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LUPO 1.7SDi Gearbox problem


YellowBox
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Can anybody on here point me in the direction of anyone who can deal with gearboxes for a 1.7sdi, either to rebuild the one I have or source a replacement?

Driving to a race track yesterday the box became particularly unhappy sounding when coating without the clutch in, happens in 1st and 2nd and the same noise has now spread to 3rd gear. Clutch in, out of gear and 4th and reverse seem to produce no whining, so I fear I've lost main bearings or something along that route in the gearbox. It still selects just fine, but driving it is likely to end in the inevitable loss of probably everything. I've been quoted around £1000 to have the box out, another box thats on ebay for £350 put in, along with a clutch and the labour, which I honestly can't really justify at this time. I've just put it through an MOT and at 183,000 miles its seen quite the life as my first and only car for the last 6 years. As some may understand, I'd be quite devastated to have to let it go

Can anybody point me in any less wallet crippling directions?

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In manual gearboxes, the gears are always meshed and turning - even if not selected. Don't drive or move it. Yeah probably just needs a rebuild kit for about £100. Takes under 2h with someone who knows what they're doing.

My local place charges me £50, but I supply them with everything and a drained gearbox. All they do is split it, pull all the bearings and seals, then chuck it in the auto power washer tank for ten mins. Then press in the seals and bearings, reseal, assemble, check clearances and bolt up. Perfect. Good for another 100k. I took pics last time. Just two specialist tools needed (for 5th). And you need to know how to do the selector mech (i just don't get it).

where are u?

oh and welcome to club lupo :)

 

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I think I was looking at that post earlier. I drove it home quite a few miles with that noise saturday so i imagine that has not done it much good either. I was looking at the rebuild kit (Think i saw it on ebay for £130) and was wondering where exactly they're making up the other 600 quid from but i think they just cant be bothered to deal with rebuilding my box and just want another one sticking it it, which is a common theme around here. What place are you using? Im in Leicestershire myself. And funny you should mention 5th gear, because I've not had 5th in the 6 years I've owned it. Probably would be worth checking that out too if I can afford to get it done

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I found a mechanic who can repair my gearbox for proper price, but the price only includes single adjustment of conical roller bearings to “regular width”. Adjusting of conical bearings is the expensive and time consuming stuff which can not be done in 2h rebuild. Anyway, I will take a shot and try this method of repair.

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There is no adjustment in the 085 gearbox. Only the slack setting in the 5th gear selector fork and the clearance washer on the end of the layshaft. The "cone" or roller bearings cannot be adjusted. They must be fully seated then the running clearance is perfect. Exactly like wheel bearings 👍🏻

@YellowBox, I'm lucky as one of the best and experienced race tuning gearbox places in the UK is on my doorstep, in Woodcote... If the needle roller race has melted, bearingboys can supply them. In fact you can buy all the bearings from them except the seals. Cheaper too. But the places on Ebay save you time and bundle everything together. Pull out the box, split it then have a look what's going on (straight forward). But you'll need special tools to take it further.

Edited by mk2
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7 hours ago, mk2 said:

There is no adjustment in the 085 gearbox. Only the slack setting in the 5th gear selector fork and the clearance washer on the end of the layshaft. The "cone" or roller bearings cannot be adjusted. They must be fully seated then the running clearance is perfect. Exactly like wheel bearings 👍🏻

 

Yes, the fully seated is the adjustment whats needs to be done, workshop manual also uses the word "adjustment" and after rebuild should be done for input shaft, output shaft and differential.

 https://workshop-manuals.com/volkswagen/polo-mk3/power_transmission/5-speed_manual_gearbox_085/gearboxmechanicsgearsshaftsinternal_operation/adjusting_input_shaft/

https://workshop-manuals.com/volkswagen/polo-mk3/power_transmission/5-speed_manual_gearbox_085/gearboxmechanicsgearsshaftsinternal_operation/adjusting_output_shaft/

https://workshop-manuals.com/volkswagen/polo-mk3/power_transmission/5-speed_manual_gearbox_085/final_drive_differential_differential_lock/adjusting_differential/

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@ObjectiveAway I understand what you mean now. Yeah, it's not needed when rebuilding the gearbox, so long as the replacement bearings are identical to the original- which they will be if you get quality bearings. All the bearing dimensions are very precise. Ok, so maybe 0.01mm difference, but nothing to worry about as all the components are being reused. Only the two things I mentioned need checking.

If building a new gearbox with all new components, that would be so time consuming. OMG! Like setting up the contact pattern on a hyperboloid differential, using engineer's blue... Very tricky!

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14 minutes ago, mk2 said:

@ObjectiveAway I understand what you mean now. Yeah, it's not needed when rebuilding the gearbox, so long as the replacement bearings are identical to the original- which they will be if you get quality bearings. All the bearing dimensions are very precise. Ok, so maybe 0.01mm difference, but nothing to worry about as all the components are being reused. Only the two things I mentioned need checking.

If building a new gearbox with all new components, that would be so time consuming. OMG! Like setting up the contact pattern on a hyperboloid differential, using engineer's blue... Very tricky!

Thank you! Now I understand the idea of no adjustment needed.

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