2nd gear clunking

[treed2 at u.washington.edu (T. Reed)]

Rhett,

My newly built 4k w/bolt kit + 0.80 grinds in second, too. The synchros
were fine when I had it apart so I didn't replace them -- I attribute the
2nd gear grind just to the car being a VW.

Redline MTL does help the grind, but I don't trust the stuff anymore.. so
for now I'm just living with it and going easy on 2nd. I've got NAPA
Sta-lube MT-4 gear oil in it right now. Maybe it needs the 'friction
modifier' that someone was talking about recently.

As far as replacing synchros, you need to do most of the tranny teardown.
I'd almost say its a full teardown because just a couple more circlips
and 4 bolts and it IS a full teardown.

You need to pull the tranny, remove 5th gear (kind of a pain), split the
case (you have to build a special tool, and you have to remove the drive
flanges which requires a flange compressor), and pull a bunch of circlips
(you need circlip pliers). You need a lot of time (several days at least)
and a big space to work in since there will be parts strewn everywhere.

It's not really a job for a novice, but I wouldn't hesitate to do it
again now that I know how the gearbox goes together (and now that I have
all the tools)

In your case.. I would try a gear oil additive of some type. Ask around
and find out what works, then report back to me :)

Just remember that synchros operate on friction. With too little friction
they won't work at all and you'll grind in every gear. Think of them as
miniature clutches that mesh together just before you engage a gear.. you
don't want over-lubricate them (but if you under-lubricate them, they
will wear out quickly).

-Toby

On Sun, 7 Sep 2003, Rhett Farnum wrote:

> The rocco my friend is going to be getting mon. (and joining here soon
> after) does the same thing. When I drove it and power shifted into second it
> didn't do it but any other time it does.
>
> How hard are syncros to replace? Is it like an afternoon project for some
> rookies or more like a wknd?
>
>
> Peace Out,
> Rhett
> Rocco_crossing
> '83 Rocco (autocross ready, tune up, install harness, and finally I may get
> to makeing it look better!!)
>
>
>
>
>
> >From: Ron Pieper <rapieper@yahoo.com>
> >To: Scirokn Virginia <scirokn@hotmail.com>, scirocco-l@scirocco.org
> >Subject: Re: 2nd gear clunking
> >Date: Sun, 7 Sep 2003 03:19:36 -0700 (PDT)
> >
> >Please describe "speed shifting" - how exactly did you shift (up and down),
> >how fast, etc.
> >
> >Sounds like you baked 2nd gear synchro, possibly from forcing a
> >downshift???
> >
> >LMK
> >
> >Ron
> >
> >--- Scirokn Virginia <scirokn@hotmail.com> wrote:
> > > Last friday I lost my clutch cable and drove home 38 miles, ten in town
> > > traffic...starting it in 2nd gear and speed shifting. I got it home fine
> >but
> > > after installing the new cable, 2nd gear clunked into place with a mild
> > > grind. I figured I had thrown the linkage off. So after fiddleing with
> >it
> > > for 3 hours and finally having all gears where they belong again....it
> >STILL
> > > clunks. Only at idle speed will it go in quietly, but who grabs 2nd at
> >that
> > > low rpm...nobody. And it doesn't matter if it's an up or down shift.
> >Have I
> > > broken something inside the tranny? tell me NO...agh!!!! help!!
> >
> >
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