syncro gearbox problems

i think my gearbox has sh*t itself! today in freo there was this kinda banging jumping out of gear thing going on then nothing - no drive in any of the gears, not even reverse!

any ideas??? any boxes for sale any where? mines a rear box 6pa 11 059.

cheers jon. i'll be giving mike in o'connor a shout later!

it makes u wonder why we own or want to own these buses with a notorious reputation for gearbox problems..?

I want to own one yet all I have heard since starting my research is how problematic the boxes are..

I am still hooked though .the upside ,heaps of room for mum dad and the three kids with 4wd capability and euro comfort

my brieif troll through the archives regarding syncros brought up some old posts of yours with the gearbox being the feature subject ,back then,
is this your second major g/box issue...?

I might be able to help u in your hunt for a replacement box, it will be an east coast to west freight job though if it works out...!

pm or email me ..bushtraka@hotmail.com

cheers

From the small discription you posted sounds like the planetary gears have broken in the diff ....this is not a huge job and may well worth getting the box disassembled and quoted on.....syncro gear boxes become troublesome due to la lack of mechanical understanding.....after the 140k mileage mark the pinion bearing should be renewed and geqarbox oil changed a little more regular.Most failures occur at the crown wheel with bad wearing at the mesh.........oil in a syncro box gets veery very hot and have often considered fitting a external cooler and pump to ensure a little longer life....the syncro I own has 245ks with one rebuild on the gearbox..these are great buses understanding the beast and getting the job done right is of parramount importance cheerws steve

Hi Steve ,trying to find someone/business on the east coast who treats these boxes with paramount importance and gets the job done right ..?
who did the rebuild on your box ,if thats not a rude question..?

just looked at a one owner caravelle syncro 250ks ,the box has been out twice in that ,along with the front diff,about 2yrs ago. they were both rebuilt by a "very reputable" vw bus specialists and the box came out a second time shortly after as the main shaft had issues that were not picked up the first time....
I am seriously interested in this bus and the first thing i think is, the front diff has not been used since rebuild,owner has left driveshaft out since rebuild,so is this going to have issues when it gets it s first workout with me...?
I wonder how reputable the guy was putting box back together

After speaking to about ten syncro box "specialists" in three countries you would be the first person I have heard suggest a cooler for the box
its not rocket science is it......

yet after all those enquiries ,here in aus ,I have not found anyone who fills me with confidence regarding thier capabilities with rebuilds.
people seem disinterested or even worse ignorant, when i mention crown wheel and pinion variations such as Albins' manufacture, where you can alter your final drive ratios ,same again with the longer gear sets for 3rd and 4th gears....
It would be great to know going into a purchase of one of these buses that there was some quality rebuild specialists out there for the boxes
cheers

yes i had MAJOR problems with my box about 18months ago, another box was sourced, that was un well as well. but out of the 2 boxes 1 reasonable box was made. the crown and pinion had a couple of marks but i'm thinking they would be ok.

i've travelled about 30,000 inc some very rough tuff off roading it was whining a little i checked the oil, all good, then bang it went.
i removed the box last monday removed the bell housing to find the jointing sleve shattered and the first bearing you can see missing and the hole it sits in totally ovaled.

theres a really good guy in freo, he's doing me a massive favour and by saturday i should know the extent of the damage

i'll tell you guys everything as i get to know it!

ps a big hi to mike in freo at volkshop. he's gonna be busy this week so dont call him!!

make sure the axle nuts are really bloody tight

make sure the axle nuts are really bloody tight

hi greedy the axle nuts are ok- not so sure about the nut behind the steering wheel!!!😂

mike helped me strip the box yesterday, what we found was either a failure of the small bearing due to lack of oil (*oil was to the level and good) or there was play in the big bearing and the movement caused the failureof the small bearing, the metal on metal dried the case and blued it slightly.

the main shaft has gone, the hardening is thru on the teeth, and where the small bearing was is VERY badly worn. bugger!