gearbox crunch 3rd to 4th and 4th to 3rd

[avant-garde]

Hi all, my local garage has just fitted a new recon gearbox into my 2.0 Aircooled CU 1982 T25. I replaced the old gearbox because the 2nd gear jumped out every time I put my foot on the gas.

The new gearbox is a vast improvement but on changing from 3rd to 4th and vice versa there is a grinding sound

The scrap yard that sold me the gearbox assured me that the gearbox was noise free and smooth. 1st and 2nd are fantastic, 3rd and 4th there is a noise when changing.
I'm starting to think that the garage that fitted the gearbox didn't really take to much time with adjusting etc. A quick fit, take out for a test drive, works so-so and that was it sort of thing!

There is no way that that small local garage will take the time to fiddle about with it on the off-chance that it is wrongly aligned linkage because they are more interested in their MOT cash-cows!

My question is do you think this crunching may be caused by incorrectly aligned gear linkage - I read a minute ago on here:
Re: Renewing gear selector fork bushes - advice requested!
by Pootle
“how about I twist the front selector shaft ONE spline anticlockwise in the UJ so the rear shaft rotates slightly further clockwise when I engage first?” anyway what he did worked.

Should I do the same and rotate linkage? I don't really want to start taking gear levers out etc

On the defence of the scrap yard -I think if the gearbox I have was knackered then I would have heard/felt that in 1st and 2nd gear. They are positive that it was smooth etc.

Any advice would help.

[avant-garde]

Or could it be a worn out syncroniser ring?

[Aidan]

new recon gearbox

The scrap yard that sold me the gearbox

so which is it, a recon or something out of a scrappy that has previously been repaired and painted 'malecowpooh' black

noise from the gearbox when changing gear is unlikely to be a linkage problem, they either change gear or the don't if the linkage allignment is too far out
all these boxes suffer from cracked 3rd 4th synchronisers due to a design flaw

I don't do the Aircooled boxes but for further informed information on them contact Bears Motorsports in Birmingham

Second hand boxes often prove to be a false economy ime - but of course I would say that

[R0B]

Tbh mate.They wouldn't tell you it was faulty.As you would of walked away if they did.I wonder if they will offer you a refund if it is faulty.

The scrap yard that sold me the gearbox assured me that the gearbox was noise free and smooth

[avant-garde]

Yeah I know...but anyway here is the eBay listing wording and a picture:


Volkswagen T25 Gearbox
4 Speed manual off of T25 which had a 2 Litre Aircooled engine
Engine code is CU
No gear selection problems
No noises/ leaks
If you need any more information about this item then please contact John on: 077**08****
This item is collection only unless a courier can be arranged at your own expense and time.
Payment can be via paypal or cash on collection.

Why would they state that in the listing if it wasn't true? Surley any court case against them they wouldn't win.

"Second hand boxes often prove to be a false economy" yeah probably right but it only cost me £89.99. Just the luck of the draw I guess.

I've been in touch with BEARS Motorsport:

Once the transmission has been stripped we will give you a fixed price so you know what to expect.Once the price has been fixed we will require a 50% deposit with balance on completion.
Turnaround time is around two weeks,subject to parts availability.
Warranty - Rebuilt trans 12 months 6000 miles . Or if only fault repaired,warranty on fault only.

Seems pretty good.

Thanks anayway for the advice.
Kevin.

[R0B]

It wont be the first time a seller has claimed something to be in good working order on ebay.When in fact it isn't.Let us know the outcome of the strip.

[Ian Hulley]

By strange co-incidence I saw that item during my now my infrequent perusal of Ebay and thought to myself ... I would never buy anything from them, they couldn't even be bothered to undo the CV bolts, just cut the driveshafts off.

Ian

[billy739]

thats not a CU box , its a 1.6 petrol DH code or similar !

your gears will be totally out , your engine will rev very high - you may not be able to reach previous top speeds!

the garage would on needed to change the bell housing and possibly the input shaft( i think the 1.6 uses the diesel shaft!)

make sure you get all your old bits!

[avant-garde]

thats not a CU box , its a 1.6 petrol DH code or similar !

your gears will be totally out , your engine will rev very high - you may not be able to reach previous top speeds!

the garage would on needed to change the bell housing and possibly the input shaft( i think the 1.6 uses the diesel shaft!)

make sure you get all your old bits!

The garage fitted it okay, which was my initial worry - that they put it on so quick that they didn't take the time to align the gear seletor rod etc.

...the only difference with my CU gearbox and this one was the gear seleter arm? They took the gear seleter arm off my old gearbox and put it on this gearbox. Bell hosing went on fine etc. Apart from 3rd and 4th crunching works absolutely fine.

Can't hear any 'abnormal' high revs when I'm driving!

So out of curiosity - why do you think its a 1.6 petrol DH code or similar?

When put side by side it was exactly the same - (apart from the seleter arm)

I have Dellorto carbs so 70mph+ is no problem.

[billy739]

the box pictured is a 1.6 box , the dk is totally different main case , and hydraulic clutch is standard.

if this is exactly as your box then you did not have a dk originally.

look at the ribs on the top of the box- dk , 2.0 DK box has deep ribs as per watercooled boxes
http://www.ebay.co.uk/itm/Volkswagen-VW ... 0605987562" onclick="window.open(this.href);return false;

1600 DH and similar boxes have shallow ribs,
http://www.ebay.co.uk/itm/EARLY-TYPE-VW ... 45fd53c354" onclick="window.open(this.href);return false;

the balllever should be the same on bothj petrol boxes, but the diesel is differnt.

are you using standard wheels/tyres?
a 1600 petrol DH box will allow your engine to do 75mph @ 4500 rpm , 66mph @ 4000rpm
a 2000 DK box will allow your engine to do 82mph @ 4000 rpm ,71mph @ 3500rpm

as you can see quite a difference!

[avant-garde]

Thanks for pointing the difference out. They must have sent me a different one to what's in the picture then. I had a word with my garage there was no problem fitting the gearbox.

Using standard wheels. Don't have a rev counter or anything like that not even an oil temp guage ...just the dial that shows the speed in MPH.

What I'm going to do is send the original gearbox that my local garage still has up to BEARS Motorsport and get them to fix the 'sliping out of 2nd gear' problem.

I'll let you know how it goes.

Thanks again.