ABF wih 8v box - problems!

[bong69]

Hi all, just swapped my KR for n ABF, only problem is can get the clutch to work.. the gearbox is coded AUG and was running fine on the KR but when put on the ABF I cant get the clutch to fully disengage, the lever arm on the gearbox passes the '9 0'clock' position before I can hear/feel the pushrod hit the release, the cable is a bit knackered but ven putting spacers on helps only a bit, could it be a engine/box mismatch?

cheers

[rubjonny]

what clutch kit did you buy? If it was a MK2 16v kit then thats your problem. clutch splines on the 16v kit are too big for the AUG box, you need an 8v GTI clutch kit.

If clutch kit is correct I had same problem and it was due to the pushrod being too short, it had been crushed down nearly 10mm.  Replacement pushrod sorted the problem, however box had to come off as the end had mushroomed out.

link for release arm checks, also tells you how long the pushrod should be:
http://www.brokevw.com/releasearm.html

[bong69]

Cheery Jonny, its an 8v clutch, only been in bout a month then engine decided to retire, was workin fine up until i took engine out saturday, it does seem like the push rod is too short but the rod looks fine, no mushrooming etc, it does protrude around 24mm when the lever is fully up (as per the great link you sent - cheers) ive got the box out so will measure the full length of the pushrod, cheers

[rubjonny]

cool. other thing it could be is the release finger has cracked allowing it to slip on the splines, i had a similar issue in my cabby which turned out to be a damaged release plate

[bong69]

i'm thinking that could be the problem! thing is if I space up the cable end it works ok, am gonna get another look at that finger tho, the box did get a couple of knocks whilst I was wresting with it! Thanks again mate