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Gearbox Gurus: How bad did I fark things up?

Old 08-23-2018, 07:27 PM
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Gearbox Gurus: How bad did I fark things up?

So, first things first: Iím an idiot and didnít recognize the obvious warning signs of a slowly failing clutch master cylinder and dragging clutch. And then I doubled down on the idiocy by not fixing the problems right away when I recognized them. I have replaced the offending parts and the underlying issue should be fixed.

My car is an S1 but the gearbox is an S2 so... here we are.

The gearbox grinds and simply wont go into 2nd at >5k rpm. I sourced a $400 S1 gearbox to keep the car on the road while I embark on a project to learn how manual transmissions work while repairing this one. Iím not doing this to save money since thatís usually a fools errand for bumblefarks like me.

Notice how the dog teeth to the left of the 2nd gear synchro are different shape from the rest of the gears? Iím thinking this is a problem. So, itís 2nd gear as well as itís synchro that need replacing, yes? Any recommendations regarding the rest?

1st gear



2nd gear


5th gear


6th

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Old 08-24-2018, 10:57 AM
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Update:
Internet randos on Reddit say that the differently shaped dog teeth for 2nd gear are normal. This is done because the 1-2 shift has the highest different in angular velocity and this shape sacrifices ease of release for ease of insertion.

So, unless I find anything really scary when I take everything apart this weekend, it'll just be a set of synchros.
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Old 08-25-2018, 09:45 PM
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I have no idea, but the photos are stunning.
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Old 08-25-2018, 11:06 PM
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Originally Posted by Steve Dallas View Post
I have no idea, but the photos are stunning.
What he said
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Old 09-06-2018, 06:09 PM
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Just in case anyone was wondering what a mostly disassembled S2 gearbox looks like...


Going to do some measurements and get started with a parts list in the next couple of days.
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Old 09-06-2018, 07:04 PM
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Looks like you got some work ahead of you. I have no clue how it works haha
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Old 09-06-2018, 08:21 PM
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I still have some parts of the broken 5th gear sitting in a box. Messed up a shift and destroyed the synchro.

I can take some pictures later.
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Old 09-06-2018, 08:33 PM
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Originally Posted by NotAPreppie View Post
Just in case anyone was wondering what a mostly disassembled S2 gearbox looks like...
Going to do some measurements and get started with a parts list in the next couple of days.
Thanks for the pics, you got bigger ***** than I do. I've work on just about anything you can think of, but that's the only thing I would not dare to try to fix.
Good luck, keep us posted!!!
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Old 09-07-2018, 07:49 AM
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Thanks.

It's effectively broken for my needs so I can't really break it worse than it already is. Besides, if it ain't broke, you're not trying hard enough! (alternately, if it ain't broke, fix it 'til it is)

The disassembly so far has actually been relatively easy. Easier than R&R'ing my engine. The hard part is finding ways around not having a few SST's. One was replaced by a Hazard Fraught 24" adjustable wrench (to remove a 55mm nut on the main shaft). Since I have to torque that nut back down, I'm going to cut the handle off and weld a 17mm nut onto the head so I can use a torque wrench.
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Old 09-07-2018, 09:52 AM
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I've been told to use the right tools for the right job. Don't get me wrong, a hammer and adjustable wrenches are useful at times, but I would spend the $30 just to make sure it does not explode
https://www.amazon.com/Sunex-555M-1-Inch-Standard-Metric/dp/B000SOSJG0/ref=sr_1_5?ie=UTF8&qid=1536328126&sr=8-5&keywords=55mm+socket https://www.amazon.com/Sunex-555M-1-Inch-Standard-Metric/dp/B000SOSJG0/ref=sr_1_5?ie=UTF8&qid=1536328126&sr=8-5&keywords=55mm+socket
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Old 09-07-2018, 10:02 AM
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Bah, much more fun to do it the wrong way.

Also, this resolves the issue of socket depth since the main shaft protrudes a fair amount from the nut.
Alsoalso, the SST is a "universal wrench" that looks like a bearing puller but has hex sides for grabbing a nut. This more closely matches the SST than a socket.
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Old 09-16-2018, 02:32 AM
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So is anything actually wrong with your second gear?

I am asking because just yesterday, I ground it another time. That was the third time I ground my second, and without a hard acceleration at all(only coming out of 1st at 4~5k RPM). Pretty sure my clutch is all the way in as well. Never happened with any other gear, either. I ground my 6th once this year, but I knew that time I didn't push the clutch in all the way. The fluid is only a year old.
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Old 09-16-2018, 07:32 PM
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2nd gear itself? I don't think so. I haven't made all the measurements yet but it looks fine.
2nd gear synchro? Probably completely shot inside. The synchro rings for all the other gears have a clutch-like friction material on the inside face. I haven't gotten 2nd separated yet to look at the ring.
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