help! gearbox woes (long)

[danws69@earthlink.net (Dan)]

did the dudes at the junk yard (or where ever you got it from) remove the
tranny? It sounds as if they dropped it, rather hard too. If possible look
to them for $$.

Dan
Tam-pa, FL
'87 16v Scirocco
'81 Rabbit Sportruck
'00 Jetta
http://home.earthlink.net/~danws69/index.html

-----Original Message-----
From: scirocco-l-admin@scirocco.org
[mailto:scirocco-l-admin@scirocco.org]On Behalf Of Ewan Hopkins
Sent: Tuesday, February 19, 2002 07:07
To: scirocco-l@scirocco.org
Subject: help! gearbox woes (long)


Put a replacement gearbox in my scirocco on Saturday, which was a big enough
pain - everything that could go wrong went wrong: chewed inner cv bolts,
worn inner CV, wrong size flanges, no studs for lower mount plate, shagged
clutch cable, etc, etc - what should have been a few hours turned into an
all day saga. Anyway, finally got it in and working, went home on Saturday,
did a few miles on Sunday. Was just getting used to the new gearing ( audi
2L + 3.67/.75 5th make for great motorway cruising (just short of 100mph
@4000rpm)!) on the way to work Monday when 5th started to get a bit whiney &
3rd was not sounding too healthy. Drove the last few miles in 4th, get to
work & underside of gearbox & car is plastered in oil and presumably the
gearbox is pretty much empty. Put in 2 litres at lunchtime and drive home -
sounds & feels OK now but nice puddle under car this morning. Wipe off the
oil from the bottom of the box and there's a little triangular shaped dent
near the drain plug which is dripping. Fuck!  Had to patch it in the car
park of my local auto parts store with some bondo-style metal patch stuff.
Still weeps a little but much better than before.
Question is, could it be TIG welded or patched without removing the box and
splitting the case. I'm thinking, drain the box and blow out the hole with
an air line until nothing more comes out and then flush repeatedly with
degreaser & solvent to get everything clean. Alternatively, would this
approach work with some epoxy adhesive as a relatively short term solution (
a few weeks ) - the crack is only about 1/2 cm but there is enough of a dent
in the metal for something to get a purchase on. My main worry is how good a
bond it'll get with the alloy case. Any opinions would be greatly
appreciated!

TIA

Ewan Hopkins

'85 Storm 2.0
'86 GT 1.8
'87 GT 1.6

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