V40: Difficult getting into 1st and reverse. 5th jumps out!!

[Old Painless]

That v-shaped thing is one of your shift forks. The sludge looks like brass particles to me and i think your syncromeshes are probably brass. The syncromeshes sit inbetween the collar and the selector fork. When the gear is selected the collar tries to move into the gear to drive it off the shaft but it cant until the gear is up to speed, this is achieved by the syncromesh rubbing on the gear until it is going as fast as the shaft at which point the collar moves into the gear and the clutch can be released.

If there is not enough oil in the box or whoever drives it doesnt use the clutch to shift or they just crash up and down the box like a caveman the syncromeshes could have worn out.

I would give everything a serious clean and try and get a figure for the syncromesh thickness so you can measure them.

Have a look at the diagrams at the very bottom of this page for an idea of how the gearbox works. http://en.wikipedia.org/wiki/Manual_transmission

[2000S40]

Thanks very much Painless, i cleaned it completely (not a spec left in the box) and have yet to test it. It seems weird that after being rebuilt this would happen, though it was low on oil. i'm now watching out for leaks just incase a seal has gone.

if the syncromesh is beyond, would it definately cause 5th to carry on popping? and how much am i looking to have to spend for a new syncromesh?

i'm hoping that when i renew the bushes tomorrow, that combined with a full box of oil and a clean of all the rubbish in there (including the plastic) will stop any frther problems for now.

[Old Painless]

If the gearbox was rebuilt you shouldn't have a problem. I can only imagine the pound signs that would appear in a mechanics eyes at the mention of those words.

Have you been given proof the work was carried out ? It seems doubtful it was carried out and if it was, there should surely be nothing wrong with it now ?

I have no idea about syncromesh pricing i am afraid. I just noticed that my description wasnt quite accurate but it was close enough. I only learned how it all works myself yesterday evening.

That being said i don't think a worn gearbox would make the gear stick excessively loose, the gear linkage might be causing your gear jumping problem, my haynes agrees, for what its worth.

[2000S40]

Would you believe I was thinking of simply changing the bushes and testing it? However the thought of my box exploding during a long trip got me a little nervous..
I'm glad it's done now though, it's off my mind and I can keep an eye on it here-on.

Tomorrow I will be changing the bushes (I just need to figure out which is which now, as all the bushes came in one packet).. I'll start another thread about that perhaps.

I don't have proof of a rebuilt box, but as the volvo came from a circle of friends I have no reason to doubt it (I'm waiting to get receipts though still, just incase it's under warantee).

Hopefully I've caught it in time and the bushes will fix it.