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Ej Holden jumps out of 3rd gear after clutch overhaul

I know from what I have read EJ's with crashbox are a bit prone to jumping out of 3rd gear from time to time, but it only uses to be when on a long run and then coasting downhill.

A few months ago I put the car in for a clutch overhaul, I said to the mechanic while the gearbox and clutch was off they had okay to replace whatever needed replacing.they did full overhaul of clutch and while off they said flywheel had a tooth missing so they replaced that too. They also said they had to weld some damage to bellhousing. I thought great, now I wouldn't have any problems for a long time.

Straight after overhaul it kept jumping out of 3rd gear, several times on short trips, took it back and they adjusted linkages etc, but then said it must be the gearbox,funny it wasn't doing it before though.

This was just before I moved interstate, so last month I also paid someone else to fully recondition the gearbox. As I thought, made no difference to the jumping out of gear.

To me to much of a cooincidence it only started doing this after clutch overhaul.

I travel 16km to work, it can jump out of 3rd at least 6 times each way, very frustrating to say the least.

Anyone any ideas?

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but i do have a couple of heavy gear knobs, one steel and one brass that i believe were the old school fix for this problem

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Worn linkages may cause the same problem and the average gear box shop probably would not have oxy to weld them up and grind and re drill them.
I used to do them a lot for mates.

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Did they take the bell housing off the gearbox when they did the weld repair?
The welding might have distorted the bellhousing putting the input shaft slightly out of alignment.
I can remember something about a cupped spring washer between the gearbox and bellhousing causing problems if it isn't put in correctly, but if it was recently reconditioned it would have been dismantled again. Surely two mechanics couldn't make the same mistake. maybe the first bloke didn't put the washer back in?
I'm with Hustech, it could be worn linkage rods or worn slector plates on the gearbox. The rods will at the ends where they sit in the rubber bushes. They joints have to be dismantled to see the wear.
I think Rare Spares sell kits to replace the rubber bushes on the selector rods.
How are the selector slides at the bottom of the steering column? There should be a white nylon bush between the two plates where they slide against each other. If it isn't there you could have trouble.
Also, the larger plate can wear which might contribute to the problem. I think I've got a spare if you need it.
Have the rods from the column to the gearbox been replaced? EH are different to EJ.
David

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Old is good.

Thanks for the detailed response,I guess I will work through the simple stuff first, but I really suspect it is true what you said about the bellhousing.

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If it is the bellhousing, does it involve machining the face between bellhousing and gearbox?

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when old mechanic did my gearbox he told me to always check the bell housing is put on gearbox first so it not warped as gmh said the problem you mentioned happens go scribd go to documents type in harvey three speed gearbox holden then go to fb/ek holden gearbox also covers ej/eh holden very substantial reading covers your problem it also mention bell housing my email is postman_warren@yahoo... hpoe this helps warren

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warren

Thanks, that manual is a good resource 👍

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Many moons ago I had the same issue. I'd just had your bog standard 3 speed manual on an EJ reconditioned. Put it back in, kept jumping out of third. Took the box back, they checked it out, couldn't find anything. Put it back in - same thing. What I eventually found was the clutch yolk adjustment screw was protruding EVER SO SLIGHTLY past the surface of the bell housing where the box goes onto. Screwed it in half a turn - problem solved. Essentially, anything that can cause the main drive shaft of the gearbox to be out of alignment.

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Thats incredible something so simple as that.

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as above are common causes also
the selects on the side plate wear and not fully engage the slide gear in 3rd
the bell housing warp with age i had mine machined at the place i worked back in 79
found it was warped 30 thou

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The selector lever on the side of the gearbox is very sloppy, I took it off yesterday and put some shims between it and side cover, so I will see what difference that makes this week to and from work.

The thing is though it only started doing it after clutch overhaul, so not convinced it is to do with the gearbox.

Whereas in the past it only gently slipped out of gear, now it jumps out of 3rd with real force. You can really feel vibration in the gearstick if you rest your hand on it, and you can feel real force when it jumps out against your hand.

Yes they did take bellhousing off, I have been wondering if it is to do with this myself, some sort of misalignment causing the vibration and then jumping out.

I looked at the engine mounts yesterday, they are oild soaked and spongy, but that has probably been like that before clutch repair.

The rods weren't replaced, and the white nylon bush is still there. I think the linkages and levers are pretty good.

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Give this some thought.
The box has been overhauled so before when the gears were worn it would have been natural for it to slide out of gear, where as now with possibly new/recut gears, it is jumping out because the gears have a sharp edge.

Thinking the linkages and levers are good does not make them good.No offence meant.
Remove them one at a time and check for wear in the rods and also the holes where the rods go in the levers.

Not being a smart arss, just trying to help.

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I like your reasoning, except that the violent jumping out of gear started after the clutch overhaul, but before gerbox overhaul. I take your point about the linkages and levers though so will give them a closer look. No offence taken 👍

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I think the cupped spring washer should be there, it was there before clutch was done I know from last time I took the gearbox off as I replaced it with new. I also had a spare in repair kit that I gave to guy that did the gearbox overhaul.

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I had horrible problems with a crash box once after fitting a new one, turned out to be the flywheel, possible that flywheel wear dosent match new clutch and its causing vibrations which are transferring to the gearbox. a clutch plate sitting a few thou out of centre will essentially make the input shaft of gearbox wobble which could be all it needs to make it pop out

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This makes sense to me, thinking flywheel or clutch housing is the real culprit. Thanks mate 👍

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How is the spigot bush? It might be worth checking or replacing it if you pull the gearbox out again.
David

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Old is good.

They replaced the spiggott bush when they did the clutch, as they said that was the cause of the sound I first reported.I complained it was still noisy afterwards and they claim they replaced it a second time when they pulled it appart and say they could find nothing else wrong.All I know is I paid them $1500, it was still noisy afterwards, it broke down shortly afterwards but they say that was the slave cylinder piston jamming,and I had minimal jumping out issues beforehand and now I put it back in gear several times to and from work.I really probably had no need to overhaul the gearbox.

I did the clutch myself 20 years ago and didn't get issues afterwards, I wish I did it myself but getting a bit old to be crawling under cars, trouble is finding a mechanic who knows what they are doing. Very frustrating.

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worn uni joins will cause vibration through the gearbox
and worn tail shaft yolk check for movement on the yolk

spongy oil soaked engine mounts wont help old greys didn't have the best engine mount design
having the gear lever adjusted to tight will cause it as the engine moves causing it to move the levers
thers numerous causes that can cause gear jump out its a case of working through different parts till you find it fixes it
can be worn gears in the box

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The tail shaft is very good, about a year ago got a new old stock yoke, and put new uni joint front and back. As you say may have to slowly work through this. Where I live now tests it as the run from Tathra to Bega for work has a fair bit of coasting down hills, where I was before mostly on freeway to work.

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Doubly posty..

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........𝓣𝓲𝓶.

✄--------------------------------------------------------

-_--_--_ _______._
_--_-_ -/___+__|__\__
.,.,.,,.,|_O ________O_|

What if you unhooked the linkages and took it for a spin? Obviously you have to start in 3rd and keep it there, but it's not impossible to do. At least you'd know if it was the linkages or not..

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........𝓣𝓲𝓶.

✄--------------------------------------------------------

-_--_--_ _______._
_--_-_ -/___+__|__\__
.,.,.,,.,|_O ________O_|

Interesting suggestion, I might work on the linkages first anyway as it is easiest thing to do, wont do any harm thats for sure.

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Let's know how you go.

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........𝓣𝓲𝓶.

✄--------------------------------------------------------

-_--_--_ _______._
_--_-_ -/___+__|__\__
.,.,.,,.,|_O ________O_|

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