Hi all, I have the gearbox back together for Mondial QV and have some questions. The only gear I seem able to select using the shift shaft is reverse. With the shift selection mechanism disconnected, should I be able to move the shift forks individually to select the other gears? Thanks Jeff Image Unavailable, Please Login
Reverse has no synchros so it's easier to select in a static state. The synchros make it harder to engage when it's not turning. They can be selected and engaged but takes a bit more force then you'd expect, esp when dry.
without using the shifter, you should be able to select any gear, or two gears (on different shafts). You probably need to have lubrication in the box before the gears can be freely selected.
Having rebuilt a few of these boxes, on the bench, dry. They are a bugger to shift. Get the synchros lined up first, then it's easier. But it still takes some umph to engage. Esp if it's been all apart and cleaned. It's amazing how much gunk and polymerized oil gets into the synchro springs and pawls over time. Clean it all out and the engagement force goes up, it also brings back that snick/snak sound that's very noisy.
Thanks for the response guys. So I verified that I got the "pills" in correctly, disconnected all the shift forks, and was only able to move one shift rod at a time. Re-assembled, and can now get reverse, and second. So, thoughts on how to proceed? Thanks Jeff
So, although I believe I re-assembled the box correctly, I was not going to take the chance of putting everything back together until I could get reasonable shifting on all gears. Tore the whole thing apart, started with first gear assembly, could not get the first gear synchro housing/synchro to engage first gear dog teeth. So, I sprayed brake cleaner everywhere in the synchro housing, and then using a syringe, lubed the springs, ball, and pawls with Mt-90. Result? can easily engage the dogs now by hand. I will try the same process without removing everything from the main/lay shaft and see how that works. Jeff
So, re-assembled 1st/rev. cluster on the shaft, can easily shift 1st to rev. by hand, yeah! As long as both shafts are out, I will just repeat the process on the remaining gear clusters. Jeff Image Unavailable, Please Login Image Unavailable, Please Login
Once it's all back in the case, I find that turning the input shaft helps with getting the synchros to engage. There's a lay shaft and transfer idle gear that along with the 'pills' prevents engagement of gears on the two different shafts. I'm assuming that since you've got it all apart you've checked the wear on the synchros?
Yep, got it. Synchros measure about 1mm gap to dogs, and are almost level with the top of the cone. So I believe the synchros are like almost new. Thanks for the input, you helped me solve my issue. Regards Jeff
