Gearbox Update - Help!

[scam75]

So we got the old noisy UY box apart today and it revealed the crown and pinion is mint! What a pleasant surprise! Now just need to remove the AOR again, transplant crown and pinion then refit. Still another few quid in that but the winning post seems to be looming!

Turns out the UY just had goosed bearings to go with its jumpy 2nd gear. Thankfully the crown jewels, sorry crown and pinion, was perfect!

Stuart

 

[Dan944t]

Excellent news mate ????

 

[scam75]

So I have what I hope will be the 2nd last update now! The gearbox is now fully rebuilt for hopefully the last time. Although no popping of corks till its back in the car and is ok! Looks like Monday before my guy can put it back in car.

Anyway I've now got what should be an excellent box made up from my 2 gearboxes. The gear set is mint, the crown and pinion is mint, all the bearings have been renewed with the exception of the pinion bearing which is NLA, so used the best one from my two which is in reasonable nick. We had to use the main casing from the UY box due to scoring inside the AOR casing, but the main casings are identical anyway. I have my new cooler solution sorted and it should never break again and in my opinion its now far better than the original design.

My only slight grumble is that with having to use the UY main casing, the box is obviously marked UY! But it is 100% an AOR box right down to the last nut and bolt. Unfortunately I have not been able to make a 2nd box for a rainy day due to using the crown and pinion, main casing and pinion bearing from the UY box but its eventually turned out to have been a good purchase without which I would not have a complete fixed AOR box! Costs have ended up pretty astronomical, best part of £2k by the time I count cooler parts, gearbox man costs and 3 lots of gearbox in and out labour. All that remains now is to make a coffee table out the scrap AOR main casing!

So fingers crossed all goes well when it's refitted!

Stuart

 

[Frenchy]

Good luck fella, hope all is okay !

 

[Dan944t]

Good luck mate, you deserve it to be right after all your money and effort you’ve put into it! ????

 

[dlknight]

Any pictures of the dissassembled boxes??

 

[scam75]

I have no pictures currently. At home I have a mostly empty AOR main casing with the 2nd casing still bolted on. It has the main carrier bearings still in but nothing else. I don't seem to have the end casing from the UY box, it must still be lying in the gearbox shop somewhere. I also have a box of gears and bits from the UY box, which includes the open diff, I have the main shaft mostly disassembled except the middle cog. I also have a box of assorted AOR gears, bits and pieces. By my reckoning I am short an end casing, 1 crown wheel and 2 pinion shafts, and possibly some other stuff. The end casing will be fine but the crown and pinions are no use due to damage, burning and scoring. What would you like pictures of?

Stuart

 

[dlknight]

I have no pictures currently. At home I have a mostly empty AOR main casing with the 2nd casing still bolted on. It has the main carrier bearings still in but nothing else. I don't seem to have the end casing from the UY box, it must still be lying in the gearbox shop somewhere. I also have a box of gears and bits from the UY box, which includes the open diff, I have the main shaft mostly disassembled except the middle cog. I also have a box of assorted AOR gears, bits and pieces. By my reckoning I am short an end casing, 1 crown wheel and 2 pinion shafts, and possibly some other stuff. The end casing will be fine but the crown and pinions are no use due to damage, burning and scoring. What would you like pictures of?

Stuart

Hey Stuart - don't go to any effort on my behalf just wondered if you had taken any during the process to illustrate what you have done.

Got some jobs planned for mine once I've moved house and hoping the gearbox doesn't need anything apart from a good drain and fill of fresh lube.

 

[scam75]

No worries, I didn't do the work, gearbox internals are a black art to me! Hopefully some new lube will keep you right. I've got some extra Millers Nanodrive available, see other thread, which would do you just fine at a decent price!

Cheers

Stuart

 

[scam75]

Well that's the box back in. Pretty happy with it now. Super slick gear change, makes a little noise but fairly sure it's normal transmission stuff, nothing pronounced, screechy or grindy! Little noise on the over run but I'm sure it was always like that. The notch into 2nd is gone and the idle chatter is gone. All the gears seem good and that dreadful crown and pinion racket is away. I'm sure a brand new box would be better but bearing in mind it's essentially a box of 30 year old components I think it's quite good! I'd score it 95% plus. Happy with that. Plus the cooler is much improved and won't break again and there are no leaks at all for the first time I can remember!

Stuart

 

[Dan944t]

Congrats Stuart ??

i hope you can enjoy yourcar again mate and all is well now! ??

cant wait to drive mine again been way way too long

atb
Daniel

 

[scam75]

Cheers Dan. Yeah been a long saga, box won't be out again for the foreseeable and yes driving time again without distraction. Sounds like you're well on your way to righting an even bigger wrong, and at least it was just bad luck for me and not supposed expert incompetence and subsequent denial which sounds brutal. All the best for the rest of your mission!

Stuart

 

[Dan944t]

Thanyou mate, and yes I’ve had allot of s&@t luck with speacialist but on the possative side I don’t think ive ever done so much work and feel like I truly know every inch of the car now and what it could do with ect.

really looking forward to driving it again just not looking forward to having to drive it 1500 mikes before I can test out WOT to feel the difference in all the new running gear, but good things come to those who wait I’ve heard ??

Daniel

 

[scam75]

Ha ha yes, the running in period! At least you can chuck in a cheap mineral oil for the first 1500 before changing to a proper oil for the real games! I can recommend Total Quartz 10w50 fully synth which I've used in my own motor since my rebuild. Get about 10L on the bay for just over £50. I also feel like I understand gearboxes now, well audi/porsche 016 variants anyway!

Types/options/ratios/crowns/pinions/lsd's/ open diffs/oil coolers lol

Good luck

Stuart

 

[Dan944t]

Thanks mate,
and yes I’ve got a massive 25 litres of the mineral and 5 oil filters well 3 left now as I’ve already done my first oil change. 4 bosh filters and 1 genuine from porsche dealer for what its worth?
also trying a different grade and make as I used to use 10/60 I thio nk ?mobile one now going to try 15/50 the make escapes me at the minute but it’s the brand that sponsor Hamilton in F1

i also wish I did my x3 oil seals in the gearbox whilst it has been sitting on my
Garage floor for 3 years but with the engine build Busy in my mind I jut didn’t think about it till I was fitting it.

Nevermind another time maybe
??

 

[scam75]

Yes should have done the gearbox seals. I tried 10w60 but it's a bit thick. Start up on a cold day takes a tad long to get good oil pressure. I found 10w50 to be the right compromise in terms of cold start and staying strong under heavy foot on a hot day!

Stuart

 

[Dan944t]

Hi Stuart,

yes es I thought it was a bit too, I never used it before but it was what John Mitchell at JMG suggested was the best option but to be honest they drove the car more than me on hard test runs when they had it in there Poccesion for so long, that I hardly drove it When the engine burst into a puff of steam, and the amount of broken and sloppy things I’ve niw found that I paid For and should have been done and have had to rectify and replace I decided to have a complete new start and have scrapped the 10/60 and have bought 15/50 as porsche recommended it back in the day, so I will see how it reacts and gets on after the break In As I’ve already bought it all so will deffinately keep that grade in mind mate ??

 

[blade7]

I think Porsche recommended 5/40. I used that a couple times years ago and had a persistent little drip of oil on my new block paved drive []. Changed to Milllers 10/50 CFS and no more drips, and very little oil use between changes. Used it ever since.