Engine gearbox mismatch?

[chrisbarnard]

My van is 1990 Westfalia California origianlly 1.6td JX engine with 5 speed box.

About two years ago head blew on engine and I had it replaced with 1.9 diesel, which I was told was an ideal swap. I have since had numerous issues where I have doubted the garage who did that work and will never go back there again.

The gearbox seized in France last year and I found a replacement from the dealer I bought the van from.

Now having gearbox or perhaps diff issues again (back home yesterday on RAC Flatbed ;-(

I have taken a picture of the bottom of the gearbox which does not seem to fit to the engine. Surely there shouldn't be a gap? Click the picture to enlarge.



Any help would be appreciated. I'm beginning to wonder which garages I can trust now to sort this.

[mrdp]

Hi There . I'm not quite sure how the gearbox and the 1.9 engine mate like . I do know that the 1.9 aaz engine appears alot as a very good replacement for the jx engine. You usually save the sump from the JX and this should replace the sump from the 1.9 engine. I was under the impression that the engine was a direct fit onto the bell housing?? I'm sure someone with a bit more knowledge on this will be along soon, but always considered the 1.9 engine the straight forward swap when the JX died. Sorry can't be of any more help.Where abouts in the counrty are you? I am in gloucestershire and know a good mechanic that has a couple of vans himself and knows his diesels.

[toomanytoys]

Where in the country are you?? as that might help a recomendation..

Gearbox.. buying a used box is a lottery, with prob the same odds.. a rebiuld is the best option... Speak to Aidan

[chrisbarnard]

Thanks for both replies so far.
I am in Shropshire nr Bridgnorth.

[chrisbarnard]

I have a 2002 Passat SE TDi, the 'red' badge version with 130bhp. Engine code starts AWX.
What are the options regarding installing this engine (and gearbox???) into my T25?

Chris

[colinthefox]

[quote="chrisbarnard"]I have taken a picture of the bottom of the gearbox which does not seem to fit to the engine. Surely there shouldn't be a gap? [quote]

That picture looks about right, if the engine didn't fit it wouldn't bolt up at all. The oil drip looks a lot like gearbox oil to me, which leads me to suspect that the input oil seal has failed. That would be a good enough reason for gearbox failure. And it happened twice? That garage that you don't trust did install a spigot bearing in the crankshaft didn't they? Without it your input oil seals are doomed, and consequently as many gearboxes as you like to fit. Just a thought.

[chrisbarnard]

Thanks for that - makes sense.
The original gearbox knackered after garage replaced engine.
Replacement box lasted about a year, not many miles though - mostly to work and back about 10 miles a day.
Here is a link to a better picture - what I originally thought was a gap is in fact covered by a sort of brass gasket.
http://www.flickr.com/photos/cjbarnard/ ... otostream/


On my flickr page you'll also see that there is hole in the top of the gearbox that looks like it ought to have something in it.
Any ideas what is missing?

I have no idea whether there is a spigot bearing in there or not, it wouldn't have occurred to me to ask.

I had since taken it to a different garage when it was pouring fluids all over the drive and they found loose bolts all over the place, which they assumed was the cause. I think I will get them to take the box off and check bearing and seals etc. Hopefully box itself is not foobarred

Cheers for your support

Chris

[colinthefox]

.................and the hole is in fact in the bellhousing, and it's so you can check the timing. All good and normal. Does look very oily though! Yes there is a plastic plug that goes in it, but it's not an issue. If worried, use a cork.

[chrisbarnard]

Update:
have contacted local garage who will remove box, check for spigot bearing, change seals etc.

When we initially broke down the RAC sent a flatbed with only two passenger seats. There were four of us to travel. In fairness the first patrolman concluded that there were two of us as he noticed my sons bike in the van. He did not ask outright if there was anyone else and I didn't think to say. So my daughter and I came back to Shropshire and then I drove back to Birmingham to collect my wife and son.

They have agreed to come and move the van from my drive to the garage.

An honest mistake I think so fair on them for coming out a second time.

All booked in at the garage for Friday afternoon.

[docklad]

and?

[chrisbarnard]

Have asked garage to remove box and replace seals, change clutch if needed and advise on state of box
Fortunately they also MOT motorbikes so got my BMWK1100LT back on the road to use meantime

[chrisbarnard]

It seems that engine is fine but box is knackered, even beyond being an exchange unit for reconditioning.
It is also the case that the professional mechanic I paid to install the box did not fit a spigot bearing and hence why it is knackered a matter of months later.

You would hope that taking it to a 'professional' garage would be the best thing you could do. Apparently not.

Now going to be faced with a bill of around £800-£1000 to put it right AGAIN

[toomanytoys]

Unfortunately this seems to be a recurring theme ......

[chrisbarnard]

UPDATE
Found a replacement 5 speed diesel box on ebay for only £250 and £35 to courier it from kent to Shropshire. Absolute bargain!!

Garage have removed old box and found a huge scoring mark around the inside of the bell housing.
When the new engine was fitted should the original 1.6td flywheel have been used? Is the flywheel from the donor engine to big??

Chris

[docklad]

bump