Club 80-90 Forums

Folks

Ok just trying to gather some info on my hole problem.

1990 Syncro. Been driving well, sometimes a little difficult to get into gear but nothing too bad.

Problem seemed to start last week whicjh i initially thought was un related but am now thinking differently. Reversing down my drive i noticed a single clunk every morning, just one so thought it may have been cv or even something rolling around under seat.

Next issue was at an up hill junction. i came to a standstill with my foot on the clutch in second gear and running and instead of the syncro rolling backwards it just stopped as though the handbrake was on. then i pulled off and it seemed fine. it did this a few more times.

Then seemed all good until leaving work today.

started her up and got a horrible whirring noise which seemed to be as i was driving. didnt stop so i pulled over. Noise is there when foot is not on pedal and disappears when clutch is pressed. even when not in gear and clutch not pressed the noise is there.

Anyway got under the van and saw this hole. Ive looked in the bentlyand non page 35.105 there is abreakdown of the low gear housing. the hole is straight through the cover next to the reverse gear idler.
see photo(to follow)

Im now assuming the worst but hoping for the best. Hopefully the box isnt knackered and i can find a new cover plate if its repairable.

I suppose my questions are

What to do next?
Can this low gear housing be taken out on its own or is it a whole gearbox out job?

Anyone got any ideas on what might have punched the hole through.

Any advice greatly appreciated

cheers Ant

OH DEAR !! think you need to speak to Aidan .....

http://www.aidantalbot.com/live/" onclick="window.open(this.href);return false;

or try syncro spares..

If thats gone there will need to be some investigation as to why, + there will probably be loose bits that need tightening up..... Gbox out I recon... sorry I know its not what you wanted. The Last holed syncro gbox I saw was one that was bump started in reverse. as said Aidan will be along shortly

as if by magic the shopkeeper appeared...
actually the similarity is scary! maybe not so many bow ties and fezes though!

there's a hidden bolt in there that should be locktited in place, but from your description of the problem I'd venture it's full rebuild time, and with a new crown and pinion now costing £1300 you can't afford to take a chance on it - Jed did that and I had to use an angle grinder to take it apart
the intermediate housing maybe possible to remove in situ but if there's a problem then it may not be there are some tricks I have to be able to get them apart even if G gear is bound on the shaft, if you are going to have ago yourself then read the Bentley manual first don't just go in there
most syncros have had a rebuild/repair/swap of gearbox for a preloved one previously and some of the work carried out is frankly shocking, imho, and of course I would say that, but I was one of those customers once apon a time and that's why I ended up buying the tools and doing it myself
and of course that hole has let most of the oil out so you may have been running the box dry which is not a good idea
I have an AAN in here stripped I can rebuild to any spec you want but no other code boxes and no other ratio crown and pinions