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"Ze Germans"
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Discussion Starter #1
Hi everyone,

posting on behalf of a friend.
He has rebuilt his V160 using Jacks Transmission Input Shaft and 5th gear. Rest of the transmission has been rebuilt using OEM parts.
Transmission is shifting and running very smoothly. However, every gear except 5th gear makes a loud whining noise when under load.
And only under load.
Is anyone familiar with the Jack's Transmissions components and any differences they make in noise?

Thanks
Paul
 

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Paul,

Try member, Craig Bush. I seem to recall he had a whining issue with his tranny and thought it was a Jack's rebuild. I could have him mixed up with someone else, but worth a try.


Ken.
 

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"Ze Germans"
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Discussion Starter #3
I will try! Thanks Ken! (Still Need to take some time to read your recap on Blackie ;) )
 

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"Ze Germans"
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Discussion Starter #4
Okay so I am still in the game here as my friend is unfortunately not fluent in English.

What Chris told me is that whining in every gear but 5th gear hints to issues with the Input shaft bearing, as the 5th gear is the only one where there is no side thrust on the shaft and the bearing due to the 1:1 Transmission Ratio.
I have furthermore searched the Forums and found this thread: https://www.supraforums.com/forum/showthread.php?524650-6spd-mystery-whine&highlight=whining
Where a Statement from Jacks is being quoted, that a whining is in most cases resulting from a worn 5th gear.

But the issue here is, the Transmission is freshly rebuilt using Jacks 5th gear and Input shaft and OEM bearings. The Transmission hasn't seen any load since being rebuilt, my friend just drove it around the block, got annoyed with the noise and left the car the way it is.

Any hints are appreciated, he is losing his Patience with the car and is considering selling it :(
 

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Okay so I am still in the game here as my friend is unfortunately not fluent in English.

What Chris told me is that whining in every gear but 5th gear hints to issues with the Input shaft bearing, as the 5th gear is the only one where there is no side thrust on the shaft and the bearing due to the 1:1 Transmission Ratio.
I have furthermore searched the Forums and found this thread: https://www.supraforums.com/forum/showthread.php?524650-6spd-mystery-whine&highlight=whining
Where a Statement from Jacks is being quoted, that a whining is in most cases resulting from a worn 5th gear.

But the issue here is, the Transmission is freshly rebuilt using Jacks 5th gear and Input shaft and OEM bearings. The Transmission hasn't seen any load since being rebuilt, my friend just drove it around the block, got annoyed with the noise and left the car the way it is.

Any hints are appreciated, he is losing his Patience with the car and is considering selling it :(

Contact Joe Hussain on Facebook. He does V160 rebuilds and is backed up for weeks and sometimes a few months. He started the “Getrag V160/V161 Group” on Facebook and would be the person I would send a V160 to. He knows his stuff. I called him, without any intent of buying something from him, and he helped me over the phone with a V160 that I had a question about the shifter mechanism.

Edit: OP used Jack’s parts, not their service. Removed paragraph.
 

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"Ze Germans"
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Discussion Starter #6
I just wrote a polite eMail to Jacks describing the issue. Additional info: The circlip grove on the Jacks input shaft is flatter compared to the OEM one by almost a millilmeter. The guy who assembled the transmission had to grind the plastic baffle down to make it fit, otherwise the circlip wouldn't fit. Might be "just" a quality issue, I just don't know whether the grinded down plastic baffle can already create such an issue.
 

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Call Jacks. Tell them to fix it. They have to. If they deny it, maybe your friend paid by credit card and he can use his credit card company to help him to have a partial refund for repairs..

am i reading this correct that the OP did all the work on the tranny with jacks parts?
if this is the case, im not sure what good calling jacks to tell the to "fix it" will do.
 

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am i reading this correct that the OP did all the work on the tranny with jacks parts?
if this is the case, im not sure what good calling jacks to tell the to "fix it" will do.
Ah yes! I will edit it that. There could be a quality issue which they did have with shift forks which is known as per the Facebook groups but not sure about the input shaft.
 

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"Ze Germans"
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Discussion Starter #10
am i reading this correct that the OP did all the work on the tranny with jacks parts?
if this is the case, im not sure what good calling jacks to tell the to "fix it" will do.
Nah, I didn't really asked them to "fix it", only asking where the noise may be resulting from. And obviously, if it's resulting from the "Quality issue", exchanging the Not-OK part with a good one should be sufficient.
It's not really fingerpointing or anything, just asking for help as Jacks are some of the most knowledgeable guys if it comes to V160 rebuilds. The rebuild has been done by a local mechanic in Germany

Yeah I wrote Craig, he was the one who told me About the link between worn ISBs and no noise in 5th gear

What type of Quality issue did they have with the shift Forks?
 

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Nah, I didn't really asked them to "fix it", only asking where the noise may be resulting from. And obviously, if it's resulting from the "Quality issue", exchanging the Not-OK part with a good one should be sufficient.
It's not really fingerpointing or anything, just asking for help as Jacks are some of the most knowledgeable guys if it comes to V160 rebuilds. The rebuild has been done by a local mechanic in Germany

Yeah I wrote Craig, he was the one who told me About the link between worn ISBs and no noise in 5th gear

What type of Quality issue did they have with the shift Forks?
When it was first was released, there was a clearance issue of some sort. It was modified on the later shafts. Definitely not causing the issue you are having.
 

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"Ze Germans"
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Discussion Starter #12
When it was first was released, there was a clearance issue of some sort. It was modified on the later shafts. Definitely not causing the issue you are having.
Yeah, the Shift Fork is OEM anyway. I was just being curious whether it might be a similar issue to the grove Depth issue we found on the Intake Shaft.
Let's see what ideas Jacks might come up with. I will definitely Keep you guys posted.
 

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"Ze Germans"
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Discussion Starter #13
Just as an update. Jack's admitted the gear set has been part of a faulty production lot. However it was kinda hard to find a solution with them to ship back the errorous part and get a new one in exchange. They request the full price of a new set as a deposit prior sending it as a replacement. I didn't follow the discussion till the end, but I think my friend is now sending the gearbox to a mechanic for disassembly in order to make sure the issue is really related to the production issue.

So if anyone is having similar noise issues, they may be caused by a faulty production lot made by Jack's supplier
 

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"Ze Germans"
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Discussion Starter #14
Hi everyone,

another update on this topic. My friend asked me to post it here as he is pretty upset about Jack's customer service.
As I wrote the last time, Jack's admitted there is an issue with the production batch Sebastian's input shaft+5th gear set originated from. But they wouldn't send a replacement set until he would send them back the claimed part, or paid the replacement set upfront and wait for the money being returned upon arrival of the faulty part.
Back then he couldn't as the transmission was still sitting in one piece.
His wife gave birth to their wirst child, he didn't had the time to take care of it.

Fast forward some months till May this year, he finally was able to give the gearbox to Kees, Suprasport's gearbox specialist in the Netherlands. I have attached pictures of the outcome. The 5th gear is showing massive discoloration, resulting from extreme heat generated due to issues with the geometry of the teeth (most probably a wrong modulus of the teeth). Keep in mind: The car was just driven once with this gearbox around the block and then parked due to the whining noise.

He reached out to Jack's in order to have the set replaced. But they simply refused on either replacing the set (they are discontinued anyway), nor refunding the money for the faulty set. Their statement is simply "We have ceased support on the V160 plattform" and that's it.

He will now reach out to legal authorities and see what they can do, but as you can imagine, he is pretty upset about it right now.

Pictures for reference
 

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