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"They dismantled the transmission again this week and had to replace another part (a bearing .."
In other threads on this subject we usually have a 'while you are in there ' list. New bearings are inexpensive(unlike all the other parts) and are a no brainer because they are 'sealed-for-life;' - like the IMSB is ! The bearings are not expensive but they are difficult to remove and replace as I mentioned in a previous post.
That was embarrassing for your gearbox expert?
First they don't replace the 2 (?) bearings that are known to be suspect and Second ,they did not do a high speed test of their work. Lets hope they filled it with the correct fluid?
BTW for those who haven't read previous threads on bearing failure in the 6 speed , the test is simple.Stick your finger in the drain hole as far as you can and slide it around the bottom of the inside of the gearbox case. Careful, threads may be sharp. If you find greasy sludge there , it is because the seals on the bearings have failed and their grease has leaked out. The bearings are above the oil fill level and the remaining failed seals seem to exclude the splash oil, so ironically the bearings suffer a lubrication-related failure.Noise and the aforementioned grease are the early warning signs.
I have never found an expert explain why we don't remove the seals from the replacement bearings and allow oil mist/splash to lubricate them - or source bearings with better quality seals.
It will be very helpful to see the details of the work done and try to learn something for those that follow.
You did not mention the miles on the gearbox. This is usually a 90k miles+ problem.
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