Gearbox/Clutch noise in all gears but 4th

[slickshoot]

My 2004 Kia Sorento has developed gearbox/clutch noise in all gears but 4th since a 300 miles round trip towing a 1500(ish)KG trailer. It sounds like it may be the transfer gears as it changes tone as the revs change but is it not strange that there is no sound at all whilst I'm in 4th gear? I'm hoping it may just be the clutch release bearing or even just the clutch itself as presumably they're an easier(cheaper) job that replacing transfer gears/gearbox etc?

Please can anyone offer any thoughts on what it may be? I'll probably get it booked into a garage for a diagnosis anyway but I'm nervous I'm gonna get a shock when they tell me what the problems is.

[cptsideways]

4th is direct drive, sounds like layshaft bearings might be in trouble

[paintman]

^^^^^This.
I've also experienced it with a failed input shaft bearing on a Mk2 Ford Granada.

[slickshoot]

so "expensive" is what you're saying.

Do you reckon it was a coincidence that I had recently been towing or could the extra weight have stressed the gearbox enough to cause the damage?

Is this something that will worsen if I continue to drive the car or should I park it until it's fixed?

Thanks for you responses guys!

[BritishRacinGrin]

It's going to worsen but that's of little consequence if you're going to fit a replacement gearbox. If you want to get your existing gearbox repaired the best policy is obviously to mitigate the damage by not using it.

[andy-xr]

slickshoot said:

so "expensive" is what you're saying.

Do you reckon it was a coincidence that I had recently been towing or could the extra weight have stressed the gearbox enough to cause the damage?

Is this something that will worsen if I continue to drive the car or should I park it until it's fixed?

Thanks for you responses guys!

A knackered clutch on my old Rover 25 led to needing a new clutch and gearbox. I sourced both and had them fitted for £325 from a local garage. The gearbox came from ebay for £75, the clutch from the motor factors for £60, so a shade over £400

Can be done within a reasonable budget if you're prepared to compromise. In your case, I'd run it anyway. I ran a Peugeot 307 HDi for a year with a wheezy gearbox, sold it still working, they go when they're ready

[ToothbrushMan]

i dont think its diff bearings.
not sure its shaft bearings either tbh - if it was wouldnt you get the noise in 4th too?
certainly ensure its not the clutch playing up before looking to the box itself.

i reckon its bad wear on gears 1,2 and 3 possibly due to the towing if its seen a hard life pulling heavy loads.
no amount of new bearings or oil changes will take up the slack of badly worn gear clusters.

[My Evil Twin]

Has a mate dropped a straight cut gearbox in it whilst you wernt looking?
.
.
.
No?
.

[slickshoot]

To add a conclusion to the thread it was indeed the bearings within the box. I had the damaged bearings replaced along with the layshaft which was also damaged. Unfortunately it turned out that my dual mass flywheel had melted somewhat so that too was replaced with a solid mass flywheel. The front prop shaft (used when 4WD engaged) was ceased which could explain the issues within the box. I'm back on the road now & the repair/replaced (TBC) front prop shaft will be refitted in due course.

Thanks for your responses!