jumping out of 2nd

1
Hi All
A friend of miner has a SYNCRO Combie and on the slightest bump it jumps out of 2nd .
He has tried all the gear shifting alignment procedures.
The workshops suggest a gearbox rebuild.
Could there be a more simple solution.

 Tom
2

Thomas,

Not necessarily.  There are a lots of sliding bits and pieces in the gear selection mechanism between the shift lever to the gearbox.  It might still be the internal (internal to the gearbox) process but that is an expensive solution. It pays to make sure that the external process is 100% before taking the gearbox out.

Les

From: Syncro_T3_Australia@yahoogroups.com [mailto:Syncro_T3_Australia@yahoogroups.com] On Behalf Of Thomas Mischler
Sent: 10 December 2012 20:29
To: Syncro_T3_Australia@yahoogroups.com
Subject: [Syncro_T3_Australia] jumping out of 2nd

 

Hi All

A friend of miner has a SYNCRO Combie and on the slightest bump it jumps out of 2nd .

He has tried all the gear shifting alignment procedures.

The workshops suggest a gearbox rebuild.

Could there be a more simple solution.

 

 Tom

3
Hi Thomas,
May be worth checking out,  ... someone here ages ago reckoned that the two rearmost rubber bellows on the gear selector shaft, if in very good condition and when stretched out (as would be the case when 2nd gear is selected) may have enough tension to pull it out of 2nd gear. No idea myself as it hasn't happened to me, just passing this on.
Cheers.
Ken


To: Syncro_T3_Australia@yahoogroups.com
From: leslieharris@optusnet.com.au
Date: Mon, 10 Dec 2012 20:37:02 +1100
Subject: RE: [Syncro_T3_Australia] jumping out of 2nd

 

Thomas,

Not necessarily.  There are a lots of sliding bits and pieces in the gear selection mechanism between the shift lever to the gearbox.  It might still be the internal (internal to the gearbox) process but that is an expensive solution. It pays to make sure that the external process is 100% before taking the gearbox out.

Les

From: Syncro_T3_Australia@yahoogroups.com [mailto:Syncro_T3_Australia@yahoogroups.com] On Behalf Of Thomas Mischler
Sent: 10 December 2012 20:29
To: Syncro_T3_Australia@yahoogroups.com
Subject: [Syncro_T3_Australia] jumping out of 2nd

 

Hi All

A friend of miner has a SYNCRO Combie and on the slightest bump it jumps out of 2nd .

He has tried all the gear shifting alignment procedures.

The workshops suggest a gearbox rebuild.

Could there be a more simple solution.

 

 Tom


4
Tom worth checking the nut is tight on the shift input bracket drivers side gearbox. This nut can work loose if driven by a heavy handed gear changer. Mine would not select first and the nut was the culprit. .......Regards Pete SEQ.

On Mon, Dec 10, 2012 at 7:29 PM, Thomas Mischler <energysustained@ymail.com> wrote:

Hi All
A friend of miner has a SYNCRO Combie and on the slightest bump it jumps out of 2nd .
He has tried all the gear shifting alignment procedures.
The workshops suggest a gearbox rebuild.
Could there be a more simple solution.

Tom


5
How does the magnetic drain plug look ?
If the linkage has been gone over carefully ...
and ..
there's significant metal ( a 'ball' of fine metal particles up to 10mm in diamter is normal ) on the magnetic drain plug ..
and miles are known to be pretty high on the gearbox ..
then it's likely due for rebuilding.

though I have not heard of any syncro gearboxes with this failure mode.

try this too ..
right there on the side of the gearbox where the aft end of the linkage bolts to the gearbox ..
there is some play at the mounting bolt holes..
so you can loosen two bolts and push the bracket up a little ...........or lower it a little.

also ..for sure ..condider the lever on the side of the trans ..
it's not uncommon for those to be loose on the splines where it bolts on ..
or the splines stripped out some..

and ..the white plastic ball on the end of that lever..
those can get out of place. I just had one ...it would go into reverse and not come out ..
that white ball slid on the lever to the wrong place.

for a 'final despearate test' ....put it in second, undo the linkage ..go for a drive on bumps ..
it if still jumps out ...transmission for sure Baby.

I'd take it off on the side of the gear box first though ...and check things there real carefully.
I have also seen the 'cup' ...at the aft end of the shift linage ....it's located on the shift rod with a roll pin ( rather odd I think ) I have seen those get loose too.

scott
www.turbovans.com

On 12/10/2012 2:45 PM, Peter Wilson wrote:

Tom worth checking the nut is tight on the shift input bracket drivers side gearbox. This nut can work loose if driven by a heavy handed gear changer. Mine would not select first and the nut was the culprit. .......Regards Pete SEQ.

On Mon, Dec 10, 2012 at 7:29 PM, Thomas Mischler <energysustained@ymail.com> wrote:
Hi All
A friend of miner has a SYNCRO Combie and on the slightest bump it jumps out of 2nd .
He has tried all the gear shifting alignment procedures.
The workshops suggest a gearbox rebuild.
Could there be a more simple solution.

Tom


6

Scott,

Thanks for the reply – good ‘horse’s mouth’ stuff as usual.

Les

From: Syncro_T3_Australia@yahoogroups.com [mailto:Syncro_T3_Australia@yahoogroups.com] On Behalf Of Scott Daniel - Turbovans
Sent: 11 December 2012 11:45
To: Syncro_T3_Australia@yahoogroups.com
Cc: Peter Wilson
Subject: Re: [Syncro_T3_Australia] jumping out of 2nd

How does the magnetic drain plug look ?
If the linkage has been gone over carefully ...
and ..
there's significant metal  ( a 'ball' of fine metal particles  up to 10mm in diamter is normal ) on the magnetic drain plug ..
and miles are known to be pretty high on the gearbox ..
then it's likely due for rebuilding.

though I have not heard of any syncro gearboxes with this failure mode.

try this too ..
right there on the side of the gearbox where the aft end of the linkage bolts to the gearbox ..
there is some play at  the mounting bolt holes..
  so you can loosen two bolts and push the bracket up a little ...........or lower it a little.

also ..for sure ..condider the lever on the side of the trans ..
it's not uncommon for those to be loose on the splines where it bolts on ..
or the splines stripped out some..

and ..the white plastic ball on the end of that lever..
those can get out of place. I just had one ...it would go into reverse and not come out ..
that white ball slid on the lever to the wrong place. 

for a 'final despearate test' ....put it in second, undo the linkage ..go for a drive on bumps ..
it if still jumps out ...transmission for sure Baby.

I'd take it off on the side of the gear box first though ...and check things there real carefully.
I have also seen the 'cup' ...at the aft end of the shift linage ....it's located on the shift rod with a roll pin ( rather odd I think ) I have seen those get loose too.

scott
www.turbovans.com

7
Thank you Les, so good to read your kind words.

Keep 'em shiny side up, and rubber side down !
Scott
www.turbovans.com

I'm installing a rebuilt syncro gearbox   ( Daryl of AA Transaxle, Seattle,  Wa USA ) right now...
Syncro tin top T3 Van with Subaru EZ30 six cylinder timing chain engine ..
Smallcar Bell Housing with internal slave cylinder,
 and top gear is a bit higher than stock now.
Running Swepco 210 gear oil ..per Daryl.
Going to tweak on engine altitude to slightly adjust flange angle on the rear driveshaft flange to reduce vibration ...that's the goal anyway.
On 12/10/2012 6:36 PM, Les Harris wrote:
 

Scott,

Thanks for the reply – good ‘horse’s mouth’ stuff as usual.

Les

From: Syncro_T3_Australia@yahoogroups.com [mailto:Syncro_T3_Australia@yahoogroups.com] On Behalf Of Scott Daniel - Turbovans
Sent: 11 December 2012 11:45
To: Syncro_T3_Australia@yahoogroups.com
Cc: Peter Wilson
Subject: Re: [Syncro_T3_Australia] jumping out of 2nd

How does the magnetic drain plug look ?
If the linkage has been gone over carefully ...
and ..
there's significant metal  ( a 'ball' of fine metal particles  up to 10mm in diamter is normal ) on the magnetic drain plug ..
and miles are known to be pretty high on the gearbox ..
then it's likely due for rebuilding.

though I have not heard of any syncro gearboxes with this failure mode.

try this too ..
right there on the side of the gearbox where the aft end of the linkage bolts to the gearbox ..
there is some play at  the mounting bolt holes..
  so you can loosen two bolts and push the bracket up a little ...........or lower it a little.

also ..for sure ..condider the lever on the side of the trans ..
it's not uncommon for those to be loose on the splines where it bolts on ..
or the splines stripped out some..

and ..the white plastic ball on the end of that lever..
those can get out of place. I just had one ...it would go into reverse and not come out ..
that white ball slid on the lever to the wrong place. 

for a 'final despearate test' ....put it in second, undo the linkage ..go for a drive on bumps ..
it if still jumps out ...transmission for sure Baby.

I'd take it off on the side of the gear box first though ...and check things there real carefully.
I have also seen the 'cup' ...at the aft end of the shift linage ....it's located on the shift rod with a roll pin ( rather odd I think ) I have seen those get loose too.

scott
www.turbovans.com


8
I'll second that, putting it in second with the gear linkage disconnected at the g/box that is. Typically when a gear pops out it will do it on acceleration and is caused by the face of the selector teeth being worn. There are so many other possibilities that could cause this symptom though, including a failure else where in the gearbox causing shrapnel to get lodged behind the 2nd gear selector mechanism. Try r/testing on a smooth surface and accel hard in second. Greg E

From: Scott Daniel - Turbovans <ScottDaniel@turbovans.com>
To: Syncro_T3_Australia@yahoogroups.com
Cc: Les Harris <leslieharris@optusnet.com.au>
Sent: Tuesday, 11 December 2012 2:16 PM
Subject: Re: [Syncro_T3_Australia] jumping out of 2nd
 
Thank you Les, so good to read your kind words.

Keep 'em shiny side up, and rubber side down !
Scott
http://www.turbovans.com/

I'm installing a rebuilt syncro gearbox   ( Daryl of AA Transaxle, Seattle,  Wa USA ) right now...
Syncro tin top T3 Van with Subaru EZ30 six cylinder timing chain engine ..
Smallcar Bell Housing with internal slave cylinder,
 and top gear is a bit higher than stock now.
Running Swepco 210 gear oil ..per Daryl.
Going to tweak on engine altitude to slightly adjust flange angle on the rear driveshaft flange to reduce vibration ...that's the goal anyway.
On 12/10/2012 6:36 PM, Les Harris wrote:
 
Scott,
Thanks for the reply – good ‘horse’s mouth’ stuff as usual.
Les
From: Syncro_T3_Australia@yahoogroups.com [mailto:Syncro_T3_Australia@yahoogroups.com] On Behalf Of Scott Daniel - Turbovans
Sent: 11 December 2012 11:45
To: Syncro_T3_Australia@yahoogroups.com
Cc: Peter Wilson
Subject: Re: [Syncro_T3_Australia] jumping out of 2nd
How does the magnetic drain plug look ?
If the linkage has been gone over carefully ...
and ..
there's significant metal  ( a 'ball' of fine metal particles  up to 10mm in diamter is normal ) on the magnetic drain plug ..
and miles are known to be pretty high on the gearbox ..
then it's likely due for rebuilding.

though I have not heard of any syncro gearboxes with this failure mode.

try this too ..
right there on the side of the gearbox where the aft end of the linkage bolts to the gearbox ..
there is some play at  the mounting bolt holes..
  so you can loosen two bolts and push the bracket up a little ...........or lower it a little.

also ..for sure ..condider the lever on the side of the trans ..
it's not uncommon for those to be loose on the splines where it bolts on ..
or the splines stripped out some..

and ..the white plastic ball on the end of that lever..
those can get out of place. I just had one ...it would go into reverse and not come out ..
that white ball slid on the lever to the wrong place. 

for a 'final despearate test' ....put it in second, undo the linkage ..go for a drive on bumps ..
it if still jumps out ...transmission for sure Baby.

I'd take it off on the side of the gear box first though ...and check things there real carefully.
I have also seen the 'cup' ...at the aft end of the shift linage ....it's located on the shift rod with a roll pin ( rather odd I think ) I have seen those get loose too.

scott
http://www.turbovans.com/