Noisy Reverse gear

[torque]

Hi all,
Well changed the oil in the g/box last night.
Gearbox is now smoother than ever before, the shifts are slicker than ever before but the reverse is still the same.

I can assume that from previous posts, this noise is common to the 020 g/boxes.

What is the solution, wait until it goes bang and then rebuild or is there a common fix that could prolong the life of the g/box?

It has made this noise for at least the last 35000km and possibly before (previous owner) but has gotten louder recently.

Can I still just drive is gently in reverse and get a reasonable life out of it or is it likely to go bang in the short term?

What is everyones experience on this?

Should it go bang or I decide to rebuild prior, who is recommended in brisbane?

Thanks and sorry for all the questions?

Does it do like a bank noise when you put it in reverse or it is just whinning noise as you reverse ?

If the former, don't worry. I made mine much quieter with Redline MTL gearbox oil, that is the best there is.

If the first, let it go bang and then rebuild.

[Golf Loon]

If its just clicking, just be gentle going backwards and it will be sweet.

I have experience of 020 gearboxes rebuilding and the reverse gears are weak, especially in those Mk3 and 1.6 Mk4 boxes.

Its actually the same gear used in the Mk1 4 speed boxes and these never wear out, different steel, or less gears in the gate? I dont know.

I have known em last ages with noisy reverses and it probably wont hurt the rest of the box when the teeth sheer of the reverse gear. I`d wait for other symptoms before getting it rebuilt.

[craig_the_german]

Reverse

Thanks everyone for the advice.
I'll just take it very easy in reverse as the rest of the box seems perfect.
I will get it repaired but I can wait a while and just put up with the noise
It is probably more embarassing than anything....select reverse at the shopping centre, slip the clutch...knock, knock, knock....

[Jmac]

Only thing with the reverse in an 020 i have seen the gears chip , like Loon says they are weak. Chipped gears not so flash as it can go through the rest of the box. Nice to see someone using Redline MTL. I cant recommend it enough.
Jmac

[craig_the_german]

Ouch!!!!!!

Well I finally decided that the noise in reverse was getting worse and I should do something about it before it went bang completely.

My pride and joy is sitting on a hoist as we speak with the remains of the gearbox all over the bench at Gabba Gearboxes.

After he quoted me the repair costs he suggested that I should come around and have a look for myself.

The verdict......

1. The reverse idler gear had lost a tooth and all of the remaining teeth on the idler had been chipped on the corners. Fortunately the largest chunks of tooth managed to get caught by the internal magnet inside the gearbox but the little pieces, filings etc made their way through every bearing in the box...full set of bearings.

2. The worn/bent/broken teeth on the reverse idler had damaged the larger gear that it meshes with....New gear required.

3. As the reverse idler gear meshes with a gear which is actually part of the input shaft into the gearbox, the worn/bent/broken teeth had damaged the gear on the input shaft....new input shaft.

4. While the gearbox was out, I asked the guys to have a look at the clutch...might as well......clutch linings almost down to the rivets...new clutch, pressure plate and flywheel machine ......bugger!

The cost for this little adventure...$3750

OUCH!!!!!!

[spritle]

Ouch.

I got a brand new gearbox for around $4K.


how much was the clutch & work?

[dubbed]

Shhhiiit. Surely there are stronger and cheaper alternatives? I.e. maybe a second-hand box from a GTI or something if they bolt up?

[qsilverza]

You could always try custom something Like a dogbox But that would probably be exxy

[craig_the_german]

Ouch!!!!!!

Hi,

I haven't got the invoice yet as we are still waiting on a bearing that didn't arrive today. The clutch cost is about $800 which included machining the unusual flywheel.

I'll give a breakdown of the costs when I get the invoice

[D3bb4]

just to let you now helicel gear are acctully stronger as there is more tooth because of the angle
straight cut are just better to ingauge (ie. change gear quicker)

rex boxs just break due to people smashing them it to gears
so when they get the straight cut it allows them to change quick with out as much risk of it breaking

Are you for real? I'm an engineering student, and I've studied the manufacture of straight and helical cuts, particularly in diffs -and i can tell you that you're completely wrong