Gearbox/Clutch problems.

[davegsm82]

Having just returned from a short (60 mile) run from up the coast, I pulled into the local Morrisons Car park to get some shopping and found that I couldn't get into reverse, then also realised that any of the other gears were almost impossible to get into while stationary.

With the engine off I can get all gears, but with the engine running it's very difficult. Sitting on a flat surface with the engine running and clutch pressed to the floor, if I try to engage 1st sometimes it goes in but most of the time not, I noticed that the van moves forwards *very slightly* when trying but failing to engage (I'm talking about half an inch). Similarly it moves back when trying and failing to engage reverse.

Backstory: 1.9TDi with flipped box.

I've heard that the clutch master cylinder pin wears through the pedal metal, is this inevitable or does it only happen sometimes?

Would these symptoms indicate the pedal/pin problem?

While sitting holding the clutch in with the side door open I noticed an intermittent screeching noise which went away after 5-10 seconds, bad news for the bearing that's in there I guess, but surprising as I replaced it with a brand new one and a new friction plate less than 1000 miles ago.

I tried abusing the clutch (handbrake on, 4th gear, revving at almost full steam and holding the clutch) Result, lots of white stinky clutch smoke and then I could briefly select all gears again, but then once it had cooled, it was back to being near impossible to select again.

Before I get the spanners out can anyone suggest anything worth trying?

Dave.

[davegsm82]

Did some work on this yesterday.

When I got my A4 gearbox the clutch slave cylinder mounting 'lug' was snapped off, so I made a steel clamp to hold it in place.

I think I may have made the bracket a little too short, so I have rotated it 90 deg to give it an extra push into the bellhousing. I also bled the fluid through from the M/C as it was coming through absolutely filthy.

After this the gear selecting is ok again, not perfect but certainly liveable, I can at the very least get reverse and all forward gears with the pedal fully depressed. I do have a slow weep from the top of the clutch master cylinder though so I am going to replace that in the near future, hopefully that will make for a better gearchange and I can check that the pin isn't wearing through at the same time.

As for the screechy bearing. I'm going to forget that happened for now and hope for the best.

Dave.

[DentedDevon]

We had similar symptoms with our van at the end of last year.
Clutch seemed not to disengage fully, had to start it in gear as couldn't get into gear when stationary.
I was convinced it must be slave cylinder/clutch shaft or the clutch itself.
I did notice a screechy noise when reversing it onto the ramps for investigation.
Stripdown revealed it to be the pilot bearing had seized and broken up, the remains of the needles were blue with heat!
Investigate asap, the input shaft may get damaged if this is your problem. (if it isn't already).

[davegsm82]

Since I rotated the slave cylinder bracket it's been ok, no more bearing noise and no problems with clutch slip or hanging on at all so I'm reluctant to start pulling it to pieces to inspect it again. Have been using it on and off for the last 2 weeks with no bother, 60 miles today and didn't miss a beat. It does need the matter cylinder swapping out though, almost every day there's fresh brake fluid on the rubber matting.

Dave.