New gearbox same old clunking

[lozhedgehog]

Back again with another problem.

Story as quick as I can.
-Bought van 1987 5sp 1.9 petrol in June.
-It had new engine from elite, a new clutch (don't know where or who fitted).
-On first time away (700 mile round trip) it begun clunking, slowly worstening only when in gear (all incl rev) and
putting power to the wheels.
-I found the front gearbox mount was perished and was metal to metal - this I thought was
the clunk, as when it was first changed it stopped.
-After only about 50 miles or so more the box started jamming in 1st when stopped (see prev posts), and
with advice from here scraped the cash together for a rebuild through JK.
-Got box back and in, incl new spigot bearing as it was sent with the box with a note saying replace
as this was prob the original cause of gearbox damage.
-Done about 80 careful miles since and the clunk has returned exactly the same.

The clunk is a mid pitched clunk, speeding up with revs (but only driving, not out of gear or clutch in),
if that helps. But weirdly seems better going round left hand corners?!??!

Any help here much appreciated. If whatever this clunk was 1st is in fact the same I don't want to wreck another gearbox!!!!!

Thanks guys

[CovKid]

CV joint!

[lozhedgehog]

So glad you said that CovKid.

Just been out with father-in-law hanging over the open engine- listening.
He said CV joint too, I went under, pushed and pulled final drive, went out again and noise stopped.

New CV joints all round then.

Better than another new g/box eh - especially after all my cuts, bruises and swearing putting that
one in!!!!!

Thank you

[CovKid]

Possibly new CV joint. Depends how you're fixed for cash. Often a load of fresh grease in the joint will extend the life of CV joints a little. For sure thats what it is. You can soon tell cos if it makes the noise while you're out, pull over, give the shafts a tug to resettle them an noise will probably go temporarily. Fit proper splined bolts (nearly £2 each from VW x 24) but there a guy on ebay does some good quality ones for about £15 a full set.

Its nearly always the outer one and remember that when removing driveshafts, undo from gearbox end first - reverse when refitting.

[HarryMann]

Ohhhh my law... you didn't check the CVs originally... gulp!

So sorry you had bum advice, but have to say your description of clunking as when and where and how often not exactly fullsome!

Fit proper splined bolts (nearly £2 each from VW x 24)

I like the 12-point splined ones too but...
Hey, Hex socket caps, £7-05 per dozen from Brickwerks complete with those (essential) serrated washers
(£15 the whole sheabang)

Didn't even know JK did G/B rebuilds... thought Aidan did them all

As CovKid says, just squeezing the boot a bit can make that noise go away..

[lozhedgehog]

Thanks again guys.

Harry, the gearbox had deffo gone too, I could tell when I drained the oil off and there was more
shrapnel than mag-plug!!!!!!!! Also the fact that I could no longer get it into Rev / out of 1st and
struggled with the rest too. All gears seem sweet now

I got 12 of the bolts for gearbox end from JK when I replaced the box and will replace
the rest when I replace CVs.

The more I learn from you guys one day I'll be able to give advise too

[HarryMann]

Ah Ok, so bet it'll be nice to drive now then...

[lozhedgehog]

Oh yeh, she's much better.
Shouldn't get CD player volume button knuckle rash now either