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Discussion Starter #1
Hi,
I've read a lot about 4th gear "swarf" fixes if you can't get it into 4th gear, but what about if it pops out of 4th gear?
Mine works fine until about 2 miles down the road (i.e. it's fine when cold) and then it starts popping out for 4th. Changed the gear oil, no noticeable improvement..
Am I looking at a replacement box and if so can a 2.0 box go in (more available).
Thanks
 

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Try swapping the gear detent plugs which are grouped together near the gear oil level plug. It may just save a box swap.

Don't try a 2.0 box in a 1.6. The higher final drive ratio means acceleration will be slower. The 1.6 had a lower final drive ratio because it has less torque.

I can't see exactly what is going to cause the jumping out of gear issue but it sounds like someone has used the gear lever as an armrest for quite some time. I once had a damaged gearbox due to an ignorant previous owner.:grumpy:
Annoying.
 

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Discussion Starter #3
Sounds about right, 4th must've been their favourite gear too..
Is the gear detent doable in situ? I guess not but thought I'd check
 

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Detents easily changed in situ.
17mm plugs, I think. About 25mm long.
3 of them (1st&2nd, 3rd&4th and 5th&reverse).
Ideally do in neutral.
 
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