VW T3 Syncro 094 Gearbox Repair

My VW T3 Syncro gearbox was popping out of 2'nd gear while decelerating. Even though I'm not a professional, I have decided to try and fix it by myself. When I have inspected the gears i have
found multiple parts of the teeth were missing. 4th gear even though wasn't popping out, was in extremely poor condition.
Test drive after ~2000 km.

[@leninchinchillavzla3273]

It is the most complete video related to the assembly and disassembly of the vw Syncro box, from Venezuela, thank you very much

[@Gadomaitis]

Cheers from Lithuania!!

[@user-fb9pl8sy4d]

Це дуже хороша робота!👍

[@Gadomaitis]

Dumaju sto net, no sleduscij karobka tocnai budut lucse.

[@user-rv2nd8xr4m]

Hi my problem is that it's makes lots of noise on inner cv by the gearbox is it possible it can be bearings and how to take them out help pls thanks

[@Gadomaitis]

Hi, hard to understand what's the problem, oner CV is bolted, if they make cracking noise you can change only the CV joint

[@user-rv2nd8xr4m]

@@Gadomaitis ok the cup that is holding the inner cv it's also has a pley and another problem I have my clutch, to clutch it you have to press it to the floor to get it on gears

[@Gadomaitis]

Remove the rubber cup with pick, under the cap you will find cirklip and washer. Maybe the washer is placed the loose way, you can try twist it the other way. Does it leaks oil there? Clutch is a complete different story. When I have placed my tdi clutch, I had same thing in the beginning.

[@user-rv2nd8xr4m]

@@Gadomaitis yes it does lick oil

[@user-ho5yy9bp7z]

Hi my friend nice job i have the same problem in second gear is jumping in a restored gearbox...why is this happen?

[@Gadomaitis]

Hi, thanks. Could be a changed slider but the gear it self is slightly worn out. Or gear and slider new, but not very good quality slider, like in my case. Rebuilder could tell you the possible reason exactly

[@hgelectronica]

Hola Que buen trabajo!! Saludos desde Argentina.

[@Gadomaitis]

Hello, always could do better, anyways, thanks for a good word! Cheers from Lithuania.

[@thefilozof01]

Looking at this video I am now wondering, can you change gear ratios by putting different sized gears? I have a problem because my Golf mk2 is Diesel swapped by the previous owner, but the gearbox is original - made for petrol engines, so my gears come out very short. Any clue?

[@Gadomaitis]

Hi, it depends, in this gearbox you can change only 3&4 gear pairs, as the idler gear and gear is let's say "pressed" on the shaft, the 1&2 pair idler is placed on the shaft and the gear itself is cut into the shaft. so if you want to change gear ratios for 1&2 pairs you need to change the shaft and the idler. But the shortness of the gearbox depends on the Ring&Pinion or so-called final drive. These gearboxes has a final drive originally from 4.57 to 5.83, where 4.57 would be long geared and 5.83 is very slow and short geared. So basically you want to change R&P. Cheers, G.

[@user-sy5ol8uv3z]

Hello hi can u tell me what that tools name is that is used to losen the nut on the microbus diff that big one

[@Gadomaitis]

Hi, it's a home made, a guy who sold me the syncro gave it as a bonus. I have seen guys are welding washer nuts together and gets the same tool. It doesn't require strength so it holds perfectly.

[@user-vp4ot5vg6e]

Какой талантливый человек) А как главную пару выставить на глаз? Забавно, что я в Гродно сейчас, прям рядом, и мне надо разобрать синхра коробку. Thanks)

[@Gadomaitis]

You mean height of the pinion? I left it at original height. The play of the ring maybe 1-2 mm from an eye, as you said. You can find all adjustments in service manual if you have the tools. I believe you can find alot of talented people to adjust it in Belarus. Cheers.

[@mohammedboudlal2785]

how many liters of oil for this gearbox .

[@Gadomaitis]

I think it was over 4 litres, I have filled to the level and than added 0.2 litres on top to over fill. I believe more is better than less.

[@user-xk3pk1cu6b]

جميل جدا

[@Gadomaitis]

Thanks

[@adamstawicki1872]

Hi, will you write what tools do you use to disassemble the gearbox?

[@Gadomaitis]

Hi, it's mainly universal tools or home made from scrap. No OEM codes, nothing.

[@adamstawicki1872]

@@Gadomaitis Ok, thanks :)

[@Gadomaitis]

No worries!

[@elmarruben]

Tdi killed it or?

[@Gadomaitis]

I don't think so. It had famous 2nd gear problem, that is way I have opened it. Most likely dodgy previous job on that gearbox. Mine might be the same, time will tell.

[@elmarruben]

@@Gadomaitis okay:) the first gear problem might be the gearbox mount because of the gearbox tipping.

[@Gadomaitis]

I think, it might be due to 1'st & 2"nd gear slider. I have used a 3'rd & 4'th pair slider instead for the first pair. Just to check how it will work. Because there where no issues with 1'st gear before dissembling and I have changed only the slider.