help! gearbox woes (long)

[rapieper@yahoo.com (Ron Pieper)]

Well, that sucks.  Anyhow, I'd go for your idea pretty much as written
regarding cleaning the area and attempting a JB Weld or similar
solution.  What have you got to lose?  If it doesn't work, you're not
out much, and if it does, cool.  Let it drain overnight.  Check for
anything inside the case, and peek up at the ring gear to see if
there's anything abnormal looking (there should be two circumferential
grooves in the gears, they should all be smooth with no pitting etc.). 


G/L - and where are you?

Ron


--- Ewan Hopkins <ewanhopkins@hotmail.com> wrote:
> 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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