Technical Gearbox/engine/wheel disconnect

[WildFeraligatr]

Hi all

Apologies for the spam posting but I'm starting to get a bit fed up with this car now!!! Only because I've put a lot of work into it

Part of my big overhaul project for this car was changing the clutch. I was very very careful when doing so - made sure everything was torqued to spec, everything went on the right way, everything was aligned and the gearbox slid on to the clutch beautifully when I put it back on. But now... the car won't move!!!

It goes into gear absolutely fine, I've had a look inside the inspection cover with my partner pressing the pedal and can see the thrust bearing moving, but when I get in the car and try and get it to move, it just... won't. Only thing i can think of is the slave cylinder needs replacing maybe? It seems to be pushing far, but maybe not far enough? Any ideas?

 

[John202020]

Did someone once mention something about the diff gears that they can get out of whack if not careful? Don't take this as gospel !

 

[The Panda Nut]

That sounds horribly possible. I have afear you need to support bearings after drive shafts removed. Try a search on driveshaft change.

 

[The Panda Nut]

What happens if you jack one wheel up, select a gear and then rotate the wheel You should get solid resistance.
If you depress the clutch you should see the slave cylinder rod move an inch or so. Back and fore again. This doesnt sound like a slave issue That results in bad pedal feel but observe back and fore movement and of the release arm its connected to.

 

[WildFeraligatr]

That sounds horribly possible. I have afear you need to support bearings after drive shafts removed. Try a search on driveshaft change.

I remember when I was putting the driveshafts back in there was a little conical gear that had poked up that was stopping me from getting the shafts back in. I ended up pushing it down with my finger to get the driveshaft back in... is that what you mean? (part number 10 in the below diagram I believe)

What happens if you jack one wheel up, select a gear and then rotate the wheel You should get solid resistance.
If you depress the clutch you should see the slave cylinder rod move an inch or so. Back and fore again. This doesnt sound like a slave issue That results in bad pedal feel but observe back and fore movement and of the release arm its connected to.

I pushed the car while it was in gear and it rolls smoothly - no resistance so definitely not connected to the engine. Pedal feel is about the same as my Panda - although when bleeding the clutch the fluid was coming out of the hex key slot as well as the bleed nipple. The cylinder is definitely moving though.

 

[jackwhoo]

Clutch plate on correct way around?
Did you check the clutch plate fitted splines on gearbox input shaft correctly before assembling clutch on flywheel.
Many years ago I had the very problem on mk2 golf because wrong plate in clutch kit.

 

[WildFeraligatr]

Clutch plate on correct way around?
Did you check the clutch plate fitted splines on gearbox input shaft correctly before assembling clutch on flywheel.
Many years ago I had the very problem on mk2 golf because wrong plate in clutch kit.

Believe so yes. Didn't check the clutch plate against the gearbox but looked identical to the one i took off.

In the meantime I'm gonna sulk for an evening then try and start taking it apart again over the weekend i suspect if it was an issue with diff parts being out of place I'd be hearing some crunching or something...

 

[The Panda Nut]

Yep you may have shoved it the wrong way possibly

 

[WildFeraligatr]

Yep you may have shoved it the wrong way possibly

Fair enough - time to drop the gearbox again then i guess!

Thanks for your help everyone - I'll update when i figure it out in case anyone else comes looking.

 

[WildFeraligatr]

Good news everyone!

I managed to get the gearshift mechanism off and found that the engine and gearbox are connected (put it in gear and turned the engine at the crank). I also popped open the diff of a spare gearbox I have lying around and saw how easy it was for the planetary gears to drop out of place without the driveshafts holding them in place - so time to pop the diff off and get it sorted. Pretty pleased I don't have to pull the whole gearbox!