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Anon
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Disaster!! . . . Diff ? Gearbox??
Hi all. Travelling on the A40 Brecon Bypass yesterday (returning from a weekend in South Wales) when the gearbox (at least that what I thought it was) started making an awful noise each time I took my foot off the throttle - not unlike the sound of an angle grinder! Suddenly there was a loud bang and the van juddered to a halt when the back wheels just locked up - pretty hairy at the time. The van would not move forwards or backwards - I assumed it must be the diff.
The recovery truck came to pick us up and the van had to be pretty much dragged onto it (put pads under the rear wheels). I arranged for the van to be taken straight to my local garage as I was pretty certain that whatever the problem was, it was unlikely to be anything that I could sort out.
When we arrived at the garage last night, as the van was being unloaded there was a another bang and suddenly the wheels freed up. When it was on the ground I started it up again, engaged first and it moved - but only a few inches before it locked again. Tried reverse - same thing.
Have just been over the garage this morning and been told they wont even be able to look at it for a few days because of workload/staff off.
So....anyone experienced anything like this? Is it the diff or could it be the gearbox? Its a ZF 5 speed. The van is a 350 twin wheel.
I'm guessing that the most ecenomical way of fixing this will be to replace the entire unit - but if I had to put a different gearbox in does that mean that the propshaft or other bits will have to be changed too? Or if its the diff (which I'm thinking is more likely) - is it the same for all 350s or is it different for a ZF box? Or is there someone who actually repairs these things?
Any help or advice greatly appreciated.
Had it not been for the fact that we've already spent such a massive amount of money on getting it to what I thought was 'near perfect condition' I'd probably just cut my losses by now as I'm feeling pretty gutted. But that would be daft really - in the last two and a half years we've spent out on an lpg conversion with two tanks, replacement engine with hardened valve seats etc, new bonnet, wings, doors etc, top notch respray, brake pipes, wheel cylinders, you name it.
Thanks, Jerry
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 Tue 27 Mar 2012 @ 09:45
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Anon
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ZF 5 speed came in two flavours - one with overdrive top gear for better crusing, and one with heavy loads in mind. Does sound more like a gear box fault to me.
If you disconnect the prop shaft from the rear diff,does the van then roll? This would eliminate the diff as a suspect,and easy to do (just 4 bolts). If you can find a used ZF box in good nick it isn't hard to swap like for like.should take one weekend max, even with no experience.
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Tue 27 Mar 2012 @ 10:34
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Anon
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Cheers Philbut. Current box is the 'heavy load' type - always sounds like it needed an extra gear. I've been kind of hoping it was the back axle because I've been offered one this morning.
Can I ask what leads you to think the box is more likely suspect, even though my first suspicion was the box since thats where the noise seemed to come from. Depressing the clutch doesn't free the wheels, which is what made me then think it must be the diff.
Are the ZF gearboxes completely different for petrol/diesel engines?
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Tue 27 Mar 2012 @ 11:28
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Anon
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Possibly different bell housing. I'm sure Phil Bradshaw will be along to clarify shortly.
If the gearbox is jammed then disconnecting the engine (ie pushing clutch in) wont nesescarily mean you can free wheel. If the gearbox output shaft is jammed that will effectively lock the whole drive train.
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Tue 27 Mar 2012 @ 12:03
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Anon
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ZF clutch housing is different according to engine but swapping the housing isn't difficult - comes off with a bump after removing the 6 securing nuts (slant engine housing) -
Drain gearbox oil first or it will pee out as soon as the housing is loose.
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Tue 27 Mar 2012 @ 12:40
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Anon
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Hi Jerry
Have Two zf gearboxes pm me if you want to know more
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Tue 27 Mar 2012 @ 19:04
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Anon
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Hi all. Just an update and to offer words of thanks to those who offered words of advice.
It was indeed the back axle after all. Have Replaced it with another one, kindly donated by Phil Bradshaw, and all is well again, so we'll still be able attend Brian & Jan's Shropshire meet this coming weekend - if we don't get snowed in!!
Once again, many thanks.
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Wed 04 Apr 2012 @ 18:07
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