How to fix a 200series Gearbox Synchro

On my gear box it crunches into second gear unless you double clutch it at the right time. I've been told its the synchro and as I'm probably going to sell it in the new year, how do I fix it? It doesn't bother me but it would someone else. is it a DIY job?

i've been told saw dust in the box mixed with the oil,BUT NOT RECOMENDED AT ALL, other than that a box from scrap yard,or a recon which i've opted for and cost me about a grand wiyh a new hd clutch.

Mine was rebuilt and now it's doing it again

I'm just double clutching, it annoys me when I can't get it to go in gear without some noise but if I slow down enough it's fine. I'll get it sorted when I actually lose drive :lol: I got irate with 1st gear the other day so pulled off in second and if second annoys me I go from 1st to 3rd lol
I might look for a cheap box, if I keep the darn thing

not really easy to do without special pullers

I just double clutch second now. Snicks into second from first if I change too quickly, and will not go down to second unless travelling quite slow, but it seems happy to double clutch so I will carry on dong that. Not worth taking the box out for it!

change oil regular then

is the clutch fully disengaging ?

must be if no reverse problem or other gear ,2nd is usually first to go

jamesmartin said:

must be if no reverse problem or other gear ,2nd is usually first to go

Click to expand...

I musta missed that post

James, i did check the oil the other day and it seemed reasonable, might have had a little brass in it but I also have a shot of slick 50 in there which greatly helps with rapid hear changes with anger whilst off road, where the syncros aren't really doing anything but the gear selector is working overtime, and that is a milky colour so it discolours the ATF anyway, making it hard to tell its quality. It wasn't dirty or burned at all, new stuff went in last year, maybe 2000 miles ago.

And yeah the clutch is ok Sean, I mean if anything I'd like it to bite lower. Had a new clutch in it last year too but it seems to grab around the middle and only bite properly right at the top. Not sure if it's contaminated or normal, never has a problem with overheating ir slippage, just the way it is maybe, but the point is that yeah it's well past disengaged by the time the pedal gets to the floor.

Cheers

i meant change because of baulk ring bebris it gets in all bearings ,gears and buggers it ,

Ok cheers James, as I said I think there was an amount if brass in it if anything, probably more settled in the bottomcos I only checked level from fill plug, will drop it and refresh

I think my clutch may not be fully dis engaging, as I do have to double clutch into 1st from 2nd & 3rd from second, yet 4th & 5th seem find, reverse also requires it :/

Reverse is **** it mine too though, always has been, really hard work to get engaged, either has to be done with the car rolling slightly, or I have to keep spinning the box over with the clutch to find a sweet spot where it'll slot in.

Used to be difficult but then the selector fork snapped and it got rebuilt including new second gear parts and it was more difficult than before. Second gear synchro was fixed for about 18 months though...