i bought a T3 gearbox.. the only running one i could find...
and was told it has a crunchy 2nd gear... what is making it crunch, and how do we fix it??

The synchro ring on that gear is worn.
Very basically, synchro rings work a bit like a little clutch and equalise the speed of the gears/shafts/selector rings so the selector ring engages smoothly on the gear.
The grinding noise is the splines on the inside of the selector rings clashing with the splines on the gear which is not turning at the same speed as the ring.

You could try and add and engine additive like STP or Forte. This will thicken up the oil quite a bit and may help the operation of the synchros but may make the box quite clunky, particularly when cold.
You either live with it or you have to have the box stripped and synchros replaced.
Its a big job and unless you have an understanding friend that can do it for you, Its going to cost you lots of money.
Bummer M8

L8tr
E

yeh i was told $600-$700 to fix.... :cry

A gearbox rebuild with new bearings, crownwheel and pinion and three new synchro's cost $1500 on a 2 litre box. Not inexpensive, but a pleasure to drive now.

double shuffle n u ll be right for a while

synnchro rings also at times crack !!! then its hard to double shuffle.

Always a problem that second gear syncro. The tart (71 beetle) has a crunchy second gear. When you think about it, it is the most used synchro. You change from first to second or third to second while moving more than any other gear change. Especially with a city car.

is it hard to change the second gear snchro my self??
ive got another box with didnt have any second gear probs...so i could probally mate it , if not too hard

As far as I know, there are a few tools required for gearbox rebuilding that are not part of a standard tool kit, and the diff centre will need to be pre loaded if the bearings are replaced. It is definitley a job best left to those that will offer a warranty.

Yer quite right Hellbus.
Vdub transaxles buildups are not for the faint hearted!

Live with it, try the STP or find another gearbox and finally, have it done for you.

L8tr
E