jim21070 2 Posted June 4, 2007 For a long while my GTi gearbox has had weak 3rd and 4th synchros. Recently however it has become a lot worse To the extent that I have had to re-learn the gentle art of double-declutching in order to get a smooth and quiet change Pardoxically, it only crunches on upchages into third and fourth. Downchanges are relatively OK and first, second and fifth are fine. Both oil and clutch are fine. It is currently filled with Comma 75W/80 as recommended for BE 'boxes. What is the problem? I'm guessing the synchro hubs are worn but my experience of any gearbox is zero. It is about the only automotive component I've never gone into Is it fixable by me in an economic fashion, given the rest of the 'box is in good nick or is it better in the long run to have a pro refurbish it? If so, who is recommended and at what ballpark cost? I'm assuming that good second-hand 1.6 'boxes are in fairly short supply these days but naturally, if anyone has one going spare.... Share this post Link to post Share on other sites
Miles 331 1 Cars Posted June 4, 2007 Sounds more like the spring clip that goes around the hub has broken, this is the most common reason as in all my yr's of box repairs I might have seen a handfull of bady worn hub's, The part cost's nothing but is a box strip to do it Share this post Link to post Share on other sites
jim21070 2 Posted June 4, 2007 The part cost's nothing but is a box strip to do it Thanks Miles On the face of it, a box strip does not worry me too much. Should be an interesting project Are there any traps for the unwary in stripping the 'box and are there any special tools needed? Share this post Link to post Share on other sites
luggy 13 Posted June 4, 2007 (edited) Hi Jim This link was posted before which I found quite helpful:- http://www.rallyparts.co.uk/cwp_change/ Edited June 4, 2007 by luggy Share this post Link to post Share on other sites
jim21070 2 Posted June 5, 2007 Thanks Luggy, it certainly is Share this post Link to post Share on other sites
Super Josh 4 Posted June 5, 2007 The proper Haynes 'Owners Workshop Manual' , as opposed to the sh!te 'Service and Repair' thing, has a good section on gearbox overhaul. Josh Share this post Link to post Share on other sites
jim21070 2 Posted June 5, 2007 The proper Haynes 'Owners Workshop Manual' , as opposed to the sh!te 'Service and Repair' thing, has a good section on gearbox overhaul.Josh I've got one of those Josh I threw my old red one away in disgust a few years ago. The orange one is very good and the gearbox section looks excellent. I'd forgotten the Orange BoL covered it in great detail so thanks for reminding me. Just looked at it I'm quite looking forward to getting my hards dirty on a gearbox! Share this post Link to post Share on other sites
jim21070 2 Posted June 5, 2007 Hi Jim This link was posted before which I found quite helpful:- http://www.rallyparts.co.uk/cwp_change/ That link is more useful than it first looks Luggy! I've had a closer look at the picture sequence with a view to determining the possibility of doing the job with the gearbox in the car. Miles and others on the FCF hint that it can be done The picture sequence is excellent and shows the output shaft can be removed in one piece without disturbing the diff Am I correct in saying that the 3rd/4th synchro hub is on the input shaft just below the taper roller beraring? If this bearing is removed, can the 3rd/4th synchro hub then be simply pulled off the shaft without disturbing the rest of the shaft? How difficult is the taper roller bearing to remove? Share this post Link to post Share on other sites
