cupra20v.t

I have a Tvr Cerbera and they use the T5 2wd borg warner boxes.

I have a problem with 2nd gear on my box, at slow speeds and low revs 2nd gear changes ok, but anything over 3k revs and the gear crunches, only way to get it in is to literlayy ram it in and bear through the crunch.

i have tried double cluthing etc but no joy.

Would this be the Synchro ring for 2nd gear?

I dont mind sending it away for a refurb but where do you guys recomend for price and quality of service?

Is it a job i could do in my garage or are special tools required. i have seen lots of parts on ebay and guides for rebuilds on ebay but im reluctant to spend unless i know the guide the covers my problem.

any advice is welcome. just wish my 1st post could have been a more positive one, but hey what are forums for.

oh and the box is out of the car sitting on my garage floor. thanks in advance

tabetha

It's worn synchros most likely, the ends of the selector forks on the early ones were shit as well which made this worse.
I would put it in a box place, I have an ace one near me but a few miles from you, fifth gear in particular if it needs to come off often breaks even with the correct tool and heating, around Ł100 on it's own this bit, so I would ask around garages etc who they use.
tabetha

pacwest

Were you using gear oil in it? It works west with ATF in it. Crunchy second gear is a common effect of running something like 75/90 gear oil in it - If the synchros aren't bad.

As tabetha says, get a good place to look it over. Some repairers will just throw any old gear set in there. Make sure the ratios stay intact or get upgraded to a better spec. Not worse!

This is a common issue over here for XR4Ti owners. Using the 4 cylinder input shaft gives you rotten gearing. Gearbox ratio selection is critical. Make sure you get a rebuild only. If it NEEDS gears, then get the right ones.

I've stressed that too much maybe.

tabetha

It's actually the use of ATF that screws the synchro up, the synchro ringhs need FRICTION to do thier job and they get the right amount with gear oil, next to none with ATF.
tabetha

cupra20v.t

i bought the car with the 2nd gear problem, however the seller wasn't aware of it as he just wanted rid of the car.

I had to wait for the car to be fixed before i could have it and the problem was 1st wouldnt engage. so he had that fixed and trailered the car staright to me. from looking in the paperwork for the car i can see he has hand written "gearbox oil 10w40" i was shocked to see this and i asked him over the phone and he said someone reccomended engine oil!!!! for the box? so i have bought the tvr's recomended gearbox oil/atf now and i will put it in once the repair has been carried.

I understand what you mean with gear ratios etc and ensure that the same gear is replaced not one with a different ratio etc.

The only place i have had a quote from so far is Gearbox man and i had that months ago and ive written down Ł185 for synchro kit, seals, and bearings and Ł310 for fitting etc, all plus vat. i dont know if this is good or not as i have never had to have a box refurbed before. thanks so much for all the replies.

tabetha

It depends on what exactly is done, but from above sounds expensive to me.
tabetha

JonnyBravo

I would use the Redline Heavy Shock Gear Oil in it, sorted my mates GTR box out nicely when that was crunching.

cupra20v.t

i have the engine out now so i would rather get it repaired for good rather than try different gearbox oil and have it cruch again meaning i have to have the box and out again which is a nightmare.

where do people recomend i take it? for a realiable rebuild and good price.? but someone with knowledge of t5's

JonnyBravo

CTS, BARA.

I use Steve @ A1 gearboxes in St Neots as he's local and has a fast turnaround.

I wouldn't use anything but some of that gear oil in future, seems to be very impressive stuff

cupra20v.t

ill read up on that oil and see the reviews, cheers mate. im not bothered about locations of shops etc as the box is going to have to be palleted and couriered to a rebuilder anyway

AndyPen

iTrader: (24)

Theres a place that sounded quite decent in the enterprise park in Swansea Vally mate. There are a lot of ex cossie rally boys around here who know their stuff. Have you asked Promax (Dafen Ind Est., lllanelli) for advice for example?

leesm

hi mate
give sall a ring he has rebuilt t5 gearboxes
instock Ł500+vat exchange
phone no.
07760 476163
lee

tabetha

As I said gear oil will be better, as it is thicker, and allows a bit of friction which is what the synchro rings need to do thier job.
tabetha

cupra20v.t

i dont fancy exchanging boxes as i want to ensure i have the right gearing on the box to suit a 4.2 litre.

i will have a phone around swansea and see if there are any ex rally boys in the rebuild business.

marco polo

iTrader: (1)

hi mate


as tabetha says it might be the syncro or the selector fork

if you want it service it will cost roughtly 250+ parts what ever it needs

the only reason why ford or tvr use atf fluid in their gearboxes is because you can drive the car away from cold

atf is ok if your just doing road mileage but if your going to drive the car hard then i would say use the 75w/90/ fully synthetic geabox oil

personally your box needs looking at it wont be the oil defo not

it will still be the same even if you put other oil in it

marco

cupra20v.t

it wont be getting driven hard really and by that i mean track days etc, its just used on normal roads with the odd hoot here and there on the motorway/dual carrigeway etc.

I definetlye wont be changing the oil to see if it cures the prob. i know the box has to go away for a new ring or fork, its just finding someone who is knowledgable and can rip these thing apart in their sleep. i dont want a monkey garage who have never seen a t5 before to take it apart and learn whilst they are doing it etc

im going to give promax a ring, and search for a rebuilder locally. if i get no joy then i think i will send it to Gearbox man

JonnyBravo

No disrespect Marco but this is exactly the same fault my mates GTR box had and that oil stopped all the problems and he now has 100hp on top of what he did and its perfect.

There is nothing to say it wouldn't sort it but being that the boxes are relatively cheap to rebuild it makes sense to pull it apart and have a look as potentially something isn't right, if it was mine I'd try the fluid first, in my mates case the fluid saved him a 2k bill on having a box rebuilt

cupra20v.t

i want the car ready for summer, so i dont want to risk changing the fluid, painting the car and engine, installing it all to find 2nd gear crunch is still there and i have to pull it all out again and risk marking the paint work and chipping the engine paint etc.

i have spoken to gearboxman and i got the maths wrong it Ł310 plus vat for kit and repair etc.

JonnyBravo

Seems a fair price and being honest I can understand your way of thinking, less hassle in the long run.

cupra20v.t

thats it, im just thinking of the long run, and i really couldn't be arsed to get the box out again in this weather.

cheers for the advice though mate. taken on board and will invest in some of that fluid for future use.

JonnyBravo

No problem

foreigneRS

as you may know, parts are readily available to rebuild these and the manuals are all available online. if you are handing with the spanners, you will be capable of, and may enjoy, rebuilding it yourself as i did.

the only trouble you will have is removing the 5th driven gear as you need an extremely long and thin puller but it's something that you can make up yourself with a bit of effort.

just be methodical with the strip down and lay everything out on a big piece of card that you can label and rebuilding is easy

AleksEU

Anyone know where I can get the 5th gear for the Borg warner T5 Cosworth gearbox and synchros for the 3rd/4th gear?

RS SHAUN

iTrader: (24)

Who's that then Lee?
Not a bad price?
And what's the location?

chrisa3

iTrader: (1)

try GEARS, they make their own 5th gears in house I believe. I got an exchange box for Ł500 inc VAT.

Also, from speaking to various specialists etc, the reason the T5 uses ATF is because of the 1st and 2nd gear synchros. The Euro T5's came with fibre rings which were designed to slow the gear down before engaging where the US T5's had metal rings and were fine on gear oil.

Apparently the ATF helps the fibre ring get friction and doesnt wear the rings out, where gear oil damages the fibre rings as it makes them too slippy. Just what I was advised

I run mine on Castrol Dex 2 multi-vehicle which is what castrol recommend and its compatible with the original ATF listed in the Cosworth owners manual.

AleksEU

Are you reffering to this company:
http://www.hpcgears.com/ ??

chrisa3

iTrader: (1)

http://www.gears.tv/