Technical Used gearbox check

[roll]

Hi, I have problem shifting into 1st and 2nd gear with my 2003 115HP JTD. I have changed the oil, but it didn't help much. I guess the synchro rings are cactus.
I have found a good deal on 2004 gearbox (50€). Can I somehow check if it is alright? (You know, before I put it in the car.)

Thanks for help

 

[Ralf S.]

You can try operating the gear linkages by hand.. but otherwise I can't think of a test.

Even if you spin it round (by hand) it will be at such slow speed compared to when it's fitted to the car that you won't be able to hear any rumbling or groaning.

On the other hand, as my mechanic used to say, it must have been working alright when the car it was fitted to drove into the ditch... so it's probably worth taking a punt.

The PITA with gearboxes is removing the old one (dismantling half the car in the process). Once you stuffed the new one in there, you can test it before you finish re-assembling everything. I think you just need the starter motor connected and the driveshaft put back in (with some amount of oil in the gearbox too) .. you can fit the battery box/suspension and anything else you removed once the box checks out.

But.. fit a new clutch *and* a new clutch slave cylinder (it's Concentric, inside the clutch housing) if yours look even slightly worn, otherwise you may be doing this job again soon Ahhhh (you really don't want to). An all new clutch/CSC and a hopefully "good" box.. you won't have to touch it ever again.


Ralf S.

 

[flyingdutch]

You can also check the main shaft ( clutch centric shaft) looseness by taking it with the hand and rying to move it in/out up/down.
The shaft has litterally no play in it so if you find some play in it dodge that gearbox .
Also you can check old oil residue for bronze parts etc as stilo sycros are bronze coated if you find exceasive amount dont buy it .
Good luck m8

 

[roll]

So I got the gearbox. Shaft has no play, every gear goes in easily, oil looks fine... but it also has play in the shifting mechanism.
It is all due to one small plastic piece, which is moving the outer shaft up and down (to select 1-2 or 5-R). Part number should be 71719518. Unfortunately Fiat is not selling it separately. I think most of jtd gearboxes have this issue. Any idea how to fix it? Currently I'm trying light coat of epoxy to fill the hole from removed plastic.

I need to replace main crankshaft seal. Clutch and flywheel were replaced three years (40k km) ago, so I hope they are good, but seal was too expensive, I guess :bang:

 

[flyingdutch]

You can get skf i think replacement seal just a seal for 15 euros at least here in netherlands

 

[roll]

I don't quite understand you. I have replacement crankshaft seal. But on shifting mechanism is this piece of plastic, which is worn. It causes gear stick to wobble

 

[Ralf S.]

Hmm.. I had a quick look here and I can't find anyone selling those linkage pieces either.

It'll be interesting if anyone can turn up a supply.. I guess all our Stilos might be getting a bit loose now.

Ralf S.

 

[roll]

I think it could be easily replaced with plastic cube with a hole in center. It should be about 11,5 mm thick new. Mine has 10,6 mm.
I used "liquid steel" to fill it, so I will see how it holds.