T25 tale of woes - new gearbox?

[painterspal]

Hi T25 experts

This is my first post and I'm hoping your collective wisdom can help me as I'm getting pretty desperate after a series of bad mishaps.

A couple of years ago we invested a large chunk of our savings on a '87 5 speed, 1.6 turbo diesel T25 camper with about 125,000 on the clock. It looks in great condition but mechanically it has been a source of endless frustration. We replaced the clutch last year but it's always been very heavy on oil and the engine died rather spectacularly in Feb this year. Having been reassured that it's basically a very sound van, we took the plunge and invested in a recon Vege engine, fitted by our local back street VW/Audi specialist garage (well known in the local area with a good reputation as far as we know) at huge expense.

This, we thought, would be problem solved. We were very WRONG! First time out the 1 year old clutch started to slip. We returned to the garage... They said oil leaking from the old engine had knackered the clutch and we needed a new one, which they duly replaced. 300 miles later, on our first major trip, i suddenly start having trouble selecting the gears. Clutch pedal feels okay, but there seems to be something very wrong. Call AA. Their mechanic fiddles about under the clutch pedal but this only makes it even worse. Relayed home last night and back to the garage this morning. Their verdict? The gearbox is shot and will also need to be replaced, assuming one can be found.

Apparently it seems to be trying to select two gears at once. They claim that it's just a coincidence that it should fail now, just as all this work has been carried out, but I'm suspicious, given the coincidence and the fact that the 'box has never previously given us a problem. What do you think?

Is there anything they could have done wrong that would allow this to happen?
And, if you think it possible that the garage is responsible, how on earth do I prove it?
What is the best solution, assuming the 'box is completely beyond repair?

In two years, the total cost is now over £8K and completely out of control. I feel like the garage has got us completely over a barrel and our dreams of relaxed, stress free and, above all, low-tech, low-cost campervanning have completely evaporated.

Any help/Advice would be very welcome - we're completely at the end of our tether.

[kevtherev]

Hey relax your in the right place..

firstly it would more likely be the complicated linkages than any gearbox itself.
If they were disturbed or bent it will cause trouble.

May I suggest finding a more T25 friendly garage.
most modern garages have fitters...not mechanics

I too have spent more on mine than it was bought for.. after twenty odd years and 130,000 miles.. I think it was to be expected.

[kevtherev]

Oh and welcome in friend

[Ian Hulley]

I would never trust anything a garage that refitted a clutch soaked in oil said ! As Kev say's find a better garage ... fill in your profile and we may be able to help you find one

Welcome to the club btw

Ian

[toomanytoys]

Where abouts in the world are you??



IF it needs a gearbox (what they say is quite possible) then you need to speak to Aidan... (link below)

[painterspal]

Thanks for the replies and suggestions.

My biggest problem is my mechanical knowledge is virtually zero. The garage suggested replacing the clutch when the engine was replaced, but as the clutch was only a year old, and they didn't tell why I should do it, I declined. If they'd explained why, or pushed it at all, I'd have taken their advice - obviously, i wish I had now.

I'm based in Ipswich and the garage I'm using is a local one specialising in older VWs such as campers, so I've assumed I'm using the experts. Perhaps I'm just unlucky, but engine, clutch twice and now gearbox - that's a pretty bad hit in just 14months...

[kevtherev]

If they are used to rear engined vans then you have done no wrong there.
So their advice may well be correct.

As far as zero knowledge goes ... no sympathy here I'm afraid, without learning some basic spanner twirling then you'll allways be on the end of a bill for labour, so don't beat yourself up.

take the hit, get it fixed, move on.. then when the next drama comes along you know we'll be here to offer more focused advice.

PS I still think the linkages should be sure to be working correctly before you cough up for a used box

[Aidan]

if you can drop the oil out of the gearbox and see what the plug tells you and ask the garage weather they fitted a new spigot bearing to the engine, unless they are certain a new one was fitted by the engine reconditioner then they should have done so; I'd suspect that as the problem, contaminated clutch by gearbox oil not engine and unsupported input shaft leading to oil seal failure damage to oil thrower in the bellhousing and possible input bearing failure, it's a real common issue with 1.9 engines fitted by numpties and the symtoms sound just like that.
There's a gearbox place over there I don't know what it's like though if it does end up being gearbox failure.
The gearbox can't select two gears simultaneously but a faulty linkage set up especially on a five speed can lead to inability to select gears but the fact that it did work and now doesn't points at something else.


Peeps

Always replace the clutch when replacing either engine or gearbox regardless of state of original as the labour is already being paid for pretty much, subsequent replacement will cost you £200plus and take the van out of service and a new clutch should be good for 60k miles if clutch master pushrod is correctly adjusted and vehicle driven with old style mechanical sympathy, neutral/handbrake at lights, no riding the clutch pedal etc......complete clutch at trade is only like £80 parts and the labour to swap it 15 mins in that situation so not doing it does not make any sense imho

[painterspal]

Thanks All, I'll certainly know where to come next time.