Noisy Gearbox an Running Warm

Post by **Bendyknees** » 22 Jun 2007, 10:03

Have just driven 500 miles back from cork ROI in 1 day(on a splash over a tankful

) The 1.6d was singing like a canarie(wit a sore throat)an was happily cruisin around the 60 mark

got caught in masses of traffic on the M6 but the joys of a van in a traffic jam

Only thing was the van seems to run a bit hotter than it used to,not in the danger area but up to just past 3/4 mark,i turn on the internal heater for a few mins an the guage drops to near halfway an is ok for a while. I fitted a shiny new rad to her at the end of last year an since then not a drop of coolant has been used.Has been bled.The pump belt is not new but has good tension,an there is noise that i can hear from the pump(but then my exhaust rattle is virtually deafening!).So do i change the pump and belt?
Secondly after nearly 6000 miles on rural ireland roads wit their hills an bends my gearbox seems to have seen its better days, its started grumbling at me on deceleration in 3rd but if i hold the gearlever back just a smidge its all quiet

Wats the score wit rebuildin these beauties

An finally my ruddy exhaust rattle

Changed the box last year as the baffle had broken an was makin a racket, same thing is happenin this year! Do i reweld the baffle or just take it out an have a deepthroated wagon

the box is still shiny!

Incidentally it sailed through the emmisions test this mornin

As well as the rest of the test

I feel quite smug

Post by **Hacksawbob** » 22 Jun 2007, 10:27

PM Beaker (Aiden) he is an 80-90 Gbox rebuilder

Post by **SplendiferousII** » 22 Jun 2007, 11:05

The 1.6d is certainly an underrated motor & boy are they economical - but boy are they slow aswell.

My temp gauge hardly moves off the stop around town and only just gets out of the orange zone on the Motorway - funny thing is the faster I go the higher the gauge rises - weird as I'd have thought the cooling would be better at speed.

So seems a bit high Ã‚Â¾ to me when mine hardly makes 1/8th - have you tried flushing the system ? hose pipe up one end?

As far as the gearbox goes, the 1.6d does not make enough power to produce any wear and tear and if holding the lever back makes the noise go away I'd say the box was ok and the linkage is in need of some TLC only.

Try changing the gearbox oil - and when you do so check the oil for any nasties - mine had ball bearings etc in the oil, which caused me great concern, but that another story - don't panic if you do find some.

And yes weld up the exahaust.

Post by **wasserleaker** » 22 Jun 2007, 18:59

Don't panic if you find ball bearings in the drained oil? ! are you trippin?rollers from what were previously a roller bearing in my gearbox oil signified a shaggd g/box and a rebuild.

Post by **Bendyknees** » 23 Jun 2007, 17:01

Just been out giving the van a service and once over. All seens in order and it didnt loose a drop of water on the run back. Re-bled the system again just to be sure.Have been through my history and it seems i fitted the pump and belt just over a year ago(and i even splashed out on genuine bits!

) So wat could it possibly be?(apart from me pushin it too hard, i am well loaded)

Post by **SplendiferousII** » 24 Jun 2007, 08:27

wasserleaker wrote:Don't panic if you find ball bearings in the drained oil? ! are you trippin?rollers from what were previously a roller bearing in my gearbox oil signified a shaggd g/box and a rebuild.

If I'd found "Rollers" in my oil - yep I'd panic too. I panic'd when I found "Ball" bearings in mine.

But its very common to find balls in the Gearbox oil on some models as the gear selector linear bearings fall apart.

It's so common aparently that in 50% of cases wher the gear box oil is dropped for service, balls are stuck to the Magnet.

He already has noises I didnt want him to panic over a couple of balls. When it might be an easy fix or even ok if left alone.

Post by **wasserleaker** » 24 Jun 2007, 11:10

didn't know about the selector retaining 'balls dropping' prob! Splendiferous, wonder if they can move and stick, cos sometimes mine is a bit reluctant to come out of 3rd, i checked carefully for cracks in the notches in the synchro hubs when i rebuilt it, which apparently can crack and eventually cause sticking in one gear, but they looked fine, so dont think thats the cause. got major gearbox paranoia cos it was a few months wasted trying a 'recon' finding out it was duff, taking it back, getting a refund, rebuilding mine, did it so often i got it down to a fine art in the end taking out/putting in that bloody g/box!

all in winter too!
dont want to be doing it again for a very long time

Post by **Aidan** » 25 Jun 2007, 19:40

holding in gear via the shifter will wear out the selector fast - the moving back and forth of the gearstick is the pinion/mainshaft moving in the case ina way it wasn't intended too. Give it an oil change and see how furry the dipstick is but I'd suggest it's rebuild time from what you describe.