gearbox - oh cr*p!

[alexm77]

gearbox has been a little noisely lately, and the garage had warned us it was on the way out, but we went away this weekend anyway. The noise got a lot worse as we drove - a constant grinding growling sort of noise, and during the last 15 miles it jumped out of 4th a few times, and once out of 2nd. Didn't fancy doing that on a motorway on the way home, so had to get the AA to bring us back

I know i need a new box and it's going to cost lots, so what are my options? Recon the one i've got or get one off JK or elsewhere, or risk a cheaper non-recon one?

The current box is a DK, 4 speed from a 2lt Aircooled, fitted to a 1Y 1.9 na diesel with 16" wheels, which seems a fairly common combination.

Would really appreciate some expert advice on this. Had a few minor issues with the van so far, but this is pretty serious, though i'm trying my best to be philosophical about it.

[Aidan]

Alex
I can't rebuild your box I'm afraid as I don't do Aircooled, and I've just sold out the only 4.57 final drive watercooled 4 speed that I had in stock but I could build you a 5 speed with a 4.57 final drive and a 0.78 fifth gear but not untill the end/beginning of next month. £850 outright sale all new bearings, synchro rings, seals, gaskets, circlips and fittings, 12 month unlimited warranty. You'd use the diesel bellhousing and input shaft that you already have.
I'd be interested to hear what JK (or their rebuilder) can do for you as I can't see how they do it for the price they quote.
Cogbox do Aircooled boxes though, maybe a cheaper bet and Bristol Transmissions may also be able to help you.
Regards
Aidan

[alexm77]

Ouch. Knew it could cost a lot, but that's even more than i anticipated. I might be interested, but will speak to bristol transmissions and cogbox and see what's what. Thanks for your help.

[ermie571]

Alex,

I have a dk in the garage. Its not brill, and has been sat for some time. Could you use it as a "keep you on the road" jobbie while you saved to get yours sorted / purchase one off Aiden?

The one in the garage could proably use drowing in gear box oil, draining and doing again, as I think most of it has leaked out from when I accindently left it at an angle Guess how I learned they have a drain hole.....

As far as I remember, it would occassionally crunch into second. But I was driving it for about 12 months like that.

Not a perfect box, but was fine in all other gears.

PM me if you want any more info.

Em
x

[alexm77]

Thanks for the offer Em. Will wait until i've got some quotes for a rebuild before making a decision.

Does anyone know what's involved in swapping the box over? How much labour is it liable to involve, and does the engine need to come out too? If it's not too much labour, then i might be more inclined to gamble on a non-recon one.

[Aidan]

3-4 hours out and in like for like, quicker with ramp and necessary jack and practice.
Engine stays put, clutch slave is biggest faff and electrical safety re starter NB.

[billy739]

also have an untested dk box(van had broken engine) in gloucester

[alexm77]

had a couple of quotes for the recon going from £460 to £590, and also had an offer of a tested non-recon box with probably 120,000 miles on it for £250.

That's a big difference between the recon quotes, and not sure exactly what they do for that - bit of a mystery to me what goes on inside a gearbox, other than some very precise cogs

Aidan, is there anything specific i should be checking that they do other than just asking them to fix it?

[Ian Hulley]

That's a big difference between the recon quotes, and not sure exactly what they do for that - bit of a mystery to me what goes on inside a gearbox

Which is why those of us who had a box 'go' have taken them to someone who DOES. Trouble is an old box with new oil and steamcleaned/painted nice and you're none the wiser.

I'd either do it right or try to drive the donor van from someone like Billy numbers

Ian

[alexm77]

got it booked in this week with bristol transmissions, so hopefully i'll be back on the road by next weekend. Thanks for all the help and advice on this