Noisy from Gearbox?

[Morganman]

Have started to have a what i would call rumble coming from the bus, it's only happening in 3rd when you lift off the accelerator and around 20>30MPH, a little less noise if the clutch is pressed but still there. In all other gears at same RPM or speed is OK. Only started this 3 days ago. No issues with gear selection or clutch slippage any idea's, I 'm planning on checking the oil levels and front gearbox mount this weekend but as an engine change will be taking place soon I'm concern the gearbox is fit for the job. bus done 103K miles 4 speed 1.9 DG 1990.

Cheers
Chris

[Aidan]

at an eductated guess the 3rd/4rth synchrohub is broken, if you find one of the keys on the drainplug that will confirm it, otherwise it's a chipped tooth or a cracked synchro ring, eitherway it won't get better and if it is the hub then they have a tendency to cam out and jam in gear

[Morganman]

I will drain the oil this weekend and see whats on the plug. I may be in contact for an approx cost as i see you are a rebuild gearbox man.

Cheers Chris

[Morganman]

I was unable to drain the oil as the gearbox drain and fill was a 17mm Allen key which i didn't have, ordered one and should be here soon, hope to complete the weekend, will post a picture of the result found on the plug.

[Ian Hulley]

as i see you are a rebuild gearbox man.

Nah he's THE rebuild gearbox man.

Ian

[jed the spread]

I was unable to drain the oil as the gearbox drain and fill was a 17mm Allen key which i didn't have, ordered one and should be here soon, hope to complete the weekend, will post a picture of the result found on the plug.

Make sure you undo the top filler one first because if you drain it then cant fill it up because its stuck your shagged for driving it for a while

jed

[Morganman]

Great tip, its always tempting to go for the drain first, man on a mission and all that, but logic says prepare for the worst.
Good news at present is the Subaru engine is nearing installation and the gearbox hasn't got any worst and is still moving through the gears with no issues, just hope the good luck keeps flowing!.

[Morganman]

Dropped the oil today and the drain plug looked like this,




This last photo shows the largest bit of metal o found in the mass on the plug and i stuck it on the side to show.
The oil was not that bad and when i strained it back into the can i didn't find and large bits.
Photo of oil.


Bit of a job had to remove the exhaust as the 17mm Allen key socket would fit in so took longer than i had planned.
Any idea's and should i be worried?

[Morganman]

Driven bus now and can report noisy has reduced still there in 3rd but approx 50% reduced great improvement with less vibration.

[Aidan]

that's fairly worn, the piece of metal I can't identify
will be better for a bit then get worse

[Ian Hulley]

will be better for a bit then get worse

I certainly wouldn't be setting off on a 2,000 mile trip having seen that

Ian

[Morganman]

Thanks for the information, looks like a box rebuild is on the cards, approx cost?
Aidan you can turn boxes around in 7>10 day's? and given I'm approx 2 > 3weeks away from dropping the engine and box how would this fit into your work load? this is the wife's daily drive so i need to plan this to limit down time or look for a 2ND hand box or exchange unit.

Cheers for your time

[Aidan]

booked up into late May at the moment, normal turnaround 10 days

[Morganman]

Thanks Aidan, i will see how i go i always under estimate how long things take anyway so will see how you are fixed just before i drop the engine. Be nice to sort in one hit and i surpose the additional power from the engine will only force the gearbox into an early grave.