Did I Destroy My Gearbox?

[wicked 103 3 Cars]

I just prepared a new td box for my pug.

Cleaned it, resprayed it, fitted a LSD and all I had to do is change the Xantia control lever for a 205 lever.

During the change the axle sank in the box. I got it out again, but it seems I cannot select the 5th gear and reverse....

 

 

 

Do I need to take the box apart (pls say no) or is there a way to fix this???

[Anthony 1,003]

Normally, you can get it to engage with the selectors properly if you give it a few goes putting it in and out.

 

Not sure if there's a more scientific method though, or whether it's just a case of trial and error as I've resorted to in the past.

[Paul_13 212 1 Cars]

Thats a common problem when doing this. You can take the diff housing off and diff out and feel in there towards the top and click the arm back in place.

 

Other option is to do it from the top and means fishing about for it to click back in. As Anthony says. P.s. cheers for the free heater blower

 

You haven't destroyed it.

Edited August 10, 2011 by Paul_13

[wicked 103 3 Cars]

So it can be fixed with putting it in and out? Don't feel like trying it for hours if it's known that you cannot fix it that way...

[pug_ham 244 3 Cars]

All you've done is when it dropped it fell out from between the fork so it only moves the internal arm in one direction,.

 

As Paul says you can correct this by taking the diff cover off & feeling inside the housing for the lever / fork to relocate it correctly.

 

You can also sort it by the method Anthony mentions but tbh if the box is out of the car then it's less than 30 minutes to do it by taking the diff cover off & far easier to get right first time.

 

g

[SurGie 54]

Are you going to use the clip in VTS type pin to reattach it or are you going with the standard 205 type of pin ?

[wicked 103 3 Cars]

Donno what the VTS type is, but this the pin I use (kind of double pin):

 

 

 

 

I think I'll take the diff off, since I didn't torque it yet and it's still waiting in a corner....

 

 

BTW, there was no gasket at all between the box and diff casing. Won't it leak when I put it together?

[welshpug 1,657]

you need to use some rtv or wellseal, its a metal to metal joint like the gti6 cam carriers

[SurGie 54]

This is how i did mine, i made sure the mating surfaces are cleaned with degreaser wipe and flat all round with a Stanley knife blade. Then used some good quality RTV and no less, mine was the clear stuff for neatness. Then i fitted a new 'O' ring where the speed gear housing meets the diff, some dont do this then wonder why the gearbox is leaking from the driveshafts. I also put some grease around the lips of the drive/S seals for a good seal.

 

Sorry, i got confused about the pin, i was thinking of the clutch arm at that time

 

I used the VTS pin spring clip because i had bent the 205 clutch arm pin

[wicked 103 3 Cars]

And we're back in business!!! Taking the diff did the trick; you can see how it works and I got it fixed in a minute.

 

Tnx!!!

[Paul_13 212 1 Cars]

Nice glad that helped