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Discussion Starter · #1 · (Edited)
Hey,

I have a weird issue with my EVO X RS. Now for a second time I have somehow managed to knock some teeth off my main driveshaft in the gearbox. Picture added. This is the second time it has happened and last time it happened in June 2016 and after that we had the full box replaced along with the casing ( as it got damaged by teeth throwing around in the box). This time it seems like it is going the same way, but we can not find the reason for it. All the gears are working fine and no problems with that, but the main shaft keeps losing the same 4 teeth which cause such big problems internally.





What could be the culprit? Using RalliArt paddle clutch and usual GRP N stuff.

Any input is highly appreciated
 

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Phil
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I've no idea what might be the cause, but can you confirm that it's an RS gearbox ie with lower gear ratios than on a non-RS model?
 

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Discussion Starter · #3 ·
Yes, its an RS gearbox. We have an EVO X RS MY2013 ( facelift model)

Can the reason be aggressive downshifting during breaking?
 

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Transmission Dynamics
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7,801 Posts
I'd say either incorrect build specs allowing the centre diff and final drive to move under high load causing the teeth to move away from their optimum mesh, or ridiculously hard driving, dropping down gears without any rev matching and engaging the clutch very aggressively, or both!
 

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Discussion Starter · #7 ·
After a long examination and talk to all the specialists and analysing everything we have found a conclusion.
What you see is a prime example of what happens when you miss a gear. If under heavy acceleration from the end of 2nd gear you happen to shift 1st instead of 3rd. This happened once with other person driving and once before with myself and both times same result.
As the clutch was that strong ( Ralliart paddle clutch), clutch did not give in.

The most funny thing about it is that it cannot be recognized during usage and the car kept working perfectly and gearbox too. Only to discover during gearbox service that there were pieces on the magnet.

Be warned and learn from my mistakes! Much cheaper!
 

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BAD BISH
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762 Posts
didn't the driver notice difficult gear engaging when redlining the second gear and shifting accidentally in first instead the third?!

poor gearbox :wallbang:
 

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Discussion Starter · #9 ·
didn't the driver notice difficult gear engaging when redlining the second gear and shifting accidentally in first instead the third?!

poor gearbox :wallbang:
Having done it myself, it doesnt matter if its third instead of fifth, second instead of fourth or first instead of third.
With purpose built very quick rally car on stages where you have VERY many full blast gear changes at the limit on very different conditions (jumps, hard gravel corners, heavy bumps), it does happen sometimes... Maybe once a year, but if it does happen. It didnt happen with earlier evos that, and when it did, there were not this kind of consequences. But EVO X RS has quite bad gear change compared to earlier evo-s. EVO X has a lot stronger synchros than earlier evo-s, but gear change is not as good even on new car. We have not had any problems with synchros during 3 years on heavy racing (over 5000 stage kilometers). With earlier generation EVO we had to change atleast one synchro per year (2nd to third usually, because of quite slow stages), often more.
 
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