Broken 1st/2nd slider spring and cracked synchro

jstar89crx

Anyone ever seen this or know what can cause it?
5000 miles of highway driving after rebuild I lost the ability to engage 1st unless I came to a stop. 3000 miles of highway driving after that I lost the ability to engage 2nd.
Both synchro's showed no wear aside for where a piece of the broken spring got stuck. 1st gear syncrho was cracked all the way through. One corner of one of the dogs in the slider that holds the spring was also chipped.
Thoughts?

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86 Syncro, weekender carat interior, the rest is bone stock for now
SOLD:91 Westy, BEW TDI with VNT17 Turbo, water cooled intercooler, Malone Tune, taller 3rd and 4th.

16CVs · Posted: Mon Sep 15, 2014 11:52 pm Post subject:

Do you have this trans up against a Diesel ?
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gears · Posted: Tue Sep 16, 2014 12:06 am Post subject:

That shouldn't matter, as this failure isn't load related. The 3 "energizers" (shift plates) will sometimes fail. It isn't common, but does happen.

Ignore the Bentley page regarding synchro rings for the Syncro, and use this page (obtain the 247B for 1st gear):

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aka Pablo, Geary
9.36 @ 146 in '86 Hot & Sticky
'90 Syncro Westy SVX
'87 Syncro GL 2.5
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jstar89crx · Posted: Tue Sep 16, 2014 7:02 am Post subject:

16cv's- yes transaxle is a 2wd mated to my tdi

gears- aside from the vw/audio logo with some letters and a '1' or '2' there are no other part numbers on the old synchros. Is there a way to tell what # the broken one is? Also, the one that is broken has a #2 on it so I am I correct to assume that that is for 2nd gear? It is cracked right at the corner where the dog goes. There is also a fracture in the corner where one of the other dogs goes.
_________________
86 Syncro, weekender carat interior, the rest is bone stock for now
SOLD:91 Westy, BEW TDI with VNT17 Turbo, water cooled intercooler, Malone Tune, taller 3rd and 4th.

gears · Posted: Tue Sep 16, 2014 7:37 am Post subject:

No, the numbers on the parts box and the description of the parts as per the page I posted are what's important. You may have to replace the hub if the shift plate (key) slot is damaged.

Also take a look at the 1st/2nd shift rod "bushing" to be certain one of the sleeves isn't cracked. (Bentley 35.46)

I'm wondering if perhaps the two springs had been hooked into the same plate (key). After installing the first spring, be certain the second spring is installed as per Bentley 35.28. There is only one proper position for the 2nd spring, and this isn't illustrated clearly enough in other sections of the Bentley.
_________________
aka Pablo, Geary
9.36 @ 146 in '86 Hot & Sticky
'90 Syncro Westy SVX
'87 Syncro GL 2.5
https://guardtransaxle.com

jstar89crx · Posted: Tue Sep 16, 2014 1:17 pm Post subject:

Gears- thanks for the info. Tranny was rebuilt yesterday so hopefully the correct synchro was installed and the spring orientation is correct. Perhaps that is what went wrong when it was rebuilt last time.
_________________
86 Syncro, weekender carat interior, the rest is bone stock for now
SOLD:91 Westy, BEW TDI with VNT17 Turbo, water cooled intercooler, Malone Tune, taller 3rd and 4th.


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