll know what I mean

)

Post by **Ollyboy** » 16 Mar 2007, 20:40

Hi!

Here is an update on "Velma's" gearbox problem.

I have just had the Van at John Forbes VW. Typically, it wouldn't do its sticking in gear trick when the mechanic had a test drive. The gear linkage has been removed, cleaned, and regreased (again?). The difference this has made is phenomenal! On the drive home it was perfect, so I am quietly confident that the problem has been solved, fingers crossed!

Post by **HarryMann** » 16 Mar 2007, 21:40

Its the cleaning before re-greasing that unsticks them

best to replace all the bushes at the same time, for the cost is negligible (except the gear-lever ball-joint repair kit), but even they have come down in price lately (~ £30 now)

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