AC Aceca
How-to & Repairs
TransmissionDriving technique

Driving a Gearbox with No Synchromesh on First

If you have only ever driven modern cars, the first crunch going into first gear can be an unwelcome surprise. It is not the box being worn or broken. It is the box asking you to do, by hand, a job that a modern gearbox does for you, and it is a skill anyone can learn in an afternoon.

What synchromesh actually is

Inside a gearbox, the gear you are selecting and the shaft it must drive are usually spinning at different speeds. Before they can be locked together, something has to bring them to the same speed, or the teeth that engage them will strike each other.

A synchromesh gear carries a small cone clutch for exactly this job. As you push the lever, the cone touches first and uses friction to drag the gear up or down to the shaft's speed, and only once the speeds match does it let the toothed sleeve slide home. That is why a modern car goes into any gear, at any road speed, with one push of the clutch and no thought from the driver.

Without synchromesh there is no cone and no automatic matching. The teeth engage directly, so the two speeds must be matched by the driver, using the clutch and the throttle, before the lever will go home quietly. If they are not matched, the teeth clash, and the clash is the crunch you hear.

Why early boxes lacked it on first

Synchromesh was expensive to make, and in the period these cars come from it was fitted where it was most needed: on the gears a driver changes between constantly on the move. First gear was assumed to be selected with the car at rest, pulling away from a standstill, where matching speeds is trivial. The design logic of the period was simply to spend the money on second, third and top, and leave first as a plain crash gear.

The consequence for a new owner is that first behaves differently from every other gear in the box. Treat it as a gear for setting off, not a gear for changing into, and most of the difficulty disappears.

Selecting first from rest

This is the straightforward case, and the one first gear was designed for. The car should be genuinely stationary, not creeping or merely nearly stopped. Even a slow roll keeps the internals turning at a speed that will not match a stationary shaft, and that is enough to make first resist or grate.

If first will not go in even at a standstill, the teeth are probably resting tooth-on-tooth rather than slotting together. Do not force the lever. Keep the car in neutral, let the clutch up briefly so the shaft turns a little and the teeth shift position, press the clutch again, and try once more. It will almost always drop straight in on the second attempt. This is normal behaviour, not a fault.

Selecting first on the move: double-declutching

Sometimes you cannot avoid first on the move: a junction you have slowed almost to walking pace for, a steep hill that has killed your speed in second. This is the part people get wrong, because it asks for a sequence rather than a single action. The sequence is called double-declutching:

  1. Clutch down, and move the lever into neutral. This disconnects the engine from the gearbox and lets everything inside the box spin freely.
  2. Clutch up, in neutral. This reconnects the engine to the gearbox internals, so the engine can now spin them. This is the step that makes the next one work.
  3. Blip the throttle. With the clutch up in neutral, a press on the accelerator spins the gearbox shafts faster. First gear needs them turning fast, because it is a low gear, so the blip raises their speed toward what first will need.
  4. Clutch down again, and select first. With the internals now spinning at roughly the right speed, the teeth meet at matched speeds and the lever slides home quietly.
  5. Clutch up, and drive on. Bring the clutch up smoothly, as you would pulling away.

The reason for understanding the steps rather than memorising them is that the whole sequence exists to do one thing: spin the gearbox internals up to the speed first gear needs, using the engine, in the only moment you can reach them, which is with the clutch up in neutral. Once that is clear, you can adapt it: a bigger blip at higher road speed, a smaller one near walking pace, and none at all if the car is nearly stopped.

Changing up does not need it

Double-declutching is for coming down the box, not going up. Changing up, the next gear needs the shaft turning slower, and the shaft slows of its own accord in the moment the clutch is down and the engine is disconnected. A deliberate, unhurried pause in neutral as you move the lever gives it time to do so. Rush the change and you may catch the teeth before they have slowed enough; give it a beat and it goes in cleanly. The pause does the work that the throttle blip does on a downchange.

What the noise means

A crunch is the dog teeth striking each other while spinning at different speeds. Each time it happens, the corners of those teeth take a blow, and forcing the lever makes it worse. Worn, rounded dog teeth are precisely what causes a gearbox to jump out of gear under load years later, so every crunch is spending the box's future. The crunch is not a noise to get used to; it is the gearbox telling you the speeds were not matched, and it rewards a driver who listens.

In traffic and on hills

The practical reality of driving one of these cars in modern traffic is planning further ahead than you would in anything newer. Look well up the road, start your slowing earlier, and let second gear take you down to walking pace where you can. If the car slows below the point where second is happy, be willing to come to a complete stop and take first from rest rather than snatch at it on the move. There is no shame in stopping; the box was designed around exactly that. On a hill, the same applies: anticipate the gradient, and if speed has collapsed, stop, select first calmly, and set off again.

Practising

Find somewhere quiet, an empty car park or a still industrial estate on a Sunday morning, without passengers, and practise until the sequence is unconscious. Try the downchange into first at walking pace, then a little faster, listening to how the size of the blip changes what you hear. It is a rhythm rather than a set of instructions: down, neutral, up, blip, down, gear, up. Within a few sessions your hands and feet will do it without being asked, and the car will reward you with silence.

Note. This article describes the driving technique, not any specific gearbox. The archive has not verified which gearbox is fitted to each variant of the Aceca, which gears carry synchromesh on it, or whether a freewheel device is fitted (Bristol gearboxes are often described as having one on first, but this has not been confirmed for the cars covered here). Establish what is in your own car from the owners' club or the workshop manual before assuming any of it. The gearbox and freewheel article covers what is known about the boxes themselves.

Common questions

What does non-synchromesh mean?

It means the gear has no synchromesh mechanism to match the speed of the gear and its shaft before they engage. On a non-synchromesh gear the driver has to match those speeds, with a pause in neutral going up or a throttle blip with the clutch released in neutral coming down. If the speeds do not match, the dog teeth clash and you hear a crunch.

How do you double declutch?

Clutch down, move the lever into neutral, clutch up, blip the throttle to raise the speed of the spinning parts inside the box, clutch down again, select the lower gear, then clutch up. The blip with the clutch up in neutral is the step that does the work: it spins the gearbox internals up to roughly the speed the lower gear needs, so the teeth engage quietly.

Why does my gearbox crunch going into first?

On a gearbox without synchromesh on first, the crunch is the dog teeth striking each other while spinning at different speeds. If it happens when the car is stationary, the layshaft is probably still spinning from the last time the clutch was up: keep the clutch down a moment, or let it up briefly in neutral and press it again, then try first once the internals have settled. If it happens on the move, the shaft speed was not matched, and the change needs a double-declutch with a throttle blip.

Do you need to double declutch when changing up?

No. Changing up, the next gear needs the shaft to be turning slower, and it slows of its own accord in the moment the clutch is down. A deliberate pause in neutral as you move the lever is usually enough. Double-declutching is a technique for coming down the box, where the shaft needs to be spun faster and only the throttle can do that.

Last updated
Jon Cosson
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About the author

A lifelong classic-car enthusiast in North Yorkshire, near Thornton-le-Dale, who owns and maintains an AC Aceca, writing the single-model reference he always wished existed. Read the full bio.