Gear oil plug

[Solidblade]

What do people think to this

 

[knightmb]

The first gear oil change it's ever had since it left the factory.

 

[Solidblade]

Literally chunks of metal

 

[knightmb]

I couldn't tell from the picture if that was just globs of old gear oil. Chunks of metal would be a bad thing. Do you hear any unusual sounds from the gear box? Do you feel any weird "grabs" or "releases" while driving under power at a steady and slow rate?

 

[Solidblade]

I couldn't tell from the picture if that was just globs of old gear oil. Chunks of metal would be a bad thing. Do you hear any unusual sounds from the gear box? Do you feel any weird "grabs" or "releases" while driving under power at a steady and slow rate?

Clunking intermittently when turning the gear oil wasn’t red but black silver looking

 

[Solidblade]

Yes grabs and releases definitely

 

[knightmb]

Yes grabs and releases definitely

Well, you know where those chunks of metal came from then, damaged gear teeth.
Can't say as to the cause, but unless you cleaned up that plug before taking a picture? Did about 1.5 L of gear oil come out when you removed the plug?

 

[Solidblade]

Well, you know where those chunks of metal came from then, damaged gear teeth.
Can't say as to the cause, but unless you cleaned up that plug before taking a picture? Did about 1.5 L of gear oil come out when you removed the plug?

Yes oil the oil was drained

 

[Solidblade]

Yes oil the oil was drained

The oil was a silver dark colour

 

[knightmb]

The oil was a silver dark colour

That's not good news, usually it's just a dark, transparent color. It means this oil has collected a lot of metal grindings and chunks. Have you owned the EV the entire time or was it bought used from someone else?

 

[Solidblade]

The oil was a silver dark colour

Will a leaf gearbox 2021 fit a 2016 env200 van

 

[Solidblade]

That's not good news, usually it's just a dark, transparent color. It means this oil has collected a lot of metal grindings and chunks. Have you owned the EV the entire time or was it bought used from someone else?

It was bought used

 

[Solidblade]

It was bought used

2 years ago I’ve done 20k in it stop start running I’m a courier driver

 

[knightmb]

Unless you are driving like the Fast and Furious movies, it's possible that a lot of things could have happened but it would be hard to pin down. Wrong gear oil, no gear oil, contaminant in the oil (water, dirt, etc.), manufacturing flaw in the gears itself, vehicle accident, etc.

 

[Solidblade]

Unless you are driving like the Fast and Furious movies, it's possible that a lot of things could have happened but it would be hard to pin down. Wrong gear oil, no gear oil, contaminant in the oil (water, dirt, etc.), manufacturing flaw in the gears itself, vehicle accident, etc.

The van is a ex cat d repaired

 

[Solidblade]

The van is a ex cat d repaired

I’m thinking of changing the gearbox but the one im looking at is from a 2021 leaf

 

[cornbinder89]

What do people think to this

Not good!
Time to pull it down and find out where it all came from. I've seen less metal on a heavy truck rear that sheared off a pinion tooth.

 

[woeful]

Will a leaf gearbox 2021 fit a 2016 env200 van

Sort of, kinda, maybe.

As far as I know, the LEAF and e-NV200 gearboxes fit the same motor, drive shaft connections and the fixings for the casing. There is one significant difference, though. The van has lower gearing than the car, by 10% or 15% or so (I don't remember the exact ratios). That gives the heavier van a bit more drive force, at the expense of a lower top speed, compared with the car.

Supposing they do fit -- this isn't something I've ever tried -- a LEAF reduction gear in an e-NV200 would restrict the maximum hill-climbing gradient and reduce the acceleration. An e-NV200 reduction gear in a LEAF would improve acceleration but limit the top speed to 85 mph or so. I've no idea whether the EV control software would object that the motor speed didn't match the road speed if the reduction ratio wasn't what it was set up for.

The reduction gear isn't nearly as complex as a multi-speed gearbox, and it should be possible to rebuild it at a realistic labour/labor cost.

 

[Solidblade]

 

[DunanyDon]

What do people think to this

I've been doing oil changes in various engines for over 50 years and have never seen anything that bad. I replaced the reduction gear oil with synthetic in my 2015 leaf at 50,000 miles and there was just a thin film of particulate on the plug magnet. It's a miracle that your gearbox hasn't seized up. It must be that the gearbox vent somehow sucked in some water. The only other things I can think of would be sabotage or a grossly defective gear.