Club 80-90 Forums

Evening,

Just bought (in the last 3 an' a bit weeks) an '86 Doka, ex-German Army. Imported May '09.

Had the 1.6D but this was removed and replaced with a 1.9NAD from a Golf MkIII - no idea of what year the Golf is/was though. The Doka has the original 4-speed gearbox mated to the Golf engine using the flywheel from the Doka as the from speaking to previous owner, the previous previous owner struggled mating the Golf parts and the Doka parts.

It's had a new clutch fitted in the last few months (reciepts to prove from previous owner) but now the clutch slips slightly in 2nd and badly in 3rd and 4th gears. Admittedly I haven't taken it all apart yet, but would like some advice if anyone has encounted a similar problem. Also would it be a viable option to upgrade the gearbox to a 5-speed unit? And if so, which one?! Having been on eBay, the T25 5-speed 'box was over £500 plus shipping... steep?! I've been told by a good friend that I can't fit a Golf 'box as the Golf is obviously front wheel drive and the Doka is rwd so they won't mate.

I just want the ol' gal to work properly! Any advice would be greatly appreciated!

Many thanks, Adam

Welcome to a large family of Type 25 lovers.....


Its a genral opinion that the 5 speed is not as durable as the 4 speed and the final drive is almost the same....
and the gear leavers are totaly different..



as to the clutch slip ????? oil leak from that end of the crank ? worn fly wheel ?
it's and hydraulic system so no adjustment there.....

and the golf and van bits should bolt up no problem so thats a bit confusing..

Good luck from a keen novice

Scott

did they fit a spigot bearing to the crank in the new engine, if not then the input shaft hasn't been fully supported and will have worn the shaft, the input seal and oil thrower and possibly the bellhousing case itself and leaked gear oil onto the clutch, this is a common issue with engine conversions done by numpties;
golf etc ie fwd cars don't have a spigot bearing cos they have a fully supported short input shaft so don't need it
if this is the fault then a spigot bearing input shaft and bellhousing and seal plus new clutch will be all that is required plus gear oil and labour to extract gearbox and swap over the necessary parts and refit, no new gearbox required

Morning,

Just thought I'd give an update...

So, the gearbox came out of her easy-peasy and as Aidan correctly suggested, there was no spigot bearing in t'box. So she's had a spigot bearing, plus the associated bushes. The clutch slave cylinder is also tired, so there's a new one just arrived in the post. Needed a new near side rear brake wheel cylinder too, so that's been changed.

The clutch issue was also dealt with. Turns out she had a fly wheel from the 1.9 and a clutch pressure plate and clutch plate from the 1.6 original engine, with 2mm of washers sandwiched between the clutch plate and the flywheel. The whole lot has been replaced with a set up for the 1.6. Sorted. New rear brake shoes have gone on, so just a couple of jobs; front discs and pads, and sort out the accelerator pedal that freezes when it... err... freezes... Anybody come across this problem before?

Thanks to Aidan for your help and information, and also a shout-out to Lee at LA Performance for his help, too. And to me Dad for fixing it...