dang John. sorry to hear that. sucks

 

+1 on that sucks!

Slight off your topic, 20C4S posted a pic of his kerfluffled Planetary Gear sitting in the case, is it literally that visible and the first thing you see once PTU case is separated for nose of gearbox?

 

Bloody fekking hell that sucks. Can we see hi-res pics of the actual fracture areas?

 

I'll do that when I pick up the car and the pieces. I'm very interested to see what type of shear it is.

 

I wonder if this is what happened to mine... one day, out of the blue... I get to work, park the car and at the end of the day when I am ready to go home, I can't get the car to come out of 2nd gear... drove all the way home in 2nd...

I later managed to get it out of 2nd gear, but it would not shift to the upper gears 1,3,5, R) only 2 and 4th and with great need for force...

Wished there were more threads or videos of taking these puppies apart... I am going to need them.

Cheers,
Jaime

 

I concur, we need the gearbox guru's to produce an epic teardown and build up for their fellow Rennlister's ... I vote for C4 box.... video and pics, Yahoo!!!

 

The selector rod was replaced and box refitted. However it failed the test drive with 3rd gear still graunching, so back out it came

Something is fundamentally wrong with this box build. Either it's an out of spec part, a damaged part or an incorrect install I don't know, but unless the true cause is found I can't have confidence in the car.

Next step is to send my spare parts to the builder to use for verification.

 

That's really frustrating for you, especially given the size of the bills involved. Fingers crossed they find the root cause quickly. Let us know how things pan out.

 

+964

 

Learning more than I wanted to know about G50/60 rebuilds. Apparently some experienced rebuilders have built either jigs or have cut cases in half to fit the assembled gears into and check the engagement of the various gears before they commit it to the full case and reinstall in the car.

The hypothesis forming is that the box action as installed is not allowing full engagement of 3rd gear. Apparently some builders use the half case to see if a shim needs to be fitted to have the gear stack at the right place for engagement. As my rebuilder doesn't have a jig or cut case this could be an unsolvable problem for them. Fingers crossed that I have this wrong.

 

Why don't they use micrometer blue? The trace left on the gears would show the depth of engagement.

 

Cutting a "window" in a donor case is the only way to get proper alignment / engagement before assembly as once together no adjustments can be made.
All aircooled VW boxes are also done this way.

 

The shop is using the only logical option left given they don't have a jig or cut away case. They have disassembled a known working G64 box and are measuring like for like as they reassemble mine. Logically the issue will emerge as more parts are fitted.

 

I hope that's not your gear stack clamped in the vise without soft jaws.

 

I thought the same thing.....