Can't shift into gear

dirtkeeper · Posted: Thu May 16, 2013 7:16 am Post subject:

I assume that you have observed the throw out bearing move properly as someone pressed the clutch pedal.

The metal shavings on the shaft seem to be an indicator of an issue... Could the splines or the clutch disc splines be mismatched or crunched that they are binding?

deho · Posted: Thu May 16, 2013 8:17 am Post subject:

The picture of your pressure plate, Is it tightened all the way down? It doesn't look like it in the picture. The edge of your pressure plate should be inside of your flywheel.

Deho

71sbeetle · Posted: Thu May 16, 2013 11:58 am Post subject:

deho · Posted: Thu May 16, 2013 3:19 pm Post subject:

One more question about your picture. The bolts use to tighten te pressure plate down, is it touching the flywheel. I have only seen bolt with a washer. Just trying to help. If the engine is out Have you been able to push the clutch in and see how much the throw out bearing moves. It should move about .2 to .4 inches accourding to Kennedy Clutches.

71sbeetle · Posted: Thu May 16, 2013 4:34 pm Post subject:

71sbeetle · Posted: Thu May 16, 2013 4:45 pm Post subject:

Yep, you are right, the head of the bolt does touch the flywheel, there are little indentations in the flywheel from it too .....
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Alte Schule Vintage and Performance VW club
www.gareymartin.com
flickr

deho · Posted: Thu May 16, 2013 6:19 pm Post subject:

I broke 2 pressure plates because I was moving the throw out bearing 0.75. It worked for a very short time then broke. After putting a stop on the clutch pedal at .4 inches. no further problems.

deho · Posted: Thu May 16, 2013 6:22 pm Post subject:

If the pressure plate isn't being tightened properly because the bolts are not pushing the pressure plate all the way in. I would think this is a problem.

71sbeetle · Posted: Thu May 16, 2013 7:42 pm Post subject:

OK, how did you measure how much it moved? I'm getting my new cross arm tomorrow from AC.net in the mail, and I picked up (another!) new bearing today from JBBugs, I will install it all tomorrow early afternoon as soon as the mail man drops off my AC.net package Smile

Now, for measuring, do I just set the clutch cable so that it doesn't pull the transmission arm at all?
And then, push the pedal all the way and measure how much it moved?

As for the PP, it looked like it was down all the way tight if I remember right it may even have been tight before the bolts touched the flywheel but still just a little under the 22 ft.lb torque (probably close to around 17-1 Cool

. My torque wrench broke so I need to go buy a new one (tried to fix that one but I can't ....)
_________________
Alte Schule Vintage and Performance VW club
www.gareymartin.com
flickr

VWNut_69 · Posted: Fri May 17, 2013 7:12 am Post subject:

The washers hitting the flywheel is definitely a issue but probably won't help the going into gear problem as the pressure plate is farther away from the disc to start with and won't fully engage the disc with the pedal released. The new parts will tell the story.
Mike

71sbeetle · Posted: Fri May 17, 2013 7:32 am Post subject:

This couldn't be an internal transmission problem right?
_________________
Alte Schule Vintage and Performance VW club
www.gareymartin.com
flickr

VWNut_69 · Posted: Fri May 17, 2013 12:39 pm Post subject:

Hard to say but while the engine is out you should measure the throw of the clutch pedal at the arm for the cable on the trans then recheck it after the engine is in just to make sure it isn't changing.
Unless of course it is all good when you are done then don't bother.
It may have been possible let for the pressure plate cover to flex towards the disc when you push the pedal since it wasn't fully seated on the flywheel. Its a stretch but you never know.
Mike

deho · Posted: Fri May 17, 2013 1:50 pm Post subject:

My clutch pedal moved to far. The way I checked this was to have a friend push the pedal all the way down. While he is doing that you are measuring the front - back movement of the throw out bearing.. Once I stopped the overmovent(now at 0.40) Have not has any further pressure plate problems. When the plate broke I could not shift when the engine was running.

71sbeetle · Posted: Sat May 25, 2013 6:53 pm Post subject:

OK so I installed the new cross shaft (old spring because the new one was a different shape and smaller and there was no way it would fit).
Throw (while pushing clutch pedal with cable touching the arm but not pulling it at all) is 1.25" at the top of the arm and 0.5" at the bearing.
Also installed a new DRD gland nut (torqued to about 475 lb.ft with red loctite) and installed the pressure plate with stock bolts/washers.
We'll see if it works now Smile

_________________
Alte Schule Vintage and Performance VW club
www.gareymartin.com
flickr

deho · Posted: Tue May 28, 2013 6:47 pm Post subject:

Checking on an update. Hoping this takes care of your problem.

Deho

71sbeetle · Posted: Tue May 28, 2013 7:03 pm Post subject:

71sbeetle · Posted: Tue Jul 09, 2013 9:21 pm Post subject:

Alright so still no go, I decided to pull the trans last night to ship it out to KCR to have it checked out, boxed it up and all, called FedEx for a pickup and left it where I usually do for FedEx to pick up. Wife got home and said trans was gone, but there was a paper from FedEx saying 1st pickup attempt, and the package that was delivered from UPS earlier in the day was also missing ....... Looks like someone decided they could just come and take our stuff Sad

_________________
Alte Schule Vintage and Performance VW club
www.gareymartin.com
flickr


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