LR
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Gearbox & transferLow severity

Crunching gear changes on Series gearboxes

Annoying rather than dangerous.

Symptoms

Grinding when engaging second or third, especially on quick changes. Series I and II have no synchromesh on first and second.

Likely cause

Worn synchro rings on Series III, or simply no synchromesh on lower gears of earlier boxes. Clutch drag makes it worse.

Suggested fixes

Listed roughly in the order most owners try them.

  1. 1

    Double declutch on non-synchro gears

    Pause in neutral, blip the throttle, then select the lower gear. Normal technique for Series I and II.

    Difficulty:
    Easy DIY
    Cost:
    £ (Under about £50 in parts)
  2. 2

    Check clutch release and adjustment

    If the clutch is not fully releasing, every change will crunch. Bleed the hydraulics and check pedal travel.

    Difficulty:
    Easy DIY
    Cost:
    £ (Under about £50 in parts)
  3. 3

    Replace synchro rings

    On Series III boxes, new baulk rings during a rebuild restore smooth changes.

    Difficulty:
    Specialist job
    Cost:
    ££ (About £50 to £300)

This is general guidance gathered from owner experience and workshop practice, not a substitute for a workshop manual or a qualified mechanic. Costs are rough parts-only guides. Brakes, steering and suspension work affects safety, so if in doubt have it checked professionally.

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