Serious gearbox problem - help / advice needed

[LHD_Kid]

Hi guys,

Just swapped a good 5-speed gearbox for another 5-speed box, supposedly good... (don't ask why...)

The newly installed box was used in a car and just stored the correct way up prior to me simply changing the fluid and installing...

Now:
1st gear is a little reluctant to engage, but goes in ok...

2nd gear, engages easily, but pops straight out, crunching the box

3rd gear crunches on engagement, unless you double de-clutch and engage VERY slowly
4th 5th and reverse work fine.

Clutch feels fine....

I thought this was symptomatic of knackered 2nd gear hub and 3rd gear syncro. But after talking to the guy who sold me the box (very well known forum memeber), I am wondering if there is any kind of adjustment which could affect this?

I know the fixing to the underneath of the shift lever would not really make so much difference, but there is a little box with a bolt sticking out by the transmissin end of the linkage... could this have any effect? I notice this bolt is rounded off slightly due to some adjustment in its earlier life. (on my own box this bolt is fresh as a daisy...)

Can this be adjusted or have I been sold a lemon?

Thanks for any help or advice....!

Chris

[LHD_Kid]

I'm reasonably convinced that the gearbox is simply no good, I have spoken to a local friendly transmission specialist, but over the phone and no specific knowledge of this precise gearbox, etc.....

But..... this is a trusted forum member and I don't believe he would knowingly sell me a knackered box...

Any thoughts or ideas guys?

Cheers

Chris

[Topher]

I'm no expert but I'll post just because no one else has

Usually:

car not going into gear or grinding while going into gear is bent shifter forks, or junk synchros.

Car not staying in gear once there bad/worn synchro springs not holding, teeth missing etc.

Hope that helps a little,
Chris

[Pirvu Eugen]

I am sorry...but from my experience in Audi quattro gearboxes...the only thing wich can let a lever to jump out from one speed is a worn syncro hub and gear or bad adjustment off the levers. The lever is out of question on this specific gearbox because is 1 simple lever and iff is wrong adjusted, then will jump out from all the upper speeds or lower speeds...1,3, 5 or 2 and 4....iff is jumping out only from second....then...for sure, is the hub and gear worn out. Probably, from what you say, the secon gear hub gear and syncro are gone and third gear syncro is gone. The clutch is out off question because will crunch on reverse (this speed is without syncro for this ARV gearbox).
On this forum are members with better knolege on gearboxes then me...as Henka..for example...he helped me alot with my quest for the best gearbox...maibe they will have another idea.... and will say that i am wrong...but...from my knoledge....the gearbox needs some parts!
All the best!
Eugen

[newsh]

Could be the box was ok in the car but the lever got a hefty bang while being removed or in transport.

[Pirvu Eugen]

Will not explain the fact that is jumping only from second...should jump from fourth aswell...

[pixsaudisex2]

remove the selector. Knock it into second gear with your hand on the gearbox an see if it jumps out then.If you can get to it,

[Pirvu Eugen]

I have installed the same gearbox in my 85 coupe with a home made lever, the gears working oposite...first was left and down and second up...and so.....but i have never had jumping out speed. And it was indeed a verry bad machined lever

[LHD_Kid]

I have installed the same gearbox in my 85 coupe with a home made lever, the gears working oposite...first was left and down and second up...and so.....but i have never had jumping out speed. And it was indeed a verry bad machined lever

So, essentially, what we are saying here, is that there is more chance than not that there is something wrong internally in the gearbox...

I am happy the shifter is not damaged or bent, with the engine not running gears engage quite easily...

Seems then, I have a car stuck in a different country, for which I have to pay a mechanic to re-install my own gearbox...

Pity I renewed the fluid in the broken one too, at quite a cost...

Thanks for the replies guys - I was clutching at small chances of an adjustment

[Pirvu Eugen]

Is not an easy job to change a quattro gearbox....but...iff you succeed to change back to your old gearbox without changing enything else...and is working as usual..then you know that the new gearbox is the culprit.
All the best!
Eugen

[AndyP]

Hi guys,
Just swapped a good 5-speed gearbox for another 5-speed box, supposedly good... (don't ask why...)
Chris

Somebody had to ask, but why?

[LHD_Kid]

Somebody had to ask, but why?

Honestly? because I was "told" the box was good .... I got subframes, box, prop, diff and wishbones, to prepare (new fluid, bushes, centre bearing, cvs, paint, etc) along with new rack and air-con pump, to simply change over the whole kaboodle in one hit... turns out, would have been better off replacing prop centre bearing and leaving everything rusty and slack, but workng....

[LHD_Kid]

Well, small update.... I drained the fluid out of the box currently fitted to the car and, filtering through some stockings..... found lots of pieces of what looks to be syncro ring metal coming out....

I think we can say that I have definitely been sold a completely knackered gearbox....

But, at least I have my old one to swap back in, which should be cpmpleted tomorrow.....

I think Eugen might well be right - if it drives perfectly with my old one, the evidence is pretty damning.....

Chris

[LHD_Kid]

OK, so, my original box is in and it drives fine... stays in each gear, no crunching... only real noise is coming from centre diff (on take up), which is the main reason for thinking about a swap - it's really not very bad, but wanted everything perfect...

So, looks like my forum sourced used "good" box was basically a drag box.... 1st is noisy, second gear hub and syncro is knackered and 3rd gear syncro also gone (most of the syncros came out the drain hole I reckon.....

I am going to PM the seller as this is really not good, lets see what he says....

Chris

[Pirvu Eugen]

Glad is sorted now!
About the clunk.... is possible to have driveshafts worn or engine...gearbox mounts. Just a thought.
The center diff...hmmm...can make that noise but expensive to change.
How much play was at output flange from the box to the propshaft? Iff is to much..then is possible.