Gearbox, Diff or cv joint failing??

[nevill3]

I have had an unwelcome whine from the van for a while now, I don't notice it in the first three gears but it is really noticeable in fourth and fifth but only when the accelerator pedal is pressed, as soon as you lift off the whine disappears. The noise is reminiscent of the sound I used to hear when I used the local bus service or a little like the noise when you reverse quickly.

Today I placed the van on axle stands and started the engine and went through the gears (without revving the engine) The wheels spun as expected and I videoed the whole action. The noise coming from the gearbox/drive shafts/CV joint can be seen and heard by clicking the image below



Does anybody have any suggestions as to what the noise is that can be heard on the video, it sounded like very noisy gears mashing together to me!!!

I have recently changed the gearbox oil and added a friction reducer(slick50 type thing). Here is a picture of my sump plug "tree"



Any suggestions or if anybody is near the Lake district that would like to come and have a listen to help with the diagnosis please get in touch.

Thanks
Nev

[New Kentish Campers]

I would guess that Aidan would be the best person to ask as he's the gearbox guru man; it does sound a gearbox type noise to me but I'm no expert! I suppose you could try disconnecting the driveshafts so as to isolate the cv's so that at least would be telling you if it is those or not.

[Ian Hulley]

What engine is it ? I ask because much of what I hear sounds like a d****l engine

I know Aidan doesn't 'do' aircold or d****l boxes.

Ian

[California Dreamin]

It is difficult to tell anything off the video as the wheels are not loaded so all you are getting is backlash through the transmission (chattering through gears and joints).
However, the whine in 4th/5th could be rather more serious as this implies a support bearing/syncro bearing failure in that area.

Not wishing to put words into Aidan's mouth here but I know these things need dealing with straight away BEFORE major damage occurs to the mainshafts and gearbox casings, many of which are obsolete. What Aidan reports is far too many owners taking the gearbox past the point of no return and main components being UNSERVICEABLE..basically rendering the gearbox as scrap.

Martin

[nevill3]

Thanks for all the input guys and gals, it is a 1.6d non turbo.

I guess I need to take it to someone who knows what they are listening for. I didn't know Aidan doesn't do diesel gearboxes......He was going to be my first port of call if it turns out to be a gearbox fault. I may have to look somewhere nearer to home if Aiden cannot repair it for me. Does anyone have any suggestions as to who could recondition a diesel box or supply a decent reconditioned one.....I realise just swapping the box for another one that hasn't been reconditioned is just asking for trouble because all the boxes are getting a little long in the tooth now.

I will get a video of the "whining noise in 4th & 5th and post it up when I am next out in it.
Thanks again.
Nev.

[Aidan]

I do diesel boxes just not the Aircooled ones
if you have the late diesel box with the single ball selector I do them just not the ones with the 2 ball selector as that is an Aircooled box with a diesel bellhousing and input shaft, used upto Dec 1982 production of the early diesels

your plug at last change is fairly big with some sludginess on the stem, ok if it was 10 years since last oil change not good if it was only a couple of years, if in doubt drop the oil and see what the plug looks like now bet it's biggerthan it was last time or some bearing needles on it

[nevill3]

Phew..thanks for clearing that up Aidan, I remember reading somewhere that you said a gearbox should almost be silent so I am fearing the worst, how long is the wait for your services at the moment?

My van was built in April 1983 (according to the Brickwerks Vin Number gizmo) and so is hopefully one that you deal with, I will have to check on the code just to be sure. The last gearbox oil change before I did it is unknown so I think another check is in order to see what is on the plug after 12 months but less than 3,000 miles of use.

Thanks again
Nev

[nevill3]

I have just been under the van and I have DX code gearbox possibly with the numbers 4 03 but that was all I could see so it could be 4th March if the Bentley codes are correct.

If anybody has a newly reconditioned DX gearbox that they would like to sell please let me know!!!

[nevill3]

Just a quick update,

After taking Aidans advice and dropping the gearbox oil again and finding a large Christmas tree of filings and grey sludge on the stem of the drain plug, I decided now was the time to get the box reconditioned, unfortunately Aidan couldn't fit me in in time for our annual trip to Cornwall so I was given a recommendation from my local independent VW garage for a place at Cleckheaton (Bradford). I booked her in and drove the 70 miles very carefully, TWO days later and I got a call to pick her up, they had the correct gearbox in stock so just swapped my poorly one for a nice fully reconditioned one. When I went to pick her up the guys who did the repair said that mine had worn through the "Case Hardening".....I mentioned that I was surprised to find that they had had a gearbox in stock and they said they often dealt with T25s and so had a stock of reconditioned boxes! They can also help with Syncros too.

Here is a link to them, Cleckheaton Gearbox & Clutch, I was really pleased with their knowledge and service and so am happy to recommend them.

Nev.

[CovKid]

Mixed reviews though:

http://www.bview.co.uk/listing/0140549/ ... re-in-bd12" onclick="window.open(this.href);return false;

[nevill3]

I found the mixed reviews after I had booked my van in, but I had a very good experience with them.

After I found the reviews I was a little worried myself, but felt that the service I received merited a mention on here. I had been searching for a gearbox replacement and thought if others were in urgent need of a gearbox then CG&C might be able to help them too.