Gearbox rebuild continued.....

[richandhazel]

Rich , been a while since I have done one of these boxes, but I think that the 1st gear syncro is the same as 2nd (or was it 3rd ). Dont "lap" the rings in, make sure they arn't bottomed out and the hub is in good order and the selector fork is not worn.
Steve.

Cheers, Steve
I'll check out the part numbers and see what I make of the synchro's. If it does turn out that they are the same, would you recommend re-using a synchro from another box, or would you always change them as a matter of course........I believe you have to change them as a complete assy as they're a matched part.
I had an idea that we might be able to use the synchro from my spare box.....unfortunately it has totally bottomed out and is worse than the one I'm repairing
Selector forks are suprisingly good

[richandhazel]

You cant magic box casings out of thin air can you rich?

Mine had 3 diff rivets go through and was good fun I must say.

I've got a casing you can have if you want, however, its not perfect. There is some internal damage where the lower pinion bearing broke up and bits of bearing went into the diff. Its just internal scoring in the cast aluminium and is structurally sound............as far as I can remember anyway, I can double check/take photo's if you're interested.

[Helios_Blue_Valver]

This is a continuation of the thread that started in the 'sure you don't want a mk2? go on, kick me!' thread...............

I worked for a g/box reconditioners for a while, most recon g/boxes just needed bearings and synchro's. If it was more than that (gears etc) they were not viable and the good parts used for spares. We used to buy a lot of low milage g/boxes out of crashed cars with broken cases for most of the internal parts.
Steve.

Thats what I figured. Out of the 5 gearboxes I have, 1 is completely knackered and I plan to use for spares, 2 is suspect and I shall probably use for spares, 3 is fitted to the cabrio and has a 2nd gear synchro that is showing signs of starting to wear, 4 is fitted to my project Mk1 and is believed to be OK, but won't know for sure until we run it and no.5 is a good low mileage box that I bought from old_boy.

On top of that I'm trying to fix MK1_BOY's for him........I've almost completely stripped it down but have come against a hurdle on the very last bit.......removing the third/fourth gear synchro.........its tight as f_ck even having heated it. Looks like I might have to purchase a  proper bearing puller set, maybe something like this:-



That would have made life very easy had I had one of them from the start.
I think I'll have to wait and see how much a new synchro assembly is going to cost to see if its all worthwhile. I'm hoping that the parts are reasonably priced from VW and that once I have all the necessary tooling I'll be able to make lighter work of repairing these gearboxes in the future.

What do you reckon???

Rich, Did You say You are an Aircraft technician? I am a Jet engine mechanic. I know when I worked in the tear down and rebuild shop we had gear pullers for secondary power unit bearings and pump bearings. I work in engine testing right now and don't have access to them anymore. just a thought. You may be able to borrow them from work for a weekend or something.

Brad

[richandhazel]

Yeah mate, you're right and back in the days when I used to work in the hangar and we had workshops I too had access to all that sort of equipment.........and more.

Unfortunately I now work out on the ramp and these days I'm lucky if I can get a tyre px gauge!

[mk1]

Quote from: richandhazel.
would you recommend re-using a synchro from another box, or would you always change them as a matter of course.....
If the syncro ring is in good shape, I would have no problem using it again. If money is no object then new parts would be the 1st choice, but in the real world, use what you have.
Don't forget to replace the clutch pushrod bush and seal in the 1st motion shaft.
Steve.

[mk1]

Gear box link for those who may need it.

http://www.elcats.ru/audivw/vag5.asp?subm=%CF%EE%E8%F1%EA&btsnr=087-00&cid=7

Sure that you have this, but it may help. 2nd seems to be the same as 3rd.
Steve.

[mk1]

Just noticed this after posting.....
 
4th - 5th syncro are also the same part no. Use the 5th one out of the spare 'box as it will have done the least work.
Steve.

[Helios_Blue_Valver]

Yeah mate, you're right and back in the days when I used to work in the hangar and we had workshops I too had access to all that sort of equipment.........and more.

Unfortunately I now work out on the ramp and these days I'm lucky if I can get a tyre px gauge!

lol. I know the feeling. then if you can get a tyre pressure gauge you can't get ahold of a nitrogen cart with full bottles to service the tyres. I'm in the same boat myself.

[richandhazel]

Cheers Steve. Looks like a lot of the parts are interchangeable.............it may be that we only need to purchase the tooling.  

Just noticed this after posting.....
 
4th - 5th syncro are also the same part no. Use the 5th one out of the spare 'box as it will have done the least work.
Steve.

[muppetsport]

question about gearboxes.

is it common for the diff to be dead in a mk2 gti with pretty much 200k on the clocks??? ive just had to change the gearbox and a friend who works as a mechanic for the local vw dealer says its quite a common thing.