V160 clunking on gear changes

My v160 box has been clunking on gear shifts and on and off throttle, like a Knocking as if something was loose, however it has TRD gbox mounts (okay), engine mounts okay, diff okay, prop okay,

so my next port of call was dual mass flywheel, (whilst it was out i've changed the clutch) hasnt solved it, and my mechanic says the noise if deffinately coming from the box itself,

so the next port of call was to give it to a transmission specialist (who seems to have taken the piss time scale wise) and he has now stripped the box and says the only obvious cause of the nocking is worn 1 & 2 syncro's how ever from my limited understanding of gearboxes i struggle to see how this would cause knocing in every gear, and when in gear

my thoughts you be something that is linked to every gear such as an input shaft or bearing etc?

i know i'm asking the impossible trying to find a fault from my rubbish description but can anyone offer any advice or help?

if i'd of known the rebuild (or not so much rebuilt) was going to take so long (nearly 7 weeks) i'd of sent my box to america to be fixed, but live and learn ey?

thanks in advance

Mike

Silly questions to start off.....

Have you had it off the deck? Can you replicate the noise by rotating the rear wheels out of gear? Have you tried rotating them both the same way and rotating them opposite each other? What about in gear? I understand you won't be able to rotate the wheels, due to the engine resistance, but can you replicate the knock in gear?

I can't think of anything, other than mounts, that would cause loud knocking..... other than the obvious. if it's the gearbox itself you should be able to replicate it off the ground, I would imagine.

Just had another thought. Can you replicate the knock by pushing down the clutch and braking? What about in reverse?

If its a thump noise. change the oem front diff bushes to a poly bush, it will stop the diff twisting and that solved my noise completely

Sounds like a worn slip or universal joint on your propshaft to me.

Yea that was my first thought as well but ended up being the bushes in the diff

sound like this?

https://www.youtube.com/watch?v=UldX74G_Pu0&list=UUKNICgeJzYm9EVlSZ7bboWQ

Silly questions to start off.....

 

Have you had it off the deck? Can you replicate the noise by rotating the rear wheels out of gear? Have you tried rotating them both the same way and rotating them opposite each other? What about in gear? I understand you won't be able to rotate the wheels, due to the engine resistance, but can you replicate the knock in gear?

 

I can't think of anything, other than mounts, that would cause loud knocking..... other than the obvious. if it's the gearbox itself you should be able to replicate it off the ground, I would imagine.

 

Just had another thought. Can you replicate the knock by pushing down the clutch and braking? What about in reverse?

It has been on the lift in his garage, after the clutch and flywheel replacement he inspeceted the drivetrain and says its deffinately coming from the box itself, how ever I havent been there whilst its been in the air, so i'm going off what he says

The box is currently on a workbench so currently cant be replicated on the car, but i also havent seen the box off the car so i dont know if it is making the clunk whilst on the workbench either

It nocked on power delivery during gear changes or on and off power whilst in gear

Sounds like a worn slip or universal joint on your propshaft to me.

I've been told the props been inspected and and is okay

If its a thump noise. change the oem front diff bushes to a poly bush, it will stop the diff twisting and that solved my noise completely

I'll get him to look at the diff bush's but he's quite confident its the box itself

sound like this?

 

https://www.youtube.com/watch?v=UldX74G_Pu0&list=UUKNICgeJzYm9EVlSZ7bboWQ

no it was a clunk, could be felt through the clutch pedal and gear stick, and when coming on and off power in gear

thanks for the input so far

Wouldn't be the release bearing would it?

Check your subframe bolts. It's probably a loose one.

Wouldn't be the release bearing would it?

I presume that will of been changed during the new clutch going in, as its a normal item to replaced when refreshing a clutch,

but i will ask him

Check your subframe bolts. It's probably a loose one.

I think i'll ask him if we can put the car back on the ramps and have a good look whilst i'm there so i can try update this thread a bit better, but after the flywheel and clutch he rang me and assured me the noise was from the Gbox itself

Google hasn't really been my friend with this problem either, it seems the v160 is pretty indistructable so there ins't much info on common problems with the gear box

Yea I didnt think it was the diff bushes cause fisual they looked alright. But I had new polys in stocl so I installed them and the thumping noise went away

So after the 'transmission specialist' has had my gearbox 10-11weeks, it is now back in the car, worse than it was originally removed, PISSED OFF doesn't even come close,

From what was a nocking on gear changes/ on and off throttle in gear it now sounds like this,

http://youtu.be/XrPT85xR2WA

http://youtu.be/MXLgjs6SNiY

Has anyone got any idea's on the cause I'm guessing incorrectly assembled, could anyone point me in the right direction to a true professional who can sort my gearbox issue, I know there is jacks transmission in America,

But is there anyone UK based?

Thanks in advanced

Habe you contacted the gearbox people that just rebuild it,, cause they should foot the bill for there fuck up

In all honesty I'm more bothered about getting the car sorted,

I'll chase that up after, I've owned the car 4 and a bit months, and it's been in the garage the last 12 weeks, so they have had it longer than me in my ownership,

I just want to know the problem and the fix at this moment in time

You knoe that the getrag boxes are always a bit noisy. Obviously. Not like in the vid. But just sayimg. The problem you might of had, might of not been an issue from the start,,

The current noise is definitely a assembly problem and needs to be looked into

Also get a steel shafted screwdriver and use it as a stethoscope and try to locate the noise bit more accurate,, when the gearbox went in what did the spigot bearing and trow out bearing look like

That sounds like either a broken DMF or it's loose.

I had a W58 rattling just like that, but they're single mass.

When the flywheel was replaced, was there any loctite on the bolts and was it torqued up properly?

brand new flywheel installed along with clutch, problem persisted and then gearbox removed,

this noise is new since the gearbox has been stripped and rebuilt,

i presume my mechanic has done all the fitting work correctly

I had the exact same problems you described with my 6 speed, left the car into SSI and had the box stripped, 1&2 syncro were knackerd, replaced with genuine toyota parts and had the car back within the week, sounds like whoever done your rebuild just hasn't reassbled properly

Clutch release bearing?

I had the exact same problems you described with my 6 speed, left the car into SSI and had the box stripped, 1&2 syncro were knackerd, replaced with genuine toyota parts and had the car back within the week, sounds like whoever done your rebuild just hasn't reassbled properly

The guy who stripped my box said the 1st and 2nd syncro had excessive wear, but I could not grasp how this would affect every gear or nock whilst in gear when he syncros are not in 'use', and due to the £800 price inc vat I turned down them bring replaced

However they didn't make this noise before the box was stripped

Gearboxes in general are expensive to be repaired, and as they say poor man pays twice cause you cheapend out on not replacibg parts that had excessive wear, you may now have to strip box again and install becoming more down time,, and if parts seem excessively priced. Then hunt them down cheaper same product and then hand hem over and save money that way

Dont try save money on shit like that cause normally it comes back to fuck you around at a later date

The cost factor wasn't the issue, I'm happy to spend what ever is needed,

It's the fact I couldn't get my head around the syncros causing a knock in gear, and after him having my box with no real progress for 2 months I'd lost all faith in the 'specialist' however was in a pickle of my gearbox being in bits on his work bench

Why not try jacks transmission?

That sounds like either a broken DMF or it's loose.

 

I had a W58 rattling just like that, but they're single mass.

 

When the flywheel was replaced, was there any loctite on the bolts and was it torqued up properly?

This.

I had a similar sound when I fitted the VVTi engine. Turned out to be the DMF, replaced that and a new clutch and the sound & vibration went away.