So recently i bought a "" revised "" 02a cda gearbox from a specialist gearbox builder here in holland for 525 euro without a trade in , sounds a bit cheap, and after fitting the box, when i started the engine there was an immediate rattle coming from the pinion shaft / differential area. So presuming it was something else i checked the whole engine bay to find another problem, manifold rattle e.t.c. however its definately from the box. I contacted the builder and fun and games began. The gearbox was not properly installed , the drive shafts are too long , the clutch is faulty............So in order to solve the problem first port is oil out to check for problems. The oil is dirty and has bronze particles in it , so i put fresh oil in. Then i switch the shifter tower from my old 02A atb box to the cda as the tower supplied was incomplete, the top was missing. While driving there was alot of back lash in the drivetrain and whining on lift-off, Again contacted the builder and now claims that it is not possible to swap shifter towers between 02 box''s and this has damaged the box. Another cowboy company ,.surprising as this guy has a very impressive workshop full of rare engines and gearbox''s including 1 complete oettinger engine fully rebuilt and 2 more in bits. After again speaking with him he refuses to take the box back and claims as i have worked on it , i swapped the tower , all damage is my fault, this was a cash deal , i spoke to a legal aid and have no leg to stand on as he simply has to claim its my fault.and thats it. So i striped the box my self and this is what i found, and a few problems.. Differential bearings are new as are the input shaft and pinion shaft lower bearings next to the clutch however the upper bearings are old and worn and make a rumble noise when turned. Reverse bearing are in good condition, i can''t tell if these are original or not. This looks a bit odd to me , is this correct?? top of pinion shaft under fifth gear The box is quite dirty , this is the fifth syncro ring.... This looks not right , excessive movement on the reverse gear and syncro ring [video]http://smg.photobucket.com/user/JOCONNELL100/media/02A%20CDA/20140105_142416_zps28ba5567.mp4.html[/video] The upper and lower rings have alot of play , this i suspect is the rattle in the box [video]http://smg.photobucket.com/user/JOCONNELL100/media/02A%20CDA/20140105_142438_zps0fee810d.mp4.html[/video] The rattle with engine running [video]http://smg.photobucket.com/user/JOCONNELL100/media/02A%20CDA/20140101_124936_zps2faffca4.mp4.html[/video] And the noise on lift off, and the backlash you can hear..what can cause this, the box has new oil in 75/90 and 2.5L [video]http://smg.photobucket.com/user/JOCONNELL100/media/02A%20CDA/20140101_143919_zpsa0bcff7b.mp4.html[/video] I suspect the pinion shaft has bad bearings or syncro rings or a host of other problems, Ihave rebuilt probally 40 of these 02a box''s but whant to be sure what the problem is before i throw more cash and time at it,,any ideas thanks
