GolfGTIforum.co.uk
Model specific boards => Golf mk2 => Topic started by: car_maniac on 04 June 2012, 21:30
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Open to suggestions on this!
I had a 1.8 16v Kr with matching 'box. To make gear changes better I had:
The linkages replaced
A new weighted rod
A metal "bush" (I think he called it) put in place between the linkages
This worked and the changing gear was fine!
Then swapped the engine for a 2.0 16v ABF but kept the same gearbox and linkages. THIS IS WHERE THE PROBLEMS BEGAN!
Engine off - gear change OK
Engine on and car stood still - Difficult to impossible to go into gear. Especially 1st & 2nd , so I've had to set off in third a few times.
The only time I can get first or second gear without having to ram it in is by slowing the car right down to walking pace and then it slots in fine
any ideas for fixing this?
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How are you setting it up? Got one of the little alignment plates or guesswork? Put any oil in the 'box?
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It was set up with guess work mate. BUT it goes into gear fine when the engine is off so i would have thought it would be properly aligned?
I could try putting some oil in for what its worth.
Could this cause it to act like the clutch pedal is never down properly?
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Possibly the gear syncro mesh is out of alinement with clutch I had avery interesting conversation with a gear box engineer he stated that if the gearbox is not set correctly the speed from the flywheel to gear box is miss matched.
Solution was to take it to a pro in gearbox to correctly set the syncro mesh on the gears and put it in correctly!
Its confusing to me as I've seen gearboxes like for like go right in, but apprently on some odd gearboxes they need setting up due to the miss match speeds? :undecided:
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Possibly the gear syncro mesh is out of alinement with clutch I had avery interesting conversation with a gear box engineer he stated that if the gearbox is not set correctly the speed from the flywheel to gear box is miss matched.
Solution was to take it to a pro in gearbox to correctly set the syncro mesh on the gears and put it in correctly!
Its confusing to me as I've seen gearboxes like for like go right in, but apprently on some odd gearboxes they need setting up due to the miss match speeds? :undecided:
WTF? Sorry but this particular gearbox engineer you spoke to was just spouting rubbish.
To the OP, check how much clearance there is to the exhaust manifold when the engine is running as something very similar happened to a friends mk1 (similar shift linkage) recently having removed the downpipe. Its also worth checking that the clutch is being fully dissengaged.
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Possibly the gear syncro mesh is out of alinement with clutch I had avery interesting conversation with a gear box engineer he stated that if the gearbox is not set correctly the speed from the flywheel to gear box is miss matched.
Solution was to take it to a pro in gearbox to correctly set the syncro mesh on the gears and put it in correctly!
Its confusing to me as I've seen gearboxes like for like go right in, but apprently on some odd gearboxes they need setting up due to the miss match speeds? :undecided:
WTF? Sorry but this particular gearbox engineer you spoke to was just spouting rubbish.
To the OP, check how much clearance there is to the exhaust manifold when the engine is running as something very similar happened to a friends mk1 (similar shift linkage) recently having removed the downpipe. Its also worth checking that the clutch is being fully dissengaged.
TBF It was just an opinion I didn't take much stock into what he said, IMO it never made any sense as the clutch does the speed matching?
Hence a new gear box once we have tried everything :sad:
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TBF It was just an opinion I didn't take much stock into what he said, IMO it never made any sense as the clutch does the speed matching?
Kind of, the clutch does a large part of the speed matching but the synchro's do help a massive amount but there is no synchronisation as such between the two devices that could need adjusting.
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Well a friend has the same issue but its a fifth gear problem.
He has changed out the linkages and bushes twice and nothing its making the fifth gear go in easy its fine when engine is off and we reckon its must be the selector bracket on the gear box thats bent too far left or right causing the manifold to hit against the selector rod?
This happened after a engine and gearbox swap out? :undecided:
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if it wont select with engine running you have a clutch issue.
clutch isnt fully disengadgeing
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The clutch not disengaging sounds about right because it's like the clutch pedal is ALWAYS raised at least a little bit so the car wants to pull forward when in 1st even with the clutch pedal in the carpet.
Any ideas on how this would be sorted if it is the case?
I've done a bit of googleing and I see people talking about replacing the slave cylinder/maser cylinder or both but as far as i know there isn't anything hydraulic on my car clutch-wise (could be wrong)
The engine is the mk3 2.0 ABF and the gearbox is from a mk2 1.8 16v kr
Thanks for the input though guys
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Is the cable adjusted properly? It could be the push rod and release bearing inside the 020, accessible from under the green tin lid on the end.. Did you swap clutch and fly over to abf ok? All bolted up as should- and then box located onto engine no probs yeah? My 020 clutch failed because the centre pushrod had off-centred and was nearly piercing its way through the plate, this hardly activated the clutch and made shifting hard.. Go 02a+ hydro, big improvement.
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Pretty sure it is an 02A with hydraulic clutch anyway. Well worth replacing master and slave cylinder, whats your fluid level like, and have you been loosing any first off?
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TBF It was just an opinion I didn't take much stock into what he said, IMO it never made any sense as the clutch does the speed matching?
Hence a new gear box once we have tried everything
Did he ask you to go get skyhooks and a long weight too?
As others have suggested - it sounds like the clutch.
Did you put a new clutch on with the ABF, or is it the same tired old KR clutch?
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TBF It was just an opinion I didn't take much stock into what he said, IMO it never made any sense as the clutch does the speed matching?
Hence a new gear box once we have tried everything
Did he ask you to go get skyhooks and a long weight too?
As others have suggested - it sounds like the clutch.
Did you put a new clutch on with the ABF, or is it the same tired old KR clutch?
Problem is this chap had a PHD in mechinical engineering. The story goes he was a friend of a friend they went to the garage which he had simular problems as mentioned, they took the box out took it apart and then bolted it back in and it worked. Specifics of the gear box rebuild and fitting I didnt witnes, but hey I think it doesnt take much for the syncro to be miss alined if you are constantly trying to ram into gear my worst fears is that once you have problems like this its more than likely to cause more issues?
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No matey says its an 020 16v box not an 02a. So its cable not hydraulic, though if it was it isn't a good idea to go buy new master + slave, you bleed them through first to prove what's going on...
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Pretty sure I saw something on here or may have been clubgti where someone had clutch issues because they forgot to put part of the clutch cable back on and it was left loose. Might be worth checking things like this first, at least its free.
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You just need to adjust the clutch cable. If you have an auto adjusting one then you need to replace it.
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The problem seems centered on the clutch and most likely the cable then because I know it's not hydraulic it isn't hydraulic.
I THINK it's the manually adjusting sort because my mate said that he'd tried adjusting it. However, the way the problem has been getting worse is like the clutch is adjusting itself.
When the problem first occurred the gears were stiff to select with the engine on (fine with engine off) but when stationary I first couldn't get 1st and then 2nd meaning I sometimes had to set off in 3rd. Now its the same with 3rd.... To me this seems like a self adjusting clutch gone wrong.
Is there any way to find out which kind just from looking? Finally getting somewhere with this :cool:
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My prediction: clutch push rod is off centre so finding it hard to engage.. I sometimes couldn't get 1st and had to pull off in 2nd gear, and when 5th gear blew apart and I 02a'd it the problem/damage was obvious.. The plate had nearly punctured so I nearly lost the clutch altogether, it was 90 % through.. Check cable, if all is good you may have to pull the box out..
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Is there any way to find out which kind just from looking? Finally getting somewhere with this :cool:
The self adjusting one has a gaitor on it. The other one is threaded with a nut on.