Gearbox sticking in 4th gear

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neil3965
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Location: Perthshire, UK

Gearbox sticking in 4th gear

Post by neil3965 »

Hi all

2.0L Aircooled with original 4-speed gearbox, 160,000 miles on clock. Around four months/2000 miles ago, it started sticking in 4th gear (on isolated occasions, most of the time it worked fine), usually managed to get it out after a wiggle or two of the gear lever, but in the last few days it is now sticking more solidly.

Nothing to do with clutch or linkage - removed the shift rod and tried the shift lever on the box, runs through all gears OK including into 4th, but needs brute force to get it out again. Just drove 200 miles home from NW Scotland without using 4th gear! Max speed 40-45mph in 3rd, all other gears changing and running smoothly.

So, I'm guessing this is something like the 4th gear synchro ring - any thoughts? Whatever, it sounds like a replacement box is needed - any experience/recommendations of where to get one? The likes of VW Heritage offer reconditioned boxes provided you trade in the old one with 'undamaged case' - unfortunately, mine has the guide pin bracket broken off, with a homebrew repair (not pretty, but it works). Can you still get the reconditioned gearbox without an exchange, but just have to pay the full whack? (£600 plus vat extra - ouch!)

Thanks for any advice.
Cheers, Neil

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1982 Volkswagen T25 (Devon Camper)
Engine: 2.0L A/C petrol (CU)

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