Problems… is it the gearbox or clutch?

[crazyhorse]

So I was planning a trip to Cornwall on Sunday but I have big problems.

I got recovered the other night as I thought a cv joint had collapsed. When were loading the van on the flatbed in neutral it felt as if the van was still in gear and had trouble moving it.. I jumped in and kept my foot on the clutch and it went on…

I have changed the cv joint, but the problem is still there. When driving every rotation i hear a loud knock at the rear. And it feels like I am going over something… I know that sounds strange. I have put the van on axel stands in neutral and I can spin it freely then it stops??

Any ideas guys?

[crazyhorse]

To add to this… I start the engine. Freewheel backwards in reverse clutch down. Then it just suddenly stops like something is in the way. I lift my foot off the clutch and it goes through with a thud, spins around again then same again… very odd

[crazyhorse]

Here is a beautiful short film I made…
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[dcworm57]

Sounds like something has come adrift in the gearbox to me .
What does Aidan think ?

[Aidan]

Dylan
so in the video 1 wheel is on the ground ? and you are spinning the wheel that is off the ground ?

If that is the case then you have a broken gearbox, could be broken tooth (or teeth) on crown and pinion or broken tooth (or teeth) on a gearset, but the jamming in reverse is usually the pinion teeth trying to climb over remains of crown tooth

Cause is usually a very worn pinion bearing, usually proceeded by box becoming noticeably noisy, when you are driving it backwards the pinion shaft is moving backwards and tightening the mesh of the crown and pinion

Draining the oil may reveal some debris on the drain plug magnet

Looks like a 4 speed, and a search on Ebay coming up.........

[Mocki]

It also could be a bad cv joint , which one collapsed?
I had one once that would lock up but i cant remember if it only did it one direction or both , it was years ago on a scrap van i got for parts

[crazyhorse]

Hi Aidan,

Yes, the wheel I am spinning is off the ground and the other is on the ground…

Nooooooooo… I thought it was too good to be just a damaged cv joint…

So, I suppose my trip to Cornwall is over…

Right so options are… repair.. can it be repaired??
Second hand gear box? Or something as drastic as selling… I know you can’t answer any of those apart from the first one maybe…

Thanks for taking the time to reply

[crazyhorse]

It also could be a bad cv joint , which one collapsed?
I had one once that would lock up but i cant remember if it only did it one direction or both , it was years ago on a scrap van i got for parts

The one on the other side, but I did lift the other side up and it was doing the same as the other side

[Mocki]

Damn!

[davidoft1]

Plenty of used gearboxes about for not crazy money, it’s worth pulling the bell housing off to have a gander inside

[crazyhorse]

Plenty of used gearboxes about for not crazy money, it’s worth pulling the bell housing off to have a gander inside

Biggest problem with that is I’m not too sure what I would be looking at…by the sounds of it getting the box out in a public car park might be a step too far… I struggled with the cv joints… the van has been a rock but this is a right dilemma

[Mocki]

If you had the drive shafts off you were only half a dozen bolts away from dropping the box !
You’ll not need more than a parking space .

[crazyhorse]

I kind of feel that removing it is a bit out of my skill set… seen a box on eBay for 250, can I swap it out in a few days.. lord knows.. not sure what bits to buy also… assume I would need a clutch as the one on the van is close to going anyhow…

[Aidan]

Anything can be repaired but if I am right it will be very expensive, a new crown and pinion isn't cheap, yours might be re-useable but until you have the box out and remove the bellhousing and take a look no way of knowing - if teeth are broken then definitely not.
Draining the oil first will be diagnostic, see what you find. You need a 17mm hex tool, a Draper 3/8" drive one is nice but you might not have a 3/8" drive breaker bar long enough so consider something 1/2" drive like laser tool on Ebay Put fresh oil in the box before you fit it it is much easier, just make sure drain plug and reverse switch are fitted.
There is an article or 2 on the wiki about removing the gearbox and some tool/methodologies, people get quite creative working in limited spaces or without help; as long you can safely jack up the van and support it then getting the box out on a 4 speed wbx is pretty easy, helps to have a friend or 2 with you, if you are young strong and fit it can be done with muscle power (aka M0cki and Martin 20 years ago style, wham bam thank you mam), but for most peeps a trolley jack is most helpful. And a ratchet strap to support the engine when box is out to save tearing the engine mounts apart.

If you fix the van it is much more saleable, even with an unknown used box in it.

Check the code stamped on the box about 4" below the reverse switch housing, probably an ABD or DU if early - you want the same or the similar ABB or DT which are 5% quicker/less revs for same speed, they are all interchangeable

[crazyhorse]

ok, cool..

Right so a lot to chew on here..
I managed to change gearbox oil a few years ago so I bought the key then so thats one bit of good news,,

The big one for me is deciding where and if I should give it a go myself. I wish I had a driveway... Do I trust a garage local to me to to do it, and at what cost..I reckon it could be a full days labour, but they have the tools, space and knowledge..

I would source the box and clutch kit..

First thing is to get the box code and put the feelers out here if anyone has a second hand gearbox which could be more sensible than repair. 'very expensive' i imagine is over 1000 expensive?
I saw a detailed post by Paul itchyfeet about how to get the gearbox out so I reckon i could do it.  Putting a new clutch and refitting....maybe not