Gearbox. How bad can it be

[Vee_Dub]

My van just broke down.

I was sitting at the lights and as they turn green i go into 1st to drive away and i hear a knocking noise and it wouldnt move. When i press the accelerator in first you just hear a knocking noise coming from gearbox.

I jumped under to check for anything loose (wishful thiinking) as i hard trouble getting in and out of 3rd awhile back and it turned out to be loose bolt. So van is sitting at a set of lights in the middle of know where

Luckily the girlfriend doesnt live to far away so walked it here with my bags, hands are recovering from the cold just enough to type now. How bad could it be? its a refurblished gearbox from only a few month back there.

Now need to find number from glynwood to see am covered for pick up, cant even remember my full registration number. so much for a quiet Sunday.

[Aidan]

either clutch has failed or it's not in gear or the crown and pinion are toast, I'd be optimistic and go with linkage and selection and start there, but if it's in neutral you can tow it out of the way.

[syncrosimon]

If it is a 2wd or you have a de-coupler then Just make sure that the outer cv joints are still attached. If they become disconnected a quick look underneath would not pick it up. Happened to me Thought the worst at first.

Simon.

[Vee_Dub]

Alright Aiden,

What should i look out for in the linkage and selector? i moved the linkage bar up and down, dont know if your meant to notice excessive play or what?

I didnt spend too long under van as idiots where still driving right up behind the van even though i had hazzards on and my legs were sticking out the side. managed to roll it into the side some more.

I will head down back down to the van in abit, onnce get hold of a tow from innsurance or the old man.

[Vee_Dub]

If it is a 2wd or you have a de-coupler then Just make sure that the outer cv joints are still attached. If they become disconnected a quick look underneath would not pick it up. Happened to me Thought the worst at first.

Simon.

I've not put the propshaft on so still a 2wd the now. How i check out cv joints?

Guessing not much i can do the now .Just a pain that it happened where its happened. just need to get it towed and worry about it in the morning. the GFs street is parking meters come monday mornning but private care park in the flats acrrossthe road dont know whether to try get it in there before they close the gates lol.

[syncrosimon]

Just get a pair of gloves on, and grab the drive shaft. Give it a good pull. It should be rock solid and only have movement in line with the shaft ie not front to back in relation to the vehicle. You will know if it is loose. fingers crossed as you can bolt it back in without too much trouble. If you have a torch with you you can look into the pressing of the rear swing arm and you will see if the joint is out. If you are brave with an assistant you can see what happens underneath when you take up drive. If the shaft is undone you will see it moving, bu the vehicle staying put. be careful though.

simon.



here is the shaft as it goes into the swing arm

[Vee_Dub]

thanks simon for your time and pics.

Dont suppose you or anyone else knows the breakdown number for glynwood insurance, tried the number off internet 0844 576 0014, its just ringing not sure if thats the right number. may have to jump home look for the paper work.

[Aidan]

Linkage shouldn't have too much movement at the rear bush, good is like 1mm play which is new bush and nearly new rod, you need to check to see that the cup and ball are intact and mated and the boot skirt if present is pulled down over the cup, rear bush shouldn't have much play as said, if play excessive quick fix is slacken the two 13mm head bolts holding the rear bush plate to the gearbox and push the shift rod etc up and then lock off the bolts in that position that should ensure good mating of the cup and ball and thus positive selection of gear, you may want to renew bush and boots etc later. If still no drive in gear then clutch or input shaft failure or final drive, assume clutch but also do an oil change on the box to ensure you know what condition it is in
clutch could be master or slave cylinder or push rod or fork or release bearing or clutch plate or friction plate or combination of, when you remove the gearbox you'll be able to check input shaft and gearbox operation manually

[Vee_Dub]

Better late than never.

Due to that bad winter we had and then doing 7 day weeks never got round to looking at the van.

But now some spare time on my hands and MOT almost up thought that better get the finger out.
Just this minute jumped over to the car park and had a quick look underneath just now and i think Simon may be right.

Looks like it is the Right Drive shaft that is loose at the wheel end I could move it up and down the length of van. Left side is solid.

Is it easy enough to fix roadside? Will I have to take other part off to get into the back of wheel to bolt back on?

What will i need or expect to find? thats if it is something i can fix where its sitting just now.

how could that come loose?


Thanks again to Simon and Aiden for your advice.

I have just taxed the van (£200 )

[syncrosimon]

You will have to establish what tool you need for the allen bolts that you have fitted. There are several different types now in use. You will then have to jack up the rear of the van on that side, enough for you to wiggle underneath. Yoy do not have to make the rear wheel leave the ground, but a bit more clearance makes it easier. With a torch look inside the swing arm and see if any of the the 6 bolts are in there respective holes. If some re in, then you should be able to tighten up around three of the lower ones at least. Move the van forward or back a bit and do the rest up. If the joint is right out and not attached then you will have to start the bolts off, which is best done by hand so as not to cross thread. You will need an extention bar, prob 3/8ths drive, with a ratchet and an allen key bit for the end, rather than your normal Ikea type allen key.

This is where a decoupler is real handy, as you can raise one wheel and spin it freely which you cant do in a permanent 4x4.

A haynes for the two wheel drive is a great help.
These are the tools for the job. Baxter at brickwerks does special washers for the bolts to prevent coming undone. But in reality if they are tight they are good.

[silverbullet]

1.You will have to establish what tool you need for the allen bolts that you have fitted. There are several different types now in use.
2.This is where a decoupler is real handy, as you can raise one wheel and spin it freely which you cant do in a permanent 4x4.

1. Both 8mm socket, but one is conventional hex, the other M8 12-point. Local motor factors will have one - just say it's for doing CV joints on an Audi A4/A6. The left one in the pic.
2. Slight aside. I'm investigating the nasty noise that the syncro makes when rolling (whine on the move, dry squeal when you come to a stop - not brakes) Jacked up one rear wheel and can just turn it i.e. rolling diff over and working the VC (no decoupler). Sound about right? Don't know the difference between a tight or normal VC anyway
Found that the N/S wheel bearing "creaks" when you grab the wheel top and bottom then push/pull. More play than the O/S. Hoping I've found the fault.

[syncropaddy]

I bought this set for my CV joint bolts

[Vee_Dub]

Well I squeezed under and could see that all the bolts are out, could freely move the joint around.

There there is actually one missing.

Looks like black grease is everywhere, this another bad sign? What will a need to do about the this grease, where has it come from?







Managed to get my hand in and take a bolt out, seem to have been a 12point sline but appears worn a hex socket fits perfectly in it. wondering if the reset will be the same.




Thanks alot Simon.

[syncropaddy]

Well I squeezed under and could see that all the bolts are out, could freely move the joint around.

There there is actually one missing.

Looks like black grease is everywhere, this another bad sign? What will a need to do about the this grease, where has it come from?

Its come out of the CV joint. No big deal so far

Managed to get my hand in and take a bolt out, seem to have been a 12point spline but appears worn a hex socket fits perfectly in it. wondering if the reset will be the same.

It looks as if you need a new CV joint kit. With this you will get 6 new bolts and all the stuff you need. Before ordering, take off the shaft and check the other joint. You might as well do it all at once. A vice is a good idea by the way. Check the bolts you get, they may be Allen head but if spline head you will need the tool for it. Do not use the old bolts again

[toomanytoys]

WHS^^^^^