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Old 04-10-2008   #1
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Exclamation 1.6 16v 2nd GEAR CRUNCHING up and down

Hi Guys,


Just wondered if anyone has any advice on this problem,
When i change into upto OR down to 2nd gear my stilo crunches BUT if i pull the stick back slowly and carefully it goes in fine but that then means i cant pull out of a junction with any speed as the change to 2nd will be nasty.

Is this a clutch problem or gear box prob? The car stalls when tryin to pull off in 5th so there is no clutch slip. My local nationwide autocentre quoted 490 for clutch and slave cylinder/thrust bearing. Is that high or standard?


I obviously dont wanna be paying 490 for a clutch if its the box.


(Does the 1.2 - 6 speed box fit the 1.6??) hmmm?
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Old 04-10-2008   #2
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Re: 1.6 16v 2nd GEAR CRUNCHING up and down

could be a worn synchro in the box- however if my understanding of gearboxes are correct, the synchro for second will also operate another gear.

example- when my third gear synchro went, the dealer had to replace third and fourth synchro even though fourth felt ok. (they on the same shaft?)

however, i think more likely the thrust bearing is worn causing this, (decks will be along soon and have a better idea!) is this sounds like the driving school chaps problem when his pupil broke his clutch

are any other gears just difficult to get into (no grinding just stiff)?
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Old 05-10-2008   #3
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Re: 1.6 16v 2nd GEAR CRUNCHING up and down

BBS has covered it all. If it's the clutch it will tend to crunch in other gears too especially reverse as that has no synchro on it. Try bleeding the clutch slave cylinder

But if it still crunches then it's the synchro and BBS is right that a synchro will often engage two gears, one on each side of the synchro, but only one side may be worn out
I would advise turning the sound down

Excessive wear on a synchro is most often caused by engaging the gear at too fast a speed and making the synchro constantly work hard and wear out prematurely. So if it's that then a new gearbox is the only cure

You could try double de clutching- like we do for vehicles that don't have synchros- clutch in-engage neutral- clutch out- clutch in- engage gear but even then you need to match your speed to the gear- just like you always should for a long lasting gearbox.
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Old 05-10-2008   #4
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Re: 1.6 16v 2nd GEAR CRUNCHING up and down

Would start by checking the gearbox oil level, check for internal hexagon plug behind the NS Driveshaft whilst car is parked on a level surface. Undertray will have to come off but if you slacken the plug and your greeted by gearbox oil seaping out you have enough gearbox oil

I had similar problems with my JTD, finding myself de-clutching to get second without crunching frequently or shifting gear very slowly. I ended up changing my gearbox oil, despite Sunwin Fiat locally taking an extended test drive and reporting it being all ok. Have found that the improvement offered by 1.75 litres of Comma SX75W90 semi synth @13 quid was instantly noticable and definately worthwhile

As posted in my thread on the subject... Valvoline on their website recommend checking the oil and replacing at 90,000 KM (55K odd) which is when my gear selection issues became obvious. Strangely enough in the handbook gearbox oil changes don't get a mention
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Old 06-10-2008   #5
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Re: 1.6 16v 2nd GEAR CRUNCHING up and down

Quote Originally Posted by wotnowarninglight View Post
I ended up changing my gearbox oil, despite Sunwin Fiat locally taking an extended test drive and reporting it being all ok.

LOL, My local Sunwin fiat are now Sunwin Renault and dont care about the vehicles they previously sold.

I'm gonna try this first thing in the morning, thanks for the advice.
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Old 06-10-2008   #6
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Re: 1.6 16v 2nd GEAR CRUNCHING up and down

Quote Originally Posted by Big Black Stilo View Post
are any other gears just difficult to get into (no grinding just stiff)?
The only other gear that feels different is 4th it can be stiff at times, i was thinkin about the selecter cable at one point due to both gears being in the same cable direction BUT i couldnt see how the cable would cause crunching?


Im hoping its not the synchro as ive a baby due next month and can only just about afford a clutch replacement if absolutly vital! Does any one know the cost of getting the box replaced?

Does the engine need to be dropped for the box replacing? OR is it like the old astra where some wiggling and jiggling would get it out?

I appreciate your help guys!
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Old 06-10-2008   #7
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Re: 1.6 16v 2nd GEAR CRUNCHING up and down

I'd go for the oil change option that wotnowarninglight suggested if I was you.

It's about the cheapest option you have anyway and can't possibly do any harm
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Old 09-03-2009   #8
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Smile Re: 1.6 16v 2nd GEAR CRUNCHING up and down

Thanks for the help guys, my selector housing ended up splitting half way to scotland (300miles away), not too sure if that was the problem or if was 2nd synchro, but when i stripped the old box it seemed that the 2nd synchro was fine BUT i know it would probably run different under load anyway!

No i'm looking for a 1.2/1.4 6speed to transplant into my baby.



THANKS FOR THE HELP GUYS
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