Club 80-90 Forums

Hi Guys,

I am not sure what gearbox I have in my camper as an engine conversion took place prior to me owning it. It is a 4 speed though and the original documentation is says DW with original engine DG so probably that one?

Any way I replaced trans oil with quality one not few months ago and the van has changed gears fine. On a recent trip yesterday however I have been finding it hard to select gears and often need to double clutch, One to get out of selected gear then all way up and down again to select new gear. Even then it needs a bit of a push to get it in.

It does not crunch (unless I started to let clutch pedal up before its in, so not sure what it could be? The clutch bites well so do not think it is that. Anything might need adjusting? Sound like linkage or gearbox probs?

Thanks

Also now noticing that the clutch is engaging very low down on the clutch pedal. Literally just as it moves slightly up from the floor when depressed.

Is there anything that might cause the clutch to suddenly not disengage as fully as previously? I can't see how any brake fluid could have leaked out. Might try bleeding it again to be sure but seems odd. Is there any way of adjusting it? I am hoping the stiffness getting into gears is due to the clutch not disengaging as fully with foot to floor as used to.

Watch the clutch lever when someone presses the pedal for you to see it go through full travel the clutch slave could be worn and not giving the full amount of push from the pedal, if not it may well be a worn thinger (thrust bearing?) in the bell housing that actually transfers the movement from the lever to the clutch for it to do its thing. you need to remove the gearbox or the engine to get at this.

Could be linkage problemsm, best diagnoses is to remove the two bolts that hold the linkage onto the gearbox and lower it, then work the gearbox selector by hand and see if its sticking or difficult in any way. there can be some difference between warm and cold if there is an internal gearbox wear issue.

I had the same symptoms to this when the fork that pushes the thrust bearing had worn, started to get difficult to change gear and eventually the clutch was biting not far off the floor, when I removed the gearbox the the lobes on the fork were completely flat. If it is this be carefull about where you buy the fork as I had lots of problems whith JK and GSF both selling an absolute piece of crap made in Denmark that had been manufactured wrong and could never work. had the box on and off so many times until we realised what was wrong.
Easiest way to tell if thats your problem is to get someone to push the clutch while you look at the relay arm on the gearbox and see how much it's being pushed down.
I ended up buying a new bellhousing from Spannerboy for £100 in the end as It was doing my head in.
I have a bellhousing here from a VW reconditioned gearbox removed from my van due to a diesel conversion if it's any good to you?
Rob.

Ok so slave replaced and all well... Nearly lol

So now I have a grind when changing into 3rd gear. Now when I was tying to get it off the road and into garage I had o get brutal with getting in gear and once in it was very stiff pulling it outa gear, when I forced it I could have sworn I heard something metal drop under the van.

Is it most likely the bush nder the gear stick or cou,d I have damaged the gearbox?

Thanks