Gears grind when downshifting

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Jackrobbo
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Gears grind when downshifting

Post by Jackrobbo »



Hi I have a CU 2.0 Aircooled but when I downshift or disengage a gear it grinds on entry. However upshiftibg doesn’t seem too. Any thoughts ? It’s only a tiny grind

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Mocki
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Re: Gears grind when downshifting

Post by Mocki »

change the oil, pay much attention to the plug magnet, much more than 10mm of xmas tree looking arrangement, prepare for refurb or replacement box, if its not massive, add molyslip and new ep80-90 oil and be gentle .....
its not unusual 2nd to be awkward as they get older and when cold
Steve
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1989 2.1LpgWBX HiTop Leisuredrive Camper
1988 2.1 Caravelle TS TinTop Camper 
 

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937carrera
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Re: Gears grind when downshifting

Post by 937carrera »

:ok

Just for clarity mocki means the gearbox oil, not engine oil. First post so unsure how technical you are.
1981 RHD 2.0 Aircooled Leisuredrive project, CU engine
1990 RHD 1.9 Auto Sleeper with DF/DG engine

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Re: Gears grind when downshifting

Post by Jackrobbo »

Thanks for the previous replys a good service is going to happen in the next week or so anyway. I was thinking maybe it could be the clutch as it feels like the box isn’t disengaging completely??

I am fairly technical to be honest, paid engineer. But I’m new to Aircooled and busses so appreciate all the help and advice

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937carrera
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Re: Gears grind when downshifting

Post by 937carrera »

As it's a CU it'll have a cable clutch so it might need adjusting if the clutch is dragging, but from the initial description it does sound as though the synchro mechanism is struggling. Where's the biting point ?
1981 RHD 2.0 Aircooled Leisuredrive project, CU engine
1990 RHD 1.9 Auto Sleeper with DF/DG engine

multisi
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Re: Gears grind when downshifting

Post by multisi »

2 ltr CU with cable clutch ?
1992 red lle 2.2 subaru 1990 rhd caravelle 2.2 subaru 1986 california import vanagon

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937carrera
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Re: Gears grind when downshifting

Post by 937carrera »

I take it I'm talking rubbish. :oops:

Apologies, I know some of the early air cooled have cable clutch and I made a leap because of the difference in feel of my CU compared to my DG. It's obviously only the CT that is cable operated. I'll know better when I stop looking at the bodywork and have to take the engine & box out for the respray :)
1981 RHD 2.0 Aircooled Leisuredrive project, CU engine
1990 RHD 1.9 Auto Sleeper with DF/DG engine

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Re: Gears grind when downshifting

Post by Jackrobbo »

It is a cable clutch so I will try that first. You could be right with synchro too I guess I hope it isn’t though or could linkage bushes be a cause? If it is synchro how big of a job is it?

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937carrera
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Re: Gears grind when downshifting

Post by 937carrera »

Ah, so I wasn't talking rubbish. I am down with my CU now and it too has cable. I am not going mad after all.

If it is the syncho rings / dog teeth then it's a gearbox out & strip down job requiring pullers & presses, if it's anything like the same as other boxes I have rebuilt. TBH I think an oil change will do wonders and the box will continue to function for a long time like that if you can;t afford an immediate rebuild, just keep an eye on magnetic deposits. Aidan on here is a gearbox specialist. (always with two a's)
1981 RHD 2.0 Aircooled Leisuredrive project, CU engine
1990 RHD 1.9 Auto Sleeper with DF/DG engine

Jackrobbo
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Re: Gears grind when downshifting

Post by Jackrobbo »

I’ll try it and let you know. Also is there a page for build threads? I know it’s off topic? Thanks for all the help

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937carrera
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Re: Gears grind when downshifting

Post by 937carrera »

There's a few in the Restoration and major repairs forum.

Pictures please :D
1981 RHD 2.0 Aircooled Leisuredrive project, CU engine
1990 RHD 1.9 Auto Sleeper with DF/DG engine

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Mocki
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Re: Gears grind when downshifting

Post by Mocki »

CU didn’t have cable clutch sfaik, but many CT engines were replaced by CU .....
Steve
tel / txt O7947-137911
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1989 2.1LpgWBX HiTop Leisuredrive Camper
1988 2.1 Caravelle TS TinTop Camper 
 

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937carrera
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Re: Gears grind when downshifting

Post by 937carrera »

You got me thinking there Steve. I've looked in my 1982 model year brochure that says the 2.0 litre model had hydraulic clutch and after a bit of research found out the CT and CU had different top gear ratios so went in search of the gearbox code.

I have DK 29 03 2

From my research the DK code is the correct code for the 2.0 litre engine (1.6 CT had DH), the gearbox being manufactured on 29th March 1982 according to the Bentley manual, which is 5 months after the date of first registration.

So that sends me to my V5 document. That has a CU engine number and 1970cc capcity which ties up with the engine.

Next is chassis number which from here https://vwt3uk.wordpress.com/t3-tech/t3 ... ure-dates/ indicates that the van was made towards the end of August 1980

So it looks like my vehicle was registered 14 months after manufacture, which seems a bit surprising as I know there was a waiting list for them at the time, local dealer couldn't get hold of one so my Dad had to get one over in Manchester.

I think you're right though, it looks like mine has a later gearbox in and therefore an engine & gearbox swap has been done, not only that the V5 has also been correctly updated :shock:

I'm not too bothered, I wanted a 2.0 Aircooled camper project in orange so that's what I have, just curious what other differences there may be.

Maybe the OP too - unless the early ones were cable ?
1981 RHD 2.0 Aircooled Leisuredrive project, CU engine
1990 RHD 1.9 Auto Sleeper with DF/DG engine

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937carrera
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Re: Gears grind when downshifting

Post by 937carrera »

I have been trying to identify the differences, without much luck, and after one search took me on a trip to ebay I went to Brickwerks

https://www.brickwerks.co.uk/clutch-cable-t3-rhd.html

Clutch cable for Early T3 models. Right Hand Drive. CT and CU engine codes.

So it looks like early CU were cable clutch as Mr Baxter is usually spot on. Now I'm confused about my gearbox date. Maybe a replacement, maybe still an engine swap, I wonder if the chassis plates have different weights or something ?
1981 RHD 2.0 Aircooled Leisuredrive project, CU engine
1990 RHD 1.9 Auto Sleeper with DF/DG engine

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Aidan
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Re: Gears grind when downshifting

Post by Aidan »

servo assistance and hydraulic clutch were options up to August 1982, fitment depended on spec and market so likely a high end passenger CU van in UK would have hydraulic and servo, but poverty spec work van maybe only servo or neither so it depends what the vehicle was built as originally and many parts can be swapped so most of those still running about from the early years may have been upgraded over time. CT was as poverty spec as it got so most probably had cable clutch but some were hydraulic. You really need the white paper sticker with the M codes or the birth certificate information to understand what a van was when it left the factory, a lot of the options are contained within the type code and destination code as UK standard market spec would be different to say Irish standard spec or Danish standard spec and often the type code just reads as "RHD van, standard body spec, 2.0 litre, standard mechanical/interior spec" so without knowing the standard spec for the destination for that model you don't know that it includes drive on left dim dip lights, speedo mph, wide angle mirror passenger side, dipping rear view mirror, laminated windscreen, radial tyres etc....

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