No matter what happens it grinds from 3rd to second unless i'm idling.
I'm gonna have to pull the box, check everything over and re assemble it I think.

I'm not going to ask who rebuilt the gearbox but I would be interested to know where the parts were sourced and which ones were replaced. If you prefer to send me a pm and have a private discussion feel free.

Three servo pieces should be installed under the synchro ring- a circular band, an energizer and anchor block. I don't see them in your pictures of damaged parts. If any or all of these pieces were not replaced, your synchro will not function properly. You might review your receipt of parts purchased, and check what damaged parts were not re-used.

Some local mechanic here in Uganda.
That would certainly explain it.
We only put in a circular band, I don't remember an 'energizer' or anchor block.
Any idea what these look like?

Since I'm going to UK this coming week I can pick up these parts.

Thanks for the heads up!

It could just need an adjustment at the coupler. Start there first. If the problems can't be adjusted out, then it is most likely internal.

were these items installed inside the syncro ring?

http://forums.pelicanparts.com/uploa...1386773854.jpg
http://forums.pelicanparts.com/uploa...1386773870.jpg

Feel full of fail right now!:rolleyes:

Ok so the ring was installed but not the other 2 smaller parts.
Oddly enough the mechanic never mentioned those parts and I don't remember seeing them.
He just brought the broken ring and said buy this.
I'll have to ask him before confirming to make doubly sure but that looks like it would confirm the terrible gearchange.

Thanks guys, it always amazes me how someone 10,000 miles away can help me out!

Be aware of all the synchromesh pieces on the gear:

*The synchro hub (toothed ring pressed onto the gear)
*The synchro ring
*The circlip (retaining ring)
*The circular brake band (upper photo)
*The energizer (small block with tab, upper photo)
*The anchor block (small wedge piece, upper photo)

There are 4 pieces which might be described as a "ring".

So I asked my regular mechanic but he is a self confessed gearbox rookie, tomorrow we're going to see the mechanic who fitted the parts in the gearbox and he will be able to tell us whether those parts were fitted.

I personally never saw them at all.
All the parts fitted were sitting on my desk for ages until they were fitted.
Makes me think they weren't fitted.

That makes me think that I'd never use that mechanic again...

JR

Lol me too.
However, this is africa.

Granted. I'd put the gearbox in an ice cooler, add padding and tape, then ship it to a country with real mechanics. Preferably all the way to a guy that rebuilt 911 gearboxes for a living.

Shipping may seem expensive but so is rebuilding the same thing, over and over. I've shipped these things around the globe.

JR

Yup I agree that's the way to go.
But I'm planning on buying a G50 in a few months to replace this one.

Maybe buy the G50 now and put this on a shelf, or sell it for parts?

JR

a whole G50 car hopefully, because a G50 won't fit in yours.

I thought you can retrofit a G50 with some work?
Anyway we're opening the gearbox on monday, hopefully it'll be an easy fix.
I'll post pics.

Thanks

"Some work" is not accurate; more like major work. Probably not something you want to tackle where you live.

JR

I can do that sort of work, I just don't know anything about the internals of gearboxes.

So all the parts are in the box;

http://i272.photobucket.com/albums/j...psacb13d09.jpg

Any other ideas?
Perhaps an adjustment issue?

Any help would be great, engines dropped and gearbox is out right now.

EDIT: I guess my mechanic isn't as bad as I thought, feel bit bad now.lol

I have some experience which involves hot-rodding in Africa :)

I went to Togo tune a standalone ECU on a turbocharged BMW 325 (E36) after the owner struggled to get it to work since there was not a single person available in Togo neither nearby countries (Ghana, Benin, Burkina Faso).
Since the guy studied in USA for few years he got a glimpse of fast cars and wanted one at home also, he built it himself and not bad but ECU install+ tune was way over his head that time.
It turned out well despite the sub-par fuel quality and already have next project in progress: his brothers E46 with full carbon body and interior, equipped with S50B32 supercharged engine. Car was built in US but was destryed due to poor fuerl and threw a rod.
So we built a new S50B32 engine with forged internals and sent it to Togo on the pallet. Engine is swapped and next step is to travel to Togo in February and tune the car.

Car that I tuned:
http://www.porsche-foorum.org/album/...mal_togo12.jpg

And car that waits for tune:
http://www.porsche-foorum.org/album/...mal_togo32.jpg



*Sorry for OT*

That looks pretty insane!

I built this;

https://fbcdn-sphotos-a-a.akamaihd.n..._5172566_n.jpg

And built the engine myself;

https://fbcdn-sphotos-d-a.akamaihd.n..._8227472_n.jpg

From a 1500 to a 1776, currently in the process of supercharging it.