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Gearbox Again! 1St Gear Sometimes Doesn't Engage And 3Rd Somtimes Hard To Find

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#1 Moshtaraq

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Posted 26 October 2021 - 07:36 PM

Hi again,

 

 

I posted this already a couple of months ago but here we go again...

 

I rebuild my gearbox because it was a bit crunchy. New synchros, layshaft, bearings, diff.... the whole works.

Now I have the following issues:

  • Won't go into 1st sometimes. It's like pushing against a wall. Shifting in other gears used to work but doesn't lately
  • When going from 2nd to 3rd, I sometimes briefly have the same problem as with 1st.

A mate told me that it could be the selectorforks. I saw the price of those and really want a second opinion on that :D

 

Could it maybe me the lever cranks?

 

Any advise is welcome!



#2 gaspen

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Posted 26 October 2021 - 07:41 PM

Clutch bleeded ? Clutch arm adjusted ?



#3 Moshtaraq

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Posted 26 October 2021 - 07:44 PM

clutch bled and clutch throw also adjusted. Verto clutch so not a lot of adjustments



#4 floormanager

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Posted 26 October 2021 - 08:04 PM

Did you measure the clearances on the selector forks?  I learnt from Spider of this parish told me to change if above 9 thou of an inch.  Here's the part of the manual he sent me

 

 

Attached File  forks.png   48.43K   0 downloads

 

Bit late now if your box is in. If was selecting okay before your rebuild, then I'd focus on the clutch.  Any wear in the pedal clevis pin?



#5 Moshtaraq

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Posted 26 October 2021 - 08:06 PM

thanks floormanager, never heard of that! Will check that when the engine is out.



#6 floormanager

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Posted 26 October 2021 - 08:14 PM

Does it crunch going into reverse?  If it is, then your clutch is dragging.



#7 Moshtaraq

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Posted 26 October 2021 - 08:17 PM

no reverse is fine!



#8 floormanager

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Posted 26 October 2021 - 08:25 PM

no reverse is fine!

Ahhh



#9 Spider

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Posted 27 October 2021 - 02:23 AM

I'd suggest here, assume nothing here, treat it all as 'suspect' until checked out.

First, see if the problem is in the Shifter itself or in the Gearbox. I'm suspecting there could be an issue in the Shifter given that he 1st and 3rd issues are on moving the Gearstick forward. It maybe worn in a way that when 'hanging' under the car, there's something that fouls up, so be mindful of that when checking it out.

I doubt there's an issue with the Clutch given it goes straight in to Reverse without Grinding.

 

I doubt worn Selector Forks are the issue here. Usually, when they are worn, it won't fully select a gear to the point where the Synchro Hub Detents are holding and so it will jump out of gear. After doing this a few times, you still need to replace the selector fork and a gear too, so, as expensive as they are, if it's out of spec, it's needed.

 

Just thinking out aloud here, if the issue is internal to the Gearbox, the Rod that the Selector Forks are mounted on could be bent, but given it was OK at first, this is not likely, however, refer rule No. 1 - assume nothing.

 

The Paddle on the Shift Input Rod could be loose, the Syncho Hub itself is worn. When this happens the outer track tends to lean over instead of sliding. There could be something foreign in the Gearbox.

All the same, I'm gravitating back to the Shifter here. I can't think of anything (other than a Bent Selector Fork Shaft) that's internally common to both 1st and 3rd gears.



#10 Moshtaraq

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Posted 07 November 2021 - 11:36 AM

Update: I drove it again today and noticed that the third gear problem is an issue in it's own. When going in 3rd or 4th, when going to far to the right, it goes into the reverse slot. I don't know if this makes sense. I had a similar issue on a vw t3 and we replaced the pushdown mechanism that blocks the reverse channel.

The shifter itself has to come out for that.

That leaves the difficult to engage 1st gear

#11 whistler

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Posted 07 November 2021 - 03:47 PM

I can suggest 2 things.

If you've not used the roll pin for the rod connector and used a nut and bolt then it could be the bolt head is fouling.

 

If you have used a roll pin then check the holes in the connector and the rod for wear. Had this happen to a friend recently. He drilled the holes out and fitted a larger diameter roll pin.



#12 Moshtaraq

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Posted 07 November 2021 - 04:16 PM

I used new pins the last time but it's worth a check.

 

by the way I fitted a new 1st gear and new synchro rings



#13 Spider

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Posted 07 November 2021 - 07:02 PM

OK, good work on getting down to tin tacks on 3rd gear.

You may find here the bottom of the gearstick worn or the housing maybe mis-aligned.

 

Regarding 1st gear, one thing I did forget to mention in my first post is that when stationary, these gearbox can be hard to get in to 1st. If you select 2nd and then 1st, they usually slip right in. I'm not sure if this is the issue you are seeing ?



#14 Moshtaraq

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Posted 07 November 2021 - 07:12 PM

for first gear, it sometimes helps going in 2nd but not always. What is the cause of that?



#15 Moshtaraq

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Posted 03 December 2021 - 04:56 PM

Do you guys have any more tips for me? I planned on taking the engine out the 20th of december.







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