I recently had an issue with my 110's R380 gearbox that led to me getting it reconditioned. However, since doing so, I've had to have it worked on again 4 times as the synchro mesh keeps failing - apparently a tooth or two keeps breaking off.

As a result, unless I crawl almost to a halt before putting it into first gear, there's a bit of a crunch.

Clearly the synchro mesh isn't at fault and it must be something else. Does anyone have any suggestions as to what the fault might be?

Also, is this something I should just live with and drive around or should I be playing hell and demanding it gets sorted. I'm just frustrated with the 3 week wait and no courtesy vehicle everytime it goes in the garage. I'm wanting to sell my vehicle but not sure how big an issue this is.

who repaired it, coz any reputable company would have checked the complete box when it was stripped.

It was a company called Cog Tec in Bradford.

i never seen dog teeth on synchro break off only front edge or entire teeth ring as weld breaks,either clutch not clearing ,which to some extent they dont on any fully ,poor build poor parts ,ive built alot of r380s and you can get a faulty baulk ring from time to time ,is it same people keep looking ,what exactly are they changing each time i

I'm not sure what they're doing but by all accounts they've just replaced the syncho mesh each time. The first time it cruched from first to second and then every other time after that it's always crunched into first. As I say, I've got used to driving around it by only changing into first when I'm stationery, but there's the odd occasion when dropping down up a steep hill or approaching a junction or traffic lights when I do need to go into first while moving and that's when it crunches. And when it crunches at its worst, the vibration goes right up my arm.

synchro mesh on r380 consits of outer baulkring centre steel ring and inner baulkring + gear cone that they push onto ,i should imagine there only changing outer ftc3584 ,+check clutch is clearing