2007 Vannis Horribilis..Your diagnosis and thoughts please!

Post by **jonny_nutt** » 31 Dec 2007, 10:19

First off folks..happy 2008..thanks to all who came to my assistance with bits and pieces this year...and those who never even knew you helped a guy out with info!!cheers
so van dies on me saturday night past

..this year has seen a serious vandalism on me wagen and the other big job/off the road for ages scenario was a totally mashed up clutch..mechanic who fixed it worked on t25s for years although i found clutch to be still noisy after..this I relay cos lately last few weeks have had a slam-stop as i reverse in the cold morning,,thought id hit something when i first done it..and also an impossible 3rd gear occasionally. other "history" to report was a recent rough running engine which i was satisfied was sorted after complete service..plugs and carb clean up too.
Anyway,,back to saturdays journey..ten miles in and cruising nicely when.POP..PFFT!!and immediate power loss."sounds like a pipe blew off"says a pal..i agreed,stopped and found that the housing breather pipe was loose at the carb air intake..phew i thought..tightened and set off again..only to immediately have crappy gears and no drive when got up to selecting fourth.Stopped turned around to crawl home when everything then sounded as if bits where trailing/flailing on the ground..not good..stopped there and then...

So??have I got a broken up box??a broken clutch or even(and not without the realms of my luck!!)a treble of an engine woe??I think the old girl has finally beat me this time!...
...yep..its an early 84 1.9 dg wbx
any thoughts or checklist would be appreciated..provided u still have the strength after readin through all this!!
cheers jonny

Post by **Sir Chad** » 31 Dec 2007, 11:56

sounds like a catalogue of problems, gearbox, diff, maybe not engine? personally I'd swap out the transmission rather than repair. good luck for 2008

Post by **Syncro G** » 31 Dec 2007, 14:14

Gearbox wise it sounds like it might be the famous 4th gear synchro[mesh] disintigrating. If so things could get really trashed in there if you keep useing it, time for another 'box or recon? Drain the gearbox oil into something and have a look at it, if it looks metalic in colour and has lumps of metal in it and a magnetic drainplug coated in a dense forrest of giant redwood iron fileings then you'll know its definately a bit sick.

On the plus side you'll get another look at the clutch while the 'box is out.

Could the powerloss actully be through increased mecanical resistance from the broken synchro'? Maybe the pipe was a coincidence, wouldn't have thought the 2 were directly related but could be a seperate problem.

A slightly depressing start the the year by the sound of it but think how much fun a summer roadtrip will be with a shiny new gearbox? (If its any consolation I think mine is in a simular situation, what came out on the last gear oil change wasn't that pritty! Once done properly it won't need doing (more reliable van

), thats how I try and stay optimistic about it)

Post by **toomanytoys** » 31 Dec 2007, 16:11

Sounds like the box is trashed now... that "sudden stop" in reverse was actualy a warning that something major ws going wrong and isnt "noral"

Speak with Aidan Talbot about the box.. it may (but I doubt it seeming its sounding like hell had broken loose) be fixable...

Otherwise..

You are going to be searching for a good second hand box... Good luck...

Post by **jonny_nutt** » 07 Jan 2008, 00:50

cheers for the replies!..months ago I was stopped my a motorist who told me he had a t25 that he had spent money on its engine but never worked for him...he offered it "for a couple of hundred" as it was doing nothin...on enquiry,all i could get was that it was 1989 and petrol..but may have been a larger 2.1..now my questions are:..as I have an early 1984 1.9 dg...would it be worth looking at..ie in view to using it for parts...esp.now I need a box more than likely...If it is indeed a 2.1..how compatable would said box be??could it be put into a dg 1.9??Are boxes swappable across engine types etc??please excuse my ignorance..and possible failure to read a glaring wiki or post on this....cheers again..jonny

Post by **camper** » 07 Jan 2008, 08:25

Yes put that box in .But linkages might need interchanging.

Post by **ermie571** » 07 Jan 2008, 09:12

put the 2.1 in as well!!!

Emma

Post by **jonny_nutt** » 30 Jan 2008, 00:22

thanks all for previous replies!!Nothing new to report only one sick van!Living where I do,Its been kinda hard to source new box...What kind of box will go straight in??(ie what dg codes compatible with what other box codes?)I have the van parked up, and start it regularly,but notice that the engine sound on idling has a definate wierd whirr to it..I can still select gears,and indeed can move it some distance back and forward..what would be the easiest option..ie...replace box??if so,what kind will go straight on...or go for an engine plus box..on a local post found a 1.6d engine and box (cheers Dazza!)but surely that would be a hassle for less power etc.My only mechanical knowledge has been the last 5 years owning the velle!!which with this forum has givin me so much of a learning curve and great satisfaction when problems are sorted..tho Im admit to bein overwhelmed with the prospect of this one!!I also recall the guy who offered the aforementioned 2.1 van was selling it as a whole, and mentioned that after shelling out 500 quid on the engine,he couldnt get the thing to start!!..im a bit apprehensive about having two non runners on the driveway!!indeed..is there any info/walkthrough on swapping over either just a box(1.9 to 2.1) or box plus engine in this case??...phew my posts aretoo long!!! anyway cheers for reading..itll cure ur insomnia!..jonny

Post by **Ian Hulley** » 30 Jan 2008, 09:22

Speaking very basically :-

You can swap the 2.1s and 1.9s around, you may have to swap the cooling system if your's is an early one. The 2.1 is normally injection but the inlet manifold and carb complete will swap from the 1.9 thus ditching the electronic injection components.

The gearbox will swap too you may have to swap the linkage, as you've been told speak to Aidan ('Beaker' on here) You didn't say whether it's a 4 or 5 speed ?

Ian.

Post by **ermie571** » 30 Jan 2008, 09:24

Jonny.....glad you are hanging in there.....lucky you to have a drive to keep them on.....wish I did!

Don't forget that with the second / donor van, you can always strip it down for spares, then sell the carcas for scrap metal.....its fetching quite a bit at the moment I think.

We did the 1.9 to 2.1 engine swap.....utter novices with someone knowledgable about t25s but who hadn't actually done that engine swap before. Was in and running in a day. But the donor engine was a runner. The only hassle we had was sorting the cooling pipes - going from an early to late system, so some minor mods needed. Never changed a gear box, only removed them from a vehicle, so can't help there. But the 4 speed box that was on the 1.9 runs the 2.1 fine.....just bolted them together after making sure that the clutch etc was all aligned.

Good luck

Emma

Post by **jonny_nutt** » 30 Jan 2008, 09:36

Cheers for that again guys

..yea Ian tis a 4speed..

Post by **irish.david** » 01 Feb 2008, 21:20

Hi,

Whereabout in Norn' Ireland are you? I'll be back in Belfast at the beginning/middle of March so if you're nearby i might be able to come and have a look. I'm almost finished overhauling a 2.1 DJ (with a regular late style cooling system) to transplant into a van that used to have an 1.9 DF (with a early syncro style cooling system). Total nightmare.....

Dave

Post by **jonny_nutt** » 03 Feb 2008, 17:13

Hi Dave...cheers..am up in Derry..did u change ur box aswell doin ur overhaul?Is there anywhere there is a link or walkthrough for a novice by any chance??

Post by **jonny_nutt** » 04 Feb 2008, 12:28

to continue!!...contacted the poss. donor van guy today..still hadnt much info only to say that his was a five speed...would that swop over for my 4 spd box..or would that be nightmare??He says the van has never moved after he claims engine was fixed tho keeps overheating??cant get any engine code info from him..tho as i said before he said it was 2 litre late eighties.. so from all ur replies before(cheers again!)..would i be right in thinkin as mine is early 84 1.9 that box swop would require new linkage also(that is if the five spd is compatible)..am i better off waiting for like for like swop?