Ford Escort gearbox problem, very perplexing, anyone know what's what?

Question

My brother's car, 94/5 UK spec Escort LX - 1.6L Zetec, 5sp box, totally original apparently.

Issues started immediately - he drove 25 miles home from place of purchase & then had trouble shifting out of 5th & 4th gears. I initially warned him / mum (who... "helped" with the purchase) there could be a problem e.g. oil level needing immediate attention, but still he's gone on a long trip (~300 miles in total at 50+ mph) without touching it. Now it won't go into 3rd gear....

Tried to open allen bolt to check / top up level, but haven't the tools (about to go out and buy an 8mm allen bit for my socket wrench). Investigated linkage instead - seemed a little out of line (fixed it) but otherwise fine. All other gears a little stiff but perfectly functional.

If one driving wheel is jacked up off the ground, the synchro for 3rd works - i.e. you push it against the position and the wheel spins, suggesting the gear is still fine, but can't be selected.

What the blue blazes is going on? :-) MP

Gary - no, the clutch seems well adjusted, though that was something i was thinking of. There's a bit of noise in neutral with it engaged, but none with it disengaged and the lifted wheel doesn't spin in any gear with the pedal down. The other synchros (except 5th... maybe the next to go?) still work well enough that with the wheel lifted you can push the stick into gear at idle (slowly, with the wheel spinning up) without using the clutch!
Your answer seems the best so far, even though it won't go in when i try speed-matching/double declutching either.

PVReditor - nice idea, but i already fully investigated the linkage i'm afraid... it was initially slightly misaligned but otherwise sound, and is now lined up. Even manually shifting the box's own selector rod using a screwdriver (thru hole on the stubby shaft) shows same pattern of working / broken gears i.e. can easily shove it in any but 3rd

A websearch suggests the "linkage synchroniser"? How's that differ from a regular synchro?

Answer 1

That synchro might make the wheel turn, but it doesn't mean that it isn't too worn to allow for alignment especially if the bearing are sloppy enough to let the shafts move in anyother way than in-line! AFTER-THOUGHT---the clutch isn't still holding-on while the peddle is fully depressed is it?

Answer 2

It could still be a linkage problem. I had a 1977 VW Rabbit that was getting increasingly difficult to shift into 4th gear. Visions of bad synchros danced in my head but I decided to adjust the linkage instead. 10 minutes later, it shifted perfectly and never gave me another problem.