[Mk2] [NA] Rev5 Gearbox rebuild.

[MR2Simon]

Hi guys

My MR2 is pretty amazing already and driving really sweet, apart from the gearbox!

Hard accelerating is producing some nasty graunching between gears and I'd like to sort it out, especially with the next 12 months that are planned in for it, a lot of charity based fun. I've not yet been officially announced but filming has already started!

www.lemons365.co.uk It would be great to see some of you guys supporting me and the car as the year and the challenges progress and in my quest to raise some cash for good UK causes at the same time!! I'll post up the Facebook links and stuff when I'm properly allowed to...

As such I'd like to rebuild the box, probably do a bit of a blog of it too as I'm going along..... As such I'm after a bit of advice from anyone with rap knowledge on the subject, of where best to go for the parts needed, syncro's etc, and for some practical hints and tips!

On the plus side, I've read today that the Rev5 came with a LSD as standard. I'm hoping to confirm this when I get home, early next week, with a check of the gearbox code. Info from the link below....!

www.roguemotorsport.co.uk/mr2challenge/mk2guide.htm

Any hints and tips greatly appreciated. Probably do a bit of work with the engine mounts while it's out to take some of he play out of the drivetrain... Got some ideas in mind so watch this space I guess!

[Peter Gidden]

Check out the relevant parts of Karl's or Ash's build threads for some gearbox info.

[MR2Simon]

Cheers for that. Do you have links to them as I've no idea who they are on here as far as their forum names go so searching for the threads will be a complete nightmare . Thanks

Just come across this info too....

Anyone tried it with success?

SYNCRO's CRUNCHING?

Thanks for MR2OC, USA. For putting me on to this,
I thought our synchros was shot especially in 2nd gear.
Then found out you can adjust the engagement point of the clutch under the pedal
you can see in the picture where the adjustment point is.
you need a 12mm spanner, unlock the nut & turn the rod out till you can feel it against the master cyl, then lock the nut back up.

now it is so easy to get into & outof gear.

There a Rev5 gearbox up for sale at the moment for not a lot of money but he's saying it's not got a LSD, where as in other info I've found it states all Rev5's had an LSD as standard and indeed t does seem to be tricky spinning an inside wheel on mine however I've not pushed ridiculously hard but have been pressing on a bit and never even a slight squeak from the rear tyres....[/quote]

[Peter Gidden]

Cheers for that. Do you have links to them as I've no IDE who they are on here as far as their forum names go so searching for the threads will be a complete nightmare . Thanks

I'll find and post them later.

Just come across this info too....

Anyone tried it with success?

SYNCRO's CRUNCHING?

Thanks for MR2OC, USA. For putting me on to this,
I thought our synchros was shot especially in 2nd gear.
Then found out you can adjust the engagement point of the clutch under the pedal
you can see in the picture where the adjustment point is.
you need a 12mm spanner, unlock the nut & turn the rod out till you can feel it against the master cyl, then lock the nut back up.

now it is so easy to get into & outof gear.

So the guy has adjusted his biting point correctly. All cars should have their biting point correctly adjusted. He's obviously a numpty.

There a Rev5 gearbox up for sale at the moment for not a lot of money but he's saying it's not got a LSD, where as in other info I've found it states all Rev5's had an LSD as standard and indeed t does seem to be tricky spinning an inside wheel on mine however I've not pushed ridiculously hard but have been pressing on a bit and never even a slight squeak from the rear tyres....

I was on the understanding Rev5 BEAMS cars had LSD as standard, and UK cars it was an option. ISTBC.

[MR2Simon]

Hi Peter, sorry I didn't realise you were sbits, been having a nose around your site!

So let's say worst case it's the syncro's. How much is a set likely to be and where would you get them from? Are they main dealer only order or are there better alternatives out there on the market?

I've searched high and low and can't for the life of me find them anywhere listed for sale.....!

[MR2Simon]

Ok, so a little back to basics on this...

The engine is completely standard except for induction kit and stainless exhaust.
Gear shift is standard, no quick shift fitted as far as I'm aware.
Gears shift perfectly fine at normal speeds. Not a crunch or a grind in sight, very smooth....
Clutch disengages when the pedal is close to/pretty much on the carpet.
High speed, high rev, shifts up the box are causing the crunching.
Clutch does not slip at all even in 4th and 5th with a full we'll of throttle.
No crunching on reverse.

So at normal speeds and stationary all is completely fine.

Very high rev changing up a gear is the only issues.

I always blip on the downchange when driving hard and have never ever noticed any grinding or difficulty engaging gears on the down shift which is when I would normally expect the first signs of worn syncro's....

Does it sound like I'm jumping the gun a bit? Are they likely to be that bad on a 94k mile Rev5?

[Peter Gidden]

Ok, so a little back to basics on this...

The engine is completely standard except for induction kit and stainless exhaust.
Gear shift is standard, no quick shift fitted as far as I'm aware.
Gears shift perfectly fine at normal speeds. Not a crunch or a grind in sight, very smooth....
Clutch disengages when the pedal is close to/pretty much on the carpet.
High speed, high rev, shifts up the box are causing the crunching.
Clutch does not slip at all even in 4th and 5th with a full we'll of throttle.
No crunching on reverse.

So at normal speeds and stationary all is completely fine.

Very high rev changing up a gear is the only issues.

I always blip on the downchange when driving hard and have never ever noticed any grinding or difficulty engaging gears on the down shift which is when I would normally expect the first signs of worn syncro's....

Does it sound like I'm jumping the gun a bit? Are they likely to be that bad on a 94k mile Rev5?

Your clutch needs adjusting. Why is it biting with the pedal buried in the carpet fibres?

Other symptoms are classic worn synchros.

Will PM you synchro ring prices tomorrow.

[MR2Simon]

Your clutch needs adjusting. Why is it biting with the pedal buried in the carpet fibres?

Indeed. It's been on my mind hence finding the info about the adjustment at the pedal...!

Wouldn't it be perfect of that and some properly decent gearbox oil sorted the problem! I'm rarely that lucky!

What oil would you recommend? Are there any other adjustments other than that behind the pedal? On my Esprit the adjustment is at the gearbox/slave cylinder end....!

Look forward to your message tomorrow! Thanks

[bobhatton]

The first thing I would do is bleed the clutch as it may have air in the line. The bite point of the clutch should be about half way up.