Manual Gearbox (M40/M41) Worn Synchros
Symptoms
Crunching into second or third gear, difficult shifting when cold, grinding noises.
Cause
The M40/M41 gearboxes are tough but not indestructible. Synchromesh rings wear with high mileage or abuse. Second gear is usually the first to go.
Fix
Full gearbox strip-down and rebuild.
Replace synchro rings, check the condition of the gear teeth, replace bearings as needed.
It's a skilled job, if you're not confident, find a gearbox specialist.
Alternatively, source a good used gearbox from a breaker.
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