Crunching second gear....help?

[skin_dog]

Sorry if this has been covered but I searched the topics and couldn't find anything relating to my specific problem. I'm getting a small crunch from 1st into second and a very nasty crunch when down shifting from 3rd to 2nd. I've read the manual but it's a little hard to understand the terminology.
Any help would be great
Cheers.

[muza]

Push the clutch pedal in funny bastard
Is your clutch working ok?

[Harv]

G'day Skin Dog,

Some possible causes:

a) Clutch plate is dragging (pray this is the cause, as it's the easiest to fix). Adjust the clutch by setting the clutch fork operating rod free travel to 5/64” (0.080”) and the clutch pedal free travel to 1/8”.

b) Synchronising cones or cone surfaces are crook because the cones are worn. Major pain in the bum. Need to remove the gearbox from the vehicle and disassemble, then replace or reface the synchronizer cones. Replacements can be gotten from a 2nd hand box… refacing cones is possible but an expensive proposition. If you are going this far though, you may as well put the whole Rare Spares overhaul kit through).

c) Second and third speed clutch (not the main engine clutch... this is a component inside the gearbox that is the partner of the syncro cones) is crook because the bronze insert is loose. Another pain in the bum. Need to remove the gearbox from the vehicle and disassemble, then replace the second and third speed clutch. Replacements can be gotten from a 2nd hand box.

d) Synchroniser energizing springs are weak or broken. Medium size bum pain. Still need to remove the gearbox from the vehicle and disassemble, then replace the synchronizer springs (these are available from Rare Spares, unlike the synchro cones and clutch above). This can also be caused if the synchro retaining ring has come adrift... again a "remove from vehicle and pull apart" task.

Cheers,
Harv (deputy apprentice crashbox cruncher).

[Devilrod]

Easy fix, lay off the race changes and double the clutch!

[parisian62]

Not being a smartass but you've checked your clutch fluid level?

[bootlegger]

Its going to be your synchros. New box or double shuffle im afraid.

[Cal]

Sometimes it could be the linkages. Mine are as loose as buggery, and if i go to chsnge from 1st to 2nd whilst turning right, it'll crunch it's balls off.

Only way to stop it is to pause a bit in neutral while changing gears

[skin_dog]

Thanks for all the hints and help guys. And thanks Harv for explaining the how's and why's.
I've got a spare box, but before I do that I'll adjust the pedal and lever.
I did notice last night that one of the gear shift rods is missing the bush at both ends so there's lots of play there, could that cause my problem?

[Devilrod]

I did notice last night that one of the gear shift rods is missing the bush at both ends so there's lots of play there, could that cause my problem?

It won't help thats for sure.