[Mk2] [Turbo] Uh oh gearbox blown!

[Total Recall]

Hi, this is on my 1993 Mk2 Rev2 Turbo Tintop.

Had just left the dual carriageway, coming down the slip road and turned off my a/c and fan blower as I was nearly home - and heard a bit of a rattly squeal - not very loud - a bit like a clutch throwout bearing.

Decided to pull over as soon as I was off exit road - changed down to 4th at 40MPH and the gear went in with a bit of a thud. Came to a stop to find trans oil everywhere and a fairly large hole with half a cog poking out of the passenger side end cover of the gearbox housing! (opposite side to flywheel)

Is this a common failure?

The car will still drive in first as I had to slowly drive up the curb to get off the road. With the engine off you can select gears 1-4 - and all seem to connect to the drive as I can feel resistance if I try and push the car in gear as normal - but you can`t even select 5th or reverse.

Is it best to get the box rebuilt or better to put a good used one on?

It`s a shame because out of the 3 turbo`s I`ve had this is the first one with a real good 3rd gear synchro!

Any advice / thoughts really appreciated!


Cheers,

Dom.

[pistol pete]

I'm sure that sounds like what Neil had at Jae. .
New end cap and new 5th gear.... Give fensport a ring they sorted neils out
Hopefully not new vix and can be repair easily

[gnzyza]

Better off sourcing a used box, with the casing damaged not really worth repairing

[pistol pete]

Better off sourcing a used box, with the casing damaged not really worth repairing

not if its just the end plate.. that just unbolts

[Total Recall]

Thanks for the replies!

Cool there may be hope for it then - if the end cap and the one gear is the only damage.


Will get the box out and have a look and a ring around.

Will post back with some info when I know more!

Thanks

Dom.

[gnzyza]

Better off sourcing a used box, with the casing damaged not really worth repairing

not if its just the end plate.. that just unbolts

[pistol pete]

Thanks for the replies!

Cool there may be hope for it then - if the end cap and the one gear is the only damage.


Will get the box out and have a look and a ring around.

Will post back with some info when I know more!

Thanks

Dom.

keep us updated.. like Gynza said if the casing itself is damaged then new box time
if its just en plate the hopefully just 5th gear.. you "may" be able to do it with box in situ? like said drop fensport a ring.. they may even have the parts in stock

[ashley]

Thanks for the replies!

Cool there may be hope for it then - if the end cap and the one gear is the only damage.


Will get the box out and have a look and a ring around.

Will post back with some info when I know more!

Thanks

Dom.

keep us updated.. like Gynza said if the casing itself is damaged then new box time
if its just en plate the hopefully just 5th gear.. you "may" be able to do it with box in situ? like said drop fensport a ring.. they may even have the parts in stock

Shop around on prices before buying, Fensport tend to be at the more expensive end of the range for parts...I would call Peter at S-bits, he's good at getting gearbox parts at cost prices

[bobhatton]

if its just the end cover the hopefully just 5th gear.. you "may" be able to do it with box in situ

My son had the same problem with two boxes, we did all the work replacing the parts without removing the box.
Toyota now make a stronger part for the bit that goes.

I can get all the parts you will need once you have it apart.

[Total Recall]

Thanks again for all the replies and help.

Just an update with some pics.

So far so good - as you have all said the end bits of the gearbox come off without taking it out - however there`s still a few things I need to check first so can`t say for sure it won`t have to come out yet....

Anyway first pic of damage from the outside - not pretty!


Once inside it seems the "number 3 clutch hub" has given up...


I`ll obviously need a replacement end cover:


Also possibly the "number 3 hub sleeve" as the teeth on the inside are ground down very sharp - more than normal wear and tear I think:


Dead "number 3 clutch hub"....


The rest of the parts look ok including the 5th gear cog itself but there`s something I want to check on this pic. The "number 3 shift fork shaft" - the one that`s sticking out the furthest at the top of the pic for 5th/reverse.


Before I took it appart, with the engine off I could select all gears except 5th and reverse - which is obvious why from the first pic as it had all jammed due to the broken bits.

When I took the fork, hub, synchros and gears off I could once again select the 5th gear position - but still not reverse.

Then I realised that the shift fork shaft had rotated anti-clockwise by nearly 90 degrees. I turned it back with a small screwdriver through the hole where the shift fork screws to it and it clicked into place nicely - and once again reverse can be selected.

The only thing that worries me is should you be able to turn the shift shaft at all (gear lever in neutral position).

Also any idea what could have caused the whole failure in the first place - is it just a weak part - or could something internally have caused it - obviously I don`t want to put new parts on just for the same thing to happen straight away if there`s actually an internal problem?

Well sorry for the long post but I thought pics explain what I mean better.
I`ll have a ring around about the parts but thought I had better check on here again about those few things first.

Cheers!

Dom.

[pistol pete]

i don't know.. sounds pretty much same as what happened to neil.. so could just be a weak point..
give a couple of the specialists on here a ring for advice, they are normally very helpful

[mr2magic]

I'm pretty sure it can be turned as soon as the shift fork is removed but only anti clockwise and max about 90 degrees (maybe a bit more). The click is a small ballbearing which is pushed up against the shaft with a spring and a set screw in the trans casing. In the shaft there are notches in which the ball bearing sits, thus holding it in a given vertical position.

[Draven]

Pme'd. I've got a rev3 LSD gearbox from my breaker.

[Total Recall]

I'm pretty sure it can be turned as soon as the shift fork is removed but only anti clockwise and max about 90 degrees (maybe a bit more). The click is a small ballbearing which is pushed up against the shaft with a spring and a set screw in the trans casing. In the shaft there are notches in which the ball bearing sits, thus holding it in a given vertical position.

That's great info thanks! Yeah a bit less than 90 degrees anti-clockwise with the shift fork removed and the ball bearing and spring makes sense as to how it felt when it clicked back into place. Was just a bit worried as to why it would still move if still connected to the reverse mechanism but if you have noticed it can move too, then short of taking box off to check, I'll assume (well hope!) it's normal.

Thanks for offer of the gearbox Draven. Atm I'm trying to source the parts as it means a lot less work than removing and replacing the box.

If I have trouble sourcing the parts though then I will probably take you up on the offer, assuming no major differences for using it on my rev 2.

Thanks,
Dom.

[Total Recall]

Btw Draven I have replied saying the same to your pm but let me know if u don't get it as for some reason it keeps going to outbox but doesn't appear in my sent box, so don't know if it's gone!

Dom.

[Draven]

Yup got both PM's they go into outbox till I read them. Then they jump into sent.

As said in PM. Hopefully your box will be salvageable. I'll be getting mine out next weekend.

[Total Recall]

Cool didn't realise that about the pm's.

Yeah I hope I can fix box too but if not i'll b in touch.

Thanks again.

Dom.

[Total Recall]

Well not looking great for the old box atm!

Despite looking undamaged I've found 5th synchro is also bent.

I'm guessing this would be the most expensive part and the total cost of parts would now be approaching a rebuilt box - and certainly more than getting a good second hand one - although looking like a lot more work....?

I was getting all excited that I might have it back on the road next week lol.

Dom.

[abovetherim]

Give Paul Woods @ woodsport a bell as he does an extended 5th gear mod. You may want to opt for that or he may have some bits laying around having removed them from a box he's converted???

Failing that, are the gears and syncros the same in an n/a box as I have an n/a box with knackered casing here that I could strip the 5th gear stuff from

[Peter Gidden]

Well not looking great for the old box atm!

Despite looking undamaged I've found 5th synchro is also bent.

I'm guessing this would be the most expensive part and the total cost of parts would now be approaching a rebuilt box - and certainly more than getting a good second hand one - although looking like a lot more work....?

I was getting all excited that I might have it back on the road next week lol.

Dom.

I have several gearboxes fully dismantled. PM me with your requirements.