Gearbox went bang!

Jon9985 · **Posted:** Sun Jan 06, 2013 3:52 am

Was out driving today, normal speed(30mph) came up to roundabout, dipped clutch, shifted to 3rd and crunch. Shifter felt all funny and weird rattly noise could be heard. Pulled over, had a look and gearbox has a cog hanging out the side. Cant get into 5th or reverse.

Basicly its gubbed but why would it of done this?

How hard is it to change box, and tips?

Does anyone have or know of good box for sale?

supersan23 · **Posted:** Sun Jan 06, 2013 4:03 am

Ah man that's bad luck

NoGT4 · **Posted:** Sun Jan 06, 2013 9:18 am

Sorry to here that mate, but 2 x 205 boxes for sale on here, and not to far from you if I remember, well Devon.

Not sure if they fit, but I am sure someone will know.

viewtopic.php?f=5&t=6176

NoGT4 · **Posted:** Sun Jan 06, 2013 9:48 am

Just found ths link which seems to sugest it will fit.

http://www.alltrac.net/phpBB2/viewtopic.php?f=7&t=43168

But there is always Nibbles to give you ideas

Is it drivable?

TrackToyFour · **Posted:** Sun Jan 06, 2013 11:05 am

Seems very strange, I presume if there's a cog visible the case has shattered?

As mentioned above, Si is selling a couple of ST205 'boxes which he says are in good working order.

I also have an ST185 'box spare and several ST205 'boxes and rear diffs so let me know if you need anything. I'm sure Nibbles can advise as our resident 185 guru

two_OH_five · **Posted:** Sun Jan 06, 2013 12:04 pm

The 205 box will fit right on and will give an improvement in synchros and different ratios IIRC

Adrian (Fensport) used to suffer regular broken selector forks which locked up the gearbox. The trackside fix was to remove the 5th gear hub, the one that you are looking at. I assume something similar happened to you and engaged two gears at once with a big bang.

I seem to recall that it was something to do with oil levels in the box as well so make sure you check all the external pipes for any signs of leakage

Gearbox swap is quite a big job. If it were me I'd be taking the engine out to do it and swapping clutches at the same time

sketchmyster · **Posted:** Sun Jan 06, 2013 12:17 pm

Had mine done at southwest lotus in lifton didnt cost to much and there top guys

Jon9985 · **Posted:** Sun Jan 06, 2013 1:57 pm

Yeah im looking at either 5th or reverse hanging out the casing. My mate found a piece of what he thinks is part of the diff as teeth are not deep enough....??!!

Its all abit of wrong timing as wanted to forge engine, new turbo set up, head work, clutch etc all in one go but never mind.

So anyway, is it in my interest to purchase a 205 box and fit that or find 185 box?

Whats the pros/cons between two including fitting?

I dont know if I made this up or overheard but I have in my head that these boxes were over engineered and dont need modification for high horsepower?

As to car being drivable still, it is. I limped home last night 30 miles, box rattles abit as bits are flying all over the place, but because hole is high I've only lost a little oil and can still use 1st, 2nd, 3rd and 4th without it welding itself.

TrackToyFour · **Posted:** Sun Jan 06, 2013 3:21 pm

Amazing you were able to drive 30 miles with the box in that state :shock:

Testimony to Toyota engineering!

two_OH_five · **Posted:** Sun Jan 06, 2013 6:06 pm

Generally a 205 box is going to be newer and thus less worn but there are knackered ones out there. By and large they are well built and tolerate power upgrades well. I think Adrian's issues were part related to a sequential shifter/dog cut nearest which just moved the weak point to the selectors instead

Fitting wise AFAIK it,s no different between a 185 and a 205. I think the ratios might be slightly different but I am not absolutely certain of that. For sure the 205 gearbox does have better synchro rings though

It could be that the timing is fortuitous if you were ready to upgrade the engine anyway as it would be coming out for the work anyway. Just add a few extra quid onto the total for a new box

Jon9985 · **Posted:** Sun Jan 06, 2013 8:11 pm

Thanks steve, im going to go for 205 box then.

I haven't got the finances to go all out on engine yet, thats why timing annoying but hey ho. Also dont have ramp space at work as have 4 big projects on that need finishing to bring in cash/get motors out the way before building up the gt4 and mx5 turbo development we got going.

Nibbles · **Posted:** Sun Jan 06, 2013 10:20 pm

Definately engine & box out the bottom on a 185. Crossmember removal is much easier than the 205, which has the suspension & steering mounted on it.

The gearboxes are interchangable. You MAY need to splice a speedo plug from a 205 loom if they are different, never checked.

The 205 has better syncros on the lower gears and slightly lower gearing from memory. The 185 has a lever allowing yo to select front wheel drive only or open centre diff, although the handbook warns not to drive the car hard in either of these modes.

AFAIK Si also has 2x 185 gearboxes, 1 good and 1 with worn synchros but he's mixed up which is which.

two_OH_five · **Posted:** Sun Jan 06, 2013 10:50 pm

MX5 Trubo eh :shock:

Still smarting from the Henstridge loss ???? :lol:

Nibbles · **Posted:** Sun Jan 06, 2013 11:27 pm

Hairdressing, at high speed :lol:

It did look serious fun though.

Jon9985 · **Posted:** Mon Jan 07, 2013 12:21 am

Yes not my ideal car but the turbo kits are wanted, so need to prefect the fueling by fpr and injectors so kit can be direct bolt on without the need for standalone ecu. Got a fiesta turbo kit in the making too but bit too powerfull for fwd. Once this lots out the way will be looking to do some development with gt4, possible ceramic bb td05.....

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Gearbox went bang!

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