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2nd gear synchro is a bit crunchy

maritimeblue911

maritimeblue911

PCGB Member
Hi Team,

I have a slight crunchiness to the gear shift into second, albeit only when the car is cold; double de-clutching avoids it and, around 20 minutes into the drive it feels smooth without double de-clutching; is this is the beginning of an expensive gearbox repair or (I can but dream..!) would a different oil help..?
 
It's very common. My car still does it a bit from cold after a gearbox rebuild, though I'm not sure the synchro's were replaced, possibly swapped over as I had a working box built from 2 boxes plus a box of gears and cogs after I toasted mine through oil starvation due to a broken cooler pipe. I'm using Swepco which is very thick, but I find after about 5 mins there is no issue. If I let it idle for a minute or two before I set off the problem lessens. Of course, changing the oil can only help, 75/90 I think is standard, the Swepco is 80/90 which is likely to make the issue worse, however I find Swepco makes the box quieter in general, has a super long service interval, and is well thought off in the transaxle world. You will find others disagree!

You will probably find 3rd to 2nd is fine, and when going from 1st to 2nd on a cold box, if you let the gear selector centre on your shift, you won't have a problem, eg, out of first into neutral, then into 2nd. I certainly do anyway and it is my work around. Personally I would change the oil and see how it is, then choose if you can live with it or not, get a 75/90 synthetic oil. I think a S2 box needs about 2 litres if it doesn't have a cooler. I'm quite happy to shift via neutral for a mile or so till it settles down. Your car, your call!

Stuart


 
Could be oil, could be the clutch. I've always eased every manual car I've had from 1st to 2nd gear after a cold start. If the OP's crunch is serious, I'd consider pulling away in 2nd gear, until the oil warms a bit.
 
The guy that put my box together told me it was defo the clutch when I reported the same cold notch into 2nd that the box had previous, before I broke it. I have a new clutch and associated gubbins after my rebuild and it's still the same! He was adamant the synchro's were perfect. He is old school and has been rebuilding and repairing boxes for 40 years including a long time working for a rally team. He was wrong though!
 
These boxes will never be as smooth as a modern box (the 968 in comparison is a joy) and mine always had a small crunch from 1st to 2nd if you tried to shift too fast. A new clutch was much smoother but made no difference to that small crunch. Make sure you change the oil religiously every 4 years or 48k miles and it will be the best it can be.
 
Thanks again team - looks like I'll be trying an oil change - anything I should be aware of? Easy access to the drain plug and place for filling?
 
maritimeblue911 said:
Eldavo said:
Make sure you can get the fill plug out before opening the drain plug!!!
Click to expand...
That’s such a good shout! I can well imagine my not doing that and having a stranded car :)
Click to expand...

It has been known on more than one occasion!
 
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