[Mk3] [Turbo] oh dear that will be the gearbox!

[markiii]

Well yesterday wasn't my best day in the world, whilst attempting to track down and cure a number of rattles, I was out on a test run, fortunately local and no A roads.

When

this huge mettalic screach comes from the rear end and the gearbox attempts to do it's best impression of a blender with a bag of nails emptied into it

So having limped very slowly back home in 1st gear, the car is in rather a sorry state.

having had to dash off for a wedding (oh what timing) I managed to get time today to diagnose further.

1. Clutch down - engine revs fine and sounds no different to normal

2. Clutch in, but in neutral as above

3. 1st and reverse gears whilst slipping the clutch just at teh biting point and she moves ok.

Whenever given full clutch engagement or using higher gears it sounds like something is dragging/catching metal on metal. Intermittently it either won't go into or out of gear and tries to stall when you attempt to move off.

I've checked the linkages and all seem ok, and with the engine off all gears can be selected.

so the possibilities seem to be

1. Flywheel (Unlikely I think)
2. Clucth
3. Throw out bearing
4. Selector fork
5. Gearbox internals

Guess who's spending next weekend dropping the box

all suggestions welcome, I'm off to swear at the wall

[ormzy]

Well, as you've probably relised...Not good! Sounds like the box is a duffer!!
It's gotta come off buddy, and from an inspection of the clutch and wheel, your gonna know for sure. But for me, it sounds like a second hand box needed or a specialist repair.
Same thing happened to my Pug306xsi, just bought the thing up from Plymouth, got home, thought i'd go and show my dad my new car, got up the road, dropped into second, sounded like it was grinding cogs to pieces.

If it is Duff, and you are on the lookout for another box i can recommend, Sports Toyota Breakers. Do a search on the forum, and drop Jon a pm.
Hope all goes well and easy on the pocket.

[Speedy]

Er. bad luck

I guess 1st and reverse have no syncro on them? - although it sounds like a pretty serious problem. Is there oil in the box (hasn't all been cooked from enthusiastic turbo motoring?)

[rmarr1980]

Well, as you've probably relised...Not good! Sounds like the box is a duffer!!
It's gotta come off buddy, and from an inspection of the clutch and wheel, your gonna know for sure. But for me, it sounds like a second hand box needed or a specialist repair.
Same thing happened to my Pug306xsi, just bought the thing up from Plymouth, got home, thought i'd go and show my dad my new car, got up the road, dropped into second, sounded like it was grinding cogs to pieces.

If it is Duff, and you are on the lookout for another box i can recommend, Sports Toyota Breakers. Do a search on the forum, and drop Jon a pm.
Hope all goes well and easy on the pocket.

Yeah they are good not sure if they will be able to help at the mo as they were moving workshops. But defo worth ago, they did have a box with LSD the other week when I spoke to them. Helen will know what the current state is from thier move. I have thier mobile contact if you need it.

[BenF]

Mark,



I'd try draining the gearbox oil out and see what condition the oil is in when it comes out. If you've got bits of metal in the oil ....

Plan B : Can you take one end off the gearbox easily by removing the NSR wheel and looking in from the open end?

Have you got the standard flywheel on your Roadster?

Just was thinking, if you've fitted a lightened one you should be able to see the outside edge of it through the breather holes under the gearbox and see if there may be problems with it.

As for gearboxes - I'm only pushing 180-200 ft/lbs through my six speed box and it appears to be lasting OK - how much torque is yours putting out?

[markiii]

right then lads

long story short, me an a couple of mates spent Saturday dropping the box, and it looks like it's lunched.

found the remains of a couple of seriously mullered ball bearings,

had a lot of metal and plastic? come out with the oil, and a number of gear teeth and bolt head had obviously been hammered by something.

the roadtser also has a captive magnet in the box which when removed was seriously covered in swarf.

looks like at least one bearing has exploded

new box time it is then

Ben to answer your question torque is 240lbft at 10psi

I'm planning on upgrading teh box to a 6 speed whilst I'm at it, and have feelers out, however if anyone hears of a 6 speed LSD UK spec box going then please let me know.