URGENT GEARBOX HELP PLEASE (update)

[Bulldog1]

Hello,

I hope someone can help with the following issue. We went to BugJam at weekend and did a 400 mile round trip without any issues. On returning home I parked the van up and left it for a couple of hours before putting it on the driveway. It is a 1.9dg engine with a 4 speed box.
When I attempted to move the van it wouldn't go into any gear with the engine running but with the engine off it went into each gear without issue.
I turned the engine off and engaged first gear. The van then drove ok for 100 metres whilst I turned it around along the street and placed it on the driveway.
Today I went to drop off my pregnant wife at her mothers and the van went into gear fine and started off on the journey of 3 miles. After going into 1st,2nd and 3rd gear the van then would not engage any gears again, unless the engine was off.
The van is now stuck in a lay by in neutral and will only engage gear if the engine is not running.
A new clutch was fitted less than 2000miles ago, when the recon engine was fitted.

Any help or ideas of the problem would be greatly appreciated.

[pionte]

sounds like the spigot bearing has seized.... this means that the input shaft is permanently being driven by the flywheel. It means the gearbox out again if so... Not expensive just in labour.

https://club8090.co.uk/forum/viewtopic.php?f=37&t=107122" onclick="window.open(this.href);return false;

have a read here too...sound familiar ?

https://club8090.co.uk/forum/viewtopic.p ... ot+bearing" onclick="window.open(this.href);return false;

[Bulldog1]

Thanks pionte,
Would it cause more damage to drive it to a garage 5 miles away?
Any ideas on the time taken to do it?
Anyone in Bolton able and willing to do for cash and brews?

[Ralf85]

It sounds like what happened to me last week. Assuming you have a hydraulic clutch like me, check the fluid level in the reservoir for the brakes and clutch, which is in the pod in front of the steering wheel behind the speedo etc. If it has suddenly dropped you probably have a fluid leak from the clutch system. Mine was a leak from a new Sachs slave cylinder which I had fitted along with the new clutch. Each time I changed gear fluid was pushed out of the system. I could not engage any gears in the end with the engine running. Replaced the slave and problem fixed.
Good luck.

[Bulldog1]

Thanks Ralf, I checked as you suggested and the reservoir is still full of fluid.

Looks like another mega bill coming my way!
I thought I'd just got things sorted as spent a fortune on interior also.
I may have to admit defeat and sell my beloved Albert as a baby is on the way soon!

[Ian Hulley]

Reads like a spigot bearing I'm afraid, 5 more miles won't make any difference IF you can drive it safely that is of course.

Ian

[Bulldog1]

Update!!!!!!!!!!!!!!
Today I drove the van and it went into each gear fine, however when in reverse and first gear on lifting off the clutch it made a horrible grinding noise!

Is this still likely to be spigot bearing?

[ChrisTriple]

that sounds like thrust bearing to me! the noise anyway! as for the non changing gear i had the same problem a while ago. it turned out to be the slave cylinder.

[Ian Hulley]

Update!!!!!!!!!!!!!!
Today I drove the van and it went into each gear fine, however when in reverse and first gear on lifting off the clutch it made a horrible grinding noise!

Is this still likely to be spigot bearing?

Spigot bearing failure typically you can select every gear easily with the engine turned off and nothing with the engine running.

You have a reply to your PM as well btw

Ian

[Bulldog1]

I reckon this could be the problem. The top bearing is the one I removed today, the other is the new one.

I've spent the whole weekend getting to this little bugger as the drive shaft bolts had been rounded by the previous owner, making it almost impossible to remove them. I ended up smashing a 13mm socket over the top of them and getting them out that way. Not very scientific and probably frowned upon but worked for me!

Does anyone have any tips for getting the gearbox back in situ?

Many thanks

[pionte]

You can do it on your own... I have , but its bloody heavy. If you have a willing mate, then much easier. Make sure the clutch plate is lined up straight, a bar with tape around to the correct size is what I use . Then lift and wiggle.... get a bolt in to hold it, be careful not to strip the thread by winding it in if its not fully in the correct position.while the box is out, remove the oil drain plug and the refill bung, so much easier when easy access, refill with 4 litres of oil.

Good luck.

[Bulldog1]

Thanks pionte,

The gear oil was renewed about 9 months ago, so I'm presuming it will still be ok!
I'm afraid I don't understand your point about the bar with tape on and stripping the thread! Do you have any photos or a further explanation?
Maybe I'm being a bit stupid after a few Budweisers.

Cheers mate

[pionte]

lol, when you bolt the clutch pressure plate back on , you have to get the clutch plate sitting in the correct place so that the input shaft from the gearbox can go through it and locate into the spigot bearing, you can buy clutch lining up tools

http://www.ebay.co.uk/itm/CLUTCH-MATE-T ... 53fbcd5002" onclick="window.open(this.href);return false;


but if you bolt the clutch back onto the flyweel loosely you can get the holes lined up using a socket extension bar and wiggle it till it looks right, or for a perfect fit wrap masking tape around the extension bar end untill its a perfect fit into the spigot bearing and the centre of the clutch, that way they will be lined up perfectly .making sliding the gearbox input shaft back in easier.

What I meant with the bolts is, I have seen some people get the gearbox back in place all wonky, and just keep winding a bolt in hoping the pull the box on straight... some times it will strip the thread on the bolt, better to get one in to stop it popping back out then wiggle the box like crazy untill another bolt on the other side can be put in, sometimes rotating the crankshaft on the engine will help the splines pop into place.

Hope this makes more sense now ?

[Bulldog1]

Many thanks pionte,
That makes sense. Lets hope I get it sorted before my week of night shifts. Due to go on holiday next Friday.

Cheers for your advice. I would be lost without the knowledge of the 80-90 people.

[Ian Hulley]

Or even better pick up a formerly appreciated input shaft ... 100% perfect fit

Ian