Gearbox Rebuild (updated pics 56k beware)

James14100 · Post by **James14100** » Sun Aug 20, 2006 5:19 pm

Right for those of you who are interested on tuesday this week i'm rebuilding my gearbox and will be taking a load of pics etc so if anyone else wants to try one day they can see what problems we've encountered

Firstly I'll tell you why. Basically I bought the car april last year 1.9D L Â£940 ebay - bargin. Had 109k on the clock and a recent rebuild of the box. By summer I had done about 6k then a new gf in manchester (me near leicester) the milage climbed - a whining sound started in the gearbox after another 10k. spoke to the old man he said it would be the bearing - leave it a while and we'll do it when we can see what the problem is. 11k later the bearing burst luckily i was 1mins drive from home so got it back ok. I crushed to gears together - things weren't looking good.

However now after 3months without the car i've finally decided to fix it.

Bought the gears and the bearing is on it's way

Gears were 73.45 +VAT and 53.61 +VAT totally Â£149.30
The bearing was about Â£20 which i got from another company (not vw)

You can see the larger one has the synchro on and was the more expensive of the 2

Will update on tuesday after (hopefully) the box gets rebuilt and back into the car

James

James14100 · Post by **James14100** » Tue Aug 22, 2006 9:27 pm

Right where to start...

Here is the new parts with the old

First stage was to use the lathe to spin the damaged shaft so that sandpaper could get a smooth surface again to fit the new bearing

Then rebuild the shafts up with the gears

Get them in place and make sure eveything fits

The selectors were so hard to get in I didn't manage to get any photos of the process of fitting them and the reverse gear so next load of pics is the gears and selectors ready in the gearbox ready for sealing

Then sealed and oil driven in.

The box feels great and 2moro evening i'll be refitting to the car and hopefully no more problems

James

olop_chris · Post by **olop_chris** » Tue Aug 22, 2006 9:38 pm

Looks good, although i wouldnt have the slightest clue lol

mysteryboy · Post by **mysteryboy** » Tue Aug 22, 2006 11:50 pm

too technical for me but hey...looks great...

wish i knew how to do some of the more advanced mechanical things like this....

James14100 · Post by **James14100** » Wed Aug 23, 2006 8:19 am

Yeah it was all about just going for it. The car had been off the road so long i just got fed up. Me and my dad have rebuilt now 4 gearboxes, 2 of those VW and 1 other vw box which we took apart to see if i could use any parts in there. Selectors were different on everyone but this one was by far the best one - although extremely difficult to fit.

I'm fitting the bax back into the car 2night if anyone wants to see some pics i'll put some up

James

zahir_213 · Post by **zahir_213** » Fri Aug 25, 2006 11:40 am

how much would you say is a good price to pay for a re-con gearbox with fitting and a 12 month 12,000 mile warranty would be?
Ive got a 6N2 1.9 SDI, 5th slips out and theres grinding noises in all gears.

James14100 · Post by **James14100** » Fri Aug 25, 2006 1:12 pm

That would probably be an easy fix to be honest mate.

Where about do u live - could be worth opening up and having a look.

I got quoted Â£395 for a recon box with 12 month warranty

James

polokaj · Post by **polokaj** » Fri Aug 25, 2006 1:55 pm

awesome stuff mate maybe next time your in manchester we could meet would love to talk to a techie about cars.

James14100 · Post by **James14100** » Fri Aug 25, 2006 2:18 pm

Unfortunatly due to the fact i couldn't get up there as much as i used to we broke up

Not to worry though i'm always travelling about

James