Club 80-90 Forums

I have owned this 1.9DG for many years and its always been very reliable.
With the change to E10 it started to backfire and run badly so I changed out the fuel lines and rebuilt the pierburg carb with new gaskets to stop it leaking, and found the old ones had long since dissolved!

I put it back together and drove it down the road and the gearbox went, which I knew was on it's last legs for a while.

I put a refurbished gearbox in, which seems to work OK. I also changed the clutch as the gearbox took the seal out and filled the clutch with Oil.

I can now start the engine and it idles perfectly, it revs well out of gear.
If I put it in reverse it seems ok, at least i can move it about, but as soon as I put it in first or second and try to pull away as I lift the clutch up it bogs down and chugs and after a second or so stalls.

I've rebuilt the carb 3 times, run a temporary fuel line from the tank so see if the fuel line was blocked, torqued every bolt within a 5 mile radius, I've tried so many things to fix this but completely out of ideas, any suggestions much appreciated! Thanks!

Might sound a bit Daft but are you sure you are selecting 1st gear? When you swapped the box did you go through the procedure to align the linkage? Just because you can select reverse doesn't mean the linkage is correct.

I would say your gear selector needs adjustment

Sounds like you are selecting another gear rather than 1st , so check linkages
It’s commmon to put the support bracket on the wrong side of the lip on the gearbox, moving it 10mm in the wrong direction and throwing all the movement out . It should be on the front edge of the lip

Wrong gear as above!
Check that you haven't the linkage bracket on the wrong side of the lug - quite often done.
Snap! - I was looking for a pic.

Thanks to all saying linkage, I did try that first, it definitely goes into first - and was doing this before swapping the box! (the old box third gear exploded - bit of gear everywhere, took the box apart to have a look).
Will upload some pics, but it definitely feels like it goes into gear. Did the old 'loose gearstick bolts and align holes' trick, is there any more alignment needed? Will take some pics when its light, if the storm doesn't get worse!

Errrr.... check which side you have bolted up to?
Do we have to keep saying it?

Oldiebut goodie wrote: ↑07 Dec 2021, 21:43 Errrr.... check which side you have bolted up to?
Do we have to keep saying it?

Sorry If i was unclear, I have checked, after making this mistake before. I am sure it is not this.

Thanks

dooglex wrote:... it definitely goes into first - and was doing this before swapping the box!

Doesn't quite fit with:

"...put it back together and drove it down the road..."

So the gearbox is a red herring, and it was like it before the box failed. Unless it's a 5 speed and you were going for 1st, getting 3rd, pulling away in 3rd, and that's what knackered the box?

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Mocki wrote: ↑08 Dec 2021, 09:37

original post wrote: filled the clutch with Oil.

Good spot! Gearbox with oil, clutch had plenty of oil before! Hence why replaced it!