Blown gearbox!

[polostu]

Right, I've only had the G40 a month and it's decided to teach me a lesson already!

Since I've had it, it's been a little awkward to get 2nd, but I'd assumed it was just a worn linkage...wrong...

On my way home on Friday,as I turned into my road it really crunched going into 2nd, then as I accelerated, BANG, I grabbed 3rd quickly and drove on, but the 'box sounded like it was full of gravel. I then tried to turn round at the bottom of the road and I could engage reverse but when I let off the clutch the car just jerked violently but wouldn't move.
It'll still get first but even when the cars idling in neutral the box is making an awful noise (there must be bits of gear/bearing floating round in it!

My question is: Can anyone recommend someone in the N West who can rebuild the 'box (I'm in N wales but don't mind sending it off if needs be).
Also, could I throw on an 8p 'box in the meantime and if so will it handle the power (the car's fairly standard)?
I've also got several GT 'boxes but I'm sure they'd be geared far too low.

I would be grateful any advice, cheers, Stu

[hayesey]

yeah you could put an 8p box, the gearing is slightly lower but in terms on strength there's no difference really except the diff crown wheel is pressed on and not bolted on but it'll be fine as a temp measure.

As for rebuilds, I'd speak to a couple of local garages/mechanics for advice on any local companies they use.  A polo 085 box is nothing special any gearbox rebuilder should be fine with it.  You just want someone with a good reputation.

The problem is if you've stripped gears then new replacements from VW are expensive.  Although the actual gear ratios inside a GT box are practically the same (it's the final drive that makes the difference) so you would probably be OK using parts from one of your GT boxes. 

[Nick_S]

Nasty, second is a G40 specific gear cog too.

Just throw on an 8P gearbox in the interim, should be able to cope well enough with some fresh oil at the same time.
I'd be tempted to crack open the G40 gearbox case and have a look inside yourself before sending it off to a refurbishers. If more than one gear has lost teeth, then its essentailly a right off. You can poach some gear cogs from a GT gearbox though, if its refurbishable.

[polostu]

Cheers for the quick replies!

It's good to know I can get her running again quickly (I'm missing driving her already!)

From what you guys are saying then, the gears in the ATV box aren't built any stronger (apart from the bolted diff), just G40 specific ratios?

I think I will crack it open and have a look, I've never done a box before but one of the GT boxes has a blown diff, so I may practice with that one.

Now I can tell my missus that I knew there was a good reason for keeping a pile of Polo bits down the side of the house!

Cheers, Stu

[Nick_S]

Yeah the diff/propshaft ratio and second gear makes a G40 what it is.

[PeteG40]

tip - always check your box oil!

[SteG40]

Depends how far you want to travel but there is K&N transmissions in Preston who are very good. I know lots of people round here who use him and i'm going to get him to do mine too.

That's his address, Dale Edge, Back Lane, Whittingham, Preston, Lancashire PR3 2FH & Tel 01772 860860

[Dan]

Much better to get your gearbox repaired for two reasons:

An 8P gearbox won't give you the ratios and FD you like from the ATV box.

Buying secondhand is a big risk, especially with gearboxes.

You can get all parts like bearings, gears etc from VW that you would need to rebuild it.