Diesel 5spd Gearbox taken out but is it broken?

[darrell]

1987 1.6D converted panel van, 5 speed, gearbox code number appears to be ABR 308 7

Hi Folks,

Had some gear problems recently but didn't know if it was the linkage, the gearbox or the clutch.

Gearbox is now out and having a play with the selector I think I can only find 4 of the 6 positions.
I'll try and add photos or video but for now I have some measurements - not sure if gears closest to the gearbox are high or low gears as I forgot to look before i dismantled it...

I have gears going forwards and backwards closest to the box (shaft is 13mm out from gearbox casing)
I have gears going forwards and backwards 10mm out from the one above
I can then pull the selector out another 10mm but can not move it forwards or backwards

Here's the video
http://www.flickr.com/photos/25805158@N04/6245769891/" onclick="window.open(this.href);return false;

The last time I drove it I reversed out of a driveway, drove in 2nd and managed to find 4th which i stayed in all the way to it's current driveway (had to start and stop at about 5 traffic lights which was fun) - so in theory I found the 3 positions, but out of the van I can only get 2 (i think)

Does anyone know the positions of a 5speed box?

Todays job is to take off the clutch for inspection - any tips for what to look for here too please?
UPDATE 1:30 it's off, looks solid, plates are 3mm thick, grooves 1mm deep - seems plates alone are not available, GSF said 220mm kit is £97, Brickwerks have 215mm suits all diesels for £97. Does 5mm make a difference?

At least it's sunny

Thanks
Daz

[Aidan]

broken 4th 5th synchro hub

[Aidan]

"thanks for the diagnosis Aidan"

[silverbullet]

Some people just can't take the bad news mate!

[darrell]

Sorry - Thanks Aiden

when your £700ish excluding transport quote for a rebuild is nearly half the cost of the van - that it is bad news.
if the van was in better nick it would be worth the investment but for now it's 2nd hand ebay etc for me.

When I find my "Van for Life" so to speak I'm sure I'll be in touch.

Cheers

[petermoore]

I have a 4 speed box I might sell. Minus bell housing. that is a little awkward to get into 3rd changing down from 4th. but is perfectly useable once you get used to it.

[Aidan]

I have a 4 speed box I might sell. Minus bell housing. that is a little awkward to get into 3rd changing down from 4th. but is perfectly useable once you get used to it.

same fault as the op's probably, 3rd 4th synchro hub cracked and breaking up, eventually it will cam and jam in gear or neutral as per the video above

this is the most common failure mode for the 091/1 094 family of gearboxes, post september 1989 they were fitted with a hub with radiused corners on the keyways that is less likely to crack, but still can be an issue, the only real solution is better quality steel or thicker and making it thicker meant redesigning the entire box so was not an option for VW
be aware the aftermarket Italian made hubs with the 'heat treated' radius cornered keyways are rubbish they crack quicker than the originals

I use Heavy Duty hubs made by Weddle from T300 which incorporate additional oilways for better lubrication or genuine VW late style ones

[petermoore]

I just thought it might have been a quick cheap solution for the time being