Picked up a gearbox from Ben, he mentioned that he couldnt get the speed sensor out of the box, so someone had a go at removing it, ended up drilling it out, wouldnt have been so bad but he blew an airline over it......
So stripped the box down to clean it out and it was a bit worse than I first imagined
Top casing off
Diff out
Whats underneath
I sat with a vacuum and removed every last piece of swarf I could find for about 3 hours, I know I wont have gotten everything out but I did find some fairly large chunks of metal that were already present in the box from wear etc, all the synchros and gears looked great, there were a few marks on the FD gear where something had obviously gotten between the teeth at some point.
Bits I found
Its actually quite surprising how dirty the inside of a box can get from not having regular oil changes... when compared to the VLSD box I had, that looked basically brand new inside
Now removing one of the selector arms I noted some odd wear marks like it has been forced down at some point some how.
Here you can see it with a normal one
and the gaps thats present as a result
I have swapped it for a mint one now, and given the box a good clean inside removing all the varnishing that had occurred.
Got it back together last night
Im going to flush the box through when I first fit it with some fresh oil, now I have a shit load of ATF fluid sitting around Im looking at just running the engine and letting the box warm up then draining this and filling with some proper fluid..
Thoughts on that? I know ATF fluid is very thin but the box wont actually be under any load....
Clutch has just arrived from Trug as I write this, just need the flywheel to turn up and its game on.