"Replace the gearbox"...are you sure??

[mk2bal]

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.

[Seanl]

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?

[Diamond Hell]

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?

[clipperjay]

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?
 

[mk2bal]

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...

[molegti]

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.

[Simeon]

You just need to adjust the clutch cable. If you have an auto adjusting one then you need to replace it.

[car_maniac]

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 

[mk2bal]

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..

[molegti]

Is there any way to find out which kind just from looking?            Finally getting somewhere with this 

The self adjusting one has a gaitor on it. The other one is threaded with a nut on.