Dear Uwe,
I think you are getting some good advice from the register but I was chatting to Rob of Volksrepair at Airport West Vic and he tells me that he does a lot of VW gearboxes including some from other VW specialists. I've always been pleased with the work they have done on my vehicle including,their knowledge, enthusiasm and access to appropriate Syncro parts.As he seemed to paint a much more optimistic picture on his access to parts you may care to try him on (03) 9338 3373 for an additional opinion &/or possible closer proximity to you. He shared the general view that the longer you leave it the more you will end up replacing and there comes a point where a gearbox can be destroyed sufficiently to become economically irrepairable.
Good luck
Roger
--- On Mon, 13/7/09, stuart parry <stuart@oddball.com.au> wrote:
From: stuart parry <stuart@oddball.com.au>
Subject: RE: [Syncro_T3_Australia] Gearbox noise
To: Syncro_T3_Australia@yahoogroups.com
Received: Monday, 13 July, 2009, 6:45 PM
We had ours reconditioned by Lloyd Davies at Volkwerke in Greensborough. It was Brian Reed (a member of this list) who recommended Lloyd. He had his syncro transaxle overhauled by Lloyd about 10 years ago, and to the best of his knowledge it's still going strong (he sold the vehicle a while ago). Lloyd has had lots of experience with VW transaxle rebuilds and syncros, and owns and drives T3s. I found him very good to deal with and he gave us a 12-month warranty on the work, so long as we either removed the tailshaft or put in a decoupler (or, presumably, a new viscous coupling - something he didn't recommend). It's worth bearing in mind, incidentally, that it's more than likely an aggressive viscous coupling, past its use-by date, that has wrecked your transaxle.
Lloyd was happy to take on the job, so long as I took on the task of sourcing the crownwheel and pinion. I located an OEM one with the correct ratio at the Syncro Hopsital in South Africa and had it shipped here, but I'm pretty sure it was their last remaining one (might be worth checking). Unfortunately, the total cost for that was just over $2K. As Les has pointed out, you can also get new ones from Albins in Ballarat for slightly less ($1600 or so). There are several days of labour involved plus sundry other parts, so you can probably get the picture that the final bill was rather large (I hesitate to say exactly how much!).
Oh, Lloyd also managed to locate a pair of factory-recondition ed syncro transaxles in Germany, but that would have worked out more expensive again. They might still be there if anyone's desperate... .. Other than that, there's a guy called Rudi Purkhart on Bribie Island who apparently meticulously reconditions syncro transaxles (among other things), but it will cost $$$$$$. There's also a guy called Aidan Talbot in the UK who rebuilds syncro transaxles, but that's probably too logistically and financially challenging from here.
Anyway, good luck and I hope you get over this hurdle to enjoy your uniquely satisfying vehicle. We have grown to love ours!
Hi and thanks for the replies Les, Hartmut and Francesca
Looks like the gearbox needs to come out and and get looked at. I'm in Melbourne also and I would love to know where you had it fixed Francesca. Going through the archives I remember reading Les had a similar problem, where did you get it fixed Les. Thanks to Hartmut also, I could read the reply in German but I guess our locations make the difference in terms of getting it fixed.
A little background on me, I joined the list almost 12 months ago after buying my Syncro, an ex-telstra with broken headstud. I've been reading all the posts but haven't had to be more active than that while the car is a still a project, I'm working on an engine transplant and body cleanup before it makes its debut. My daily car is an 85 Caravelle.
But my brother was inspired
with the syncro and finally found one recently, also ex-telstra and its now a camper, unfortunately it has the gearbox problem
Any help on where to go and maybe a ball park cost would be greatly appreciated.
Regards, Uwe
We went through the crownwheel and pinion/gearbox rebuild just recently, so I sympathise with your predicament. >From your description the noise in your gearbox matches the symptoms our syncro displayed exactly. If our experience could be of help (though we are in Melbourne), drop me a line and I can let you know how we dealt with it. It's whisper quiet and sweet-changing now - long may it last!
To elaborate on that, the symptoms match excessive wear in the crownwheel and pinion. This is irreversible and the noise will increase as it wears further. The only course is replacement. The Australian delivered ratio is 5.43 – which VAG no longer stocks. Fortunately, Albins are now making this ratio so we are covered.
Unless you have a lot of gearbox experience, this is a job for not just a professional transmission workshop but also one with experience with the 094 gearbox. Choose carefully.
It is highly recommended that you have all the bearings in the box changed while you are at it so that you get back to best possible condition. In any event, the metal particles that have been ground off the crownwheel (this is the noise you are hearing) circulate with the oil and go through the bearings and set them up for early failure.
Les
Subject: RE: [Syncro_T3_Australi a] Gearbox noise
Most likely crownwheel and pinion.
Hi all, I wonder if anyone has had a similar problem with a noise coming from the gear box. Its a loud groan while driving, noticeable more in third and fourth gear where the engine is quieter and even has a slight harmonic to it. The noise disappears when backing off the accelerator and when power is applied again to the drive train it returns. When the clutch goes in its also gone. So it only appears when the drive train is under load.
Certainly sounds like a bearing, has anyone heard or known of these symptoms before?
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