928 obsession

Hello, my car is an '82 5sp with around 78k miles. After testing a number of components we discovered the car developed a clicking/clanking sound from the transmission in 1st gear. The clicking sound almost sounds like someting is loose. The car has the usual 1st and 2nd synchro problems if not shifted properly. We originally believed either there was a bad cv joint or the torque tube bearings needed to be replaced. In trying to diagnose where the clicking sound was coming from, we jacked up the rear of the car. We checked the rear CV joints and they appeared to have been replaced in the past. The rubber boots were not dry rotted and there was no splattered grease around the surrounding parts. We then spun the wheels to test the cv joints and there was no sound or play in the joints. Next we started the car and put the trans in neutral and engaged the clutch to test the torque tube. There was no sound coming from the torque tube. So the cv joints and torque tube are good. The only thing left was the transmission We then shifted the car into 1st gear and the clicking sound began. We then shifted the car into 2nd and the sound disappeared. We then tried third, fourth and fifth, there was no sound. We shifted it back into 1st and the sound reappeared. My father used a mechanics’ stethoscope and placed it on the transmission while it was in 1st gear. The clicking was defiantly coming from inside of the transmission. The trans is running redline fluid. The question now is what should I do? Could the bad 1st gear synchro cause the clicking sound? Any help would greatly appreciated since this is my first car. Thanks

Landseer

First, Congrats on your car, be safe driving it. A 5 speed.

Second, there's some of us near you and more in Raleigh/Durham, and at least one in Charlottesville, that are 928 freaks and will help you for the sport of it.

Mark Anderson in California, and GregBBRD, also out that way, are quite experienced in 5 speed boxes.

You might send a PM to them if they don't respond to the thread. Mark runs 928 International and Greg may be the most knowledgeable 928 mechanic on earth by all accounts. Real people, too. Both know the insides of the gear boxes.

I have an 84 5 speed with bad synchros but am not getting that sound. My reverse lockout bar is broken, probably laying in the box, and causing some noise I think.

Brett Matthews

Recently, our local shark guru/den 'mother' rebuilt his manual trans, because of just your symptoms. Turned out to be more than the syncro's. I'll try to get his input, and post back with it....

928 obsession

Thanks for the information and the welcome. I live in the Danville, Virginia area. If you guys are interested there is an Octoberfest at Virginia International Raceway next month. Info here It would be awsome to see some fellow 928's out at the track. My father and I are usually the only ones. Anyway back to the topic. I will PM Mark and Greg tonight and see if they know what the sound from the trans could be. Once again thanks for the information.

928 obsession

Brett Matthews, that would be great if you could give me an update once you get his input, I would greatly appreciate it.

James Bailey

The reverse gear idler gets a bit loose and it hits one the first gears chews up the edges a bit. Fixing it require a full disassemble and rebuild PLUS shiming over spacing the gear. Just use first once in the morning never come to a full stop there after. The old very brown 1980 clicks in first .....I seldom use first

928 obsession

Thanks for the input, but it was not the news I wanted to hear. I was planning on eventually replacing the synco's in the trans, but if the first gear is chewed up I would probably be better off buying a refurbished trans. It probably is the reverse gear idler, because sometimes it takes a few attempts to get the car in reverse. It's almost like someting is jammed and pushes the shifter into seccond instead of reverse. I'll try to use seccond mostly now when taking off and only use first when I'm on a hill. I guess I have a winter project now.