Technical Gearbox problem

[Willem1988]

Hi all.i hope simeone can help me as im out of idees.i have a 2005 palio 1.2.i put in a newer model motor.as far as i inow its a 2010.also 1.2.but for some reason i can not get clutch to disengage.i had gearbox off 3 times allready.throwout bearing and fork look fine.slave is fiid and replaced clutch master.no leakes and plenty travel.when engine is running and pedal pressed it makes a kind of scratching sound not the normal screething sound that we all know.rbut its not loud.also stays the same.it doesnt get louder or anyhing.any real advice would be great tired of pulling the gearbox off for nothing.thanks in advance

 

[bugsymike]

Hi all.i hope simeone can help me as im out of idees.i have a 2005 palio 1.2.i put in a newer model motor.as far as i inow its a 2010.also 1.2.but for some reason i can not get clutch to disengage.i had gearbox off 3 times allready.throwout bearing and fork look fine.slave is fiid and replaced clutch master.no leakes and plenty travel.when engine is running and pedal pressed it makes a kind of scratching sound not the normal screething sound that we all know.rbut its not loud.also stays the same.it doesnt get louder or anyhing.any real advice would be great tired of pulling the gearbox off for nothing.thanks in advance

The most common reason for that is the clutch centre plate/friction plate fitted the wrong way around, many have it written in German saying flywheel side.
What happens is the raised centre part jams against the flywheel bolts so cannot disengage but makes horrible noise.
With clutch assembly off the car you can see when you put the parts together what happens.

 

[Willem1988]

The most common reason for that is the clutch centre plate/friction plate fitted the wrong way around, many have it written in German saying flywheel side.
What happens is the raised centre part jams against the flywheel bolts so cannot disengage but makes horrible noise.
With clutch assembly off the car you can see when you put the parts together what happens.

bugsymike thanks for the reply.i made sure i put it back the correct way.marked with tipex when i took it off the old engine,took photos and everything

 

[bugsymike]

bugsymike thanks for the reply.i made sure i put it back the correct way.marked with tipex when i took it off the old engine,took photos and everything

Oh! No sign of any damage from that noise when disengaged then?
Gearbox good?

 

[Willem1988]

Oh! No sign of any damage from that noise when disengaged then?
Gearbox good?

All looks good.cant see any damage on bearing or fingers.clutch plate and flywheel also good.im starting to drop the box again tonite.maybe i missed something...

 

[bugsymike]

All looks good.cant see any damage on bearing or fingers.clutch plate and flywheel also good.im starting to drop the box again tonite.maybe i missed something...

In my experience the most common issue is as I mentioned with the clutch centre plate, second is where when lifting gearbox in, it is left hanging on the splines and clutch plate, although usually clutch will still function but feel funny due to damaged diapragm spring plate.
A release bearing if not located properly can sound funny , but usually clutch will still disengage.
Let us know what you find.

 

[Willem1988]

There was a spacer plate on the old motor.about 80mm in diameter and about 5 mm thick.i see i did not put it back.can that be my problem?

 

[bugsymike]

There was a spacer plate on the old motor.about 80mm in diameter and about 5 mm thick.i see i did not put it back.can that be my problem?

Where abouts was the spacer fitted, can you show a photo?

 

[Willem1988]

Where abouts was the spacer fitted, can you show a photo?

this.bug looking at it.....it cant play a role.it sits to deep to space anything.rite?

 

[bugsymike]

this.bug looking at it.....it cant play a role.it sits to deep to space anything.rite?

Soon tell if there any damage marks on it.
Strange, was there different thickness of flywheels?
If you were getting a noise when pressing the clutch down I would look for signs of damage that was causing the noise.