Gearbox Noise that isn't

[davamb]

Isn't the gearbox that is.

I'd been told by someone who I trust (might make that past tense) that the horrible noise made by the gearbox under load in 4th and 5th meant I was up for a new 'box.

Gave the mighty Tony out at Fulltech a call on Friday to see if he could confirm the gearbox was at fault and if so, whether he could do the work.
Got there Friday and took him for a run around the block to demonstrate the noise. Guess what - no noise. Really weird. Do I have dikhed tattooed on my forehead or what? I still needed to get a new clutch done so I left him my details so he could call with a quote.

Anyways, I was putting the new rear brace I'd designed and had made by my local metalworker on this morning (will put some pics up later) and had to remove the exhaust from the cat back to get it on. Noticed that there was only one nut holding the cat to the exhaust at the rear, the other stud had been sheared off. So what was happening is the joint is opening up under load and the noise is actually exhaust!

Removed the cat and cleaned all the exhaust putty off, but can't see any way to repair the broken stud, I've tried to end-drill the stud to tap a thread into the cat, but it's really hard steel and beyond my meager workshop skills and equipment to attend to. Put fresh putty in and tried to get everything aligned for a no-stress reassembly. Will call a local exhaust specialist Monday to see if they can repair it.

So there ya go - things aren't always as bad as they may seem, it's always worth a second opinion and if you're still in doubt, have a bloody good look yourself.

[davamb]

Here's the brace by the way:



I wanted it with Zinc seal so I could paint it, but he was short of steel stock on the day and we just wanted to check the program was right. Next I'll run one off with the Zinc.