S3 Gearbox rebuild - How do I know what's buggered?

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Kiwi Landie

Active Member
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114
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New Zealand
OK - Finally got the boxes stripped and everything labelled in little zip lock bags.
So far so good.
Now the various manuals all say things like 'inspect and replace worn parts'. This is all very obvious when something is broken or in my case missing completely (synchro flat spring - fell out the drain plug with the oil but had clearly gone around a few teeth on its way out). What I need a bit of guidance with is how do I decide which if any of the gears are knackered? They all look pretty good to me. There are no chipped teeth, and there is just the slightest hint of 'polish' on the sides/ends of some of the teeth on some (not all by any means) of the gears. The transfer case internals also look pretty good but the Haynes manual has a picture of a 'badly worn intermediate shaft' but the photo is black and white and tiny, and to my eyes the shaft looks just like the one in my gearbox! Short of finding a gearbox expert (I live in rural New Zealand), are there rules of thumb to help determine what's buggered and what's not?
Before someone asks, I wasn't able to hear this 'box running. My S3 came with an S2a gearbox which I've sold off to help finance the rebuild.
S3 1978 Suffix B box and transfer case.
Cheers for any wisdom offered.
 
OK - Finally got the boxes stripped and everything labelled in little zip lock bags.
So far so good.
Now the various manuals all say things like 'inspect and replace worn parts'. This is all very obvious when something is broken or in my case missing completely (synchro flat spring - fell out the drain plug with the oil but had clearly gone around a few teeth on its way out). What I need a bit of guidance with is how do I decide which if any of the gears are knackered? They all look pretty good to me. There are no chipped teeth, and there is just the slightest hint of 'polish' on the sides/ends of some of the teeth on some (not all by any means) of the gears. The transfer case internals also look pretty good but the Haynes manual has a picture of a 'badly worn intermediate shaft' but the photo is black and white and tiny, and to my eyes the shaft looks just like the one in my gearbox! Short of finding a gearbox expert (I live in rural New Zealand), are there rules of thumb to help determine what's buggered and what's not?
Before someone asks, I wasn't able to hear this 'box running. My S3 came with an S2a gearbox which I've sold off to help finance the rebuild.
S3 1978 Suffix B box and transfer case.
Cheers for any wisdom offered.
You ask in the Disco section, not in here - there is even a ‘sticky’ from a moderator at the top of the page asking / begging / telling you to not post technical questions in this section...
 
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