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Almost every time I switch into the second gear, a quite loud crackle sound is heard shortly. It only happens when switching into the second gear, other gears are fine. I depress the clutch fully of course.

The vehicle is a Mercedes-Benz 308D, a T1 van, year 1992, model 602.316

The transmission is a 5-gear manual gearbox - type G1/18-5/4,69 (some sources describe it as G1/18-5/4.7) model 711.113.

Is it something to worry a lot about?

How to fix it?

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up vote 4 down vote accepted

I think this could be related to one if the gearbox synchronizers (take a look into this wikipedia article) to see what I mean, and the one that's failing is the one for first-second shifts, as you describe the issue.

I hope that helps

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might want to ask about the third to second downshifts as well. – Bob Cross Apr 17 '11 at 14:20
I think if they're not producing noise at this time they could still be working, remember using the truck on a city would result using 1st and 2nd gears all the time, so these will wear the most. – Eugenio Miró Apr 17 '11 at 14:50

I agree with Eugeio in that it sounds like a synchro. Have you changed the rpm point that your shift or hauling a heaver load recently then usual? In my truck if i shift around 2500-3000 RPMs with a decent load behind it the gears will grind a little bit. So if i shift before that point then i dont hear anything.

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This noise switching into second gear is there since ever I bought the van last year. I can't really tell is it related to at which RPM is the switch, as the van doesn't have a tachometer (I'm planning to retrofit one). – miernik Apr 17 '11 at 23:02

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