1st up, series boxes SHOULD run 90w GL4 gear oil (most standard gear oils are GL5 rated). Running a GL5 oil MAY cause excessive wear/deterioration of the phosphor bronze parts over time.
However - not related to the current problem.
How much actual clutch depression is he getting at the pedal - i.e. when you press the clutch, you can feel when the slack/freeplay is taken up. After that, you need a good few inches of travel with a solid pedal.
Sounds very strange, it really sounds like a clutch problem. But the change to 4th should be pretty easty even without a clutch.
It could be a selector issue (easy to check - just need to remove the box top cover) - but that wouldn't explain the crunching...



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