URGENT HELP: Clutch/Gearbox/Flywheel - BUSTED

JSE · Postby **JSE** » Wed Mar 14, 2007 8:31 pm

Driving home tonight...1st gear shift at 6000rpm...into neutral and then bang it won't go into second. Stuck in neutral...it won't go into any gear, they are stiff as ever. The clutch pedal feels mushy and soft not as it would normally feel. I pull over -> the car still running. Try again to engage the gears but none will engage except 3rd gear now but only just and it feels funny. Whilst pushing a few times on the clutch I hear a rattle as if something metal has fallen out from the drivetrain and then crunching of gears. I get out of the car thinking that I've busted a gear or my clutch. I turned the car off...a few seconds later I thought I'd try my luck and start it again. and then it was all back to normal -> although the gears did feel really rough as if there wasn't even grip from the clutch. I drive home using every gear now knowing that my gearbox is still alright (I HOPE) and hoping that its just my clutch and hopefull yit didn't do any damage to the flywheel. Can anybody help me solve this and tell me what the problem is? My guess would be that my clutch has had its day and/or a spring from the clutch has fallen out and mashed up in there somewhere...please help. I need the car for tomorrow.

JBT · Postby **JBT** » Wed Mar 14, 2007 8:35 pm

Check your hydraulic fluid level in the clutch master cylinder. I think you've simply had hydraulic (master or slave cylinder) failure. Check for leaks at the slave cylinder.

JSE · Postby **JSE** » Wed Mar 14, 2007 8:37 pm

fluid level in the master cylinder is at MAX

JBT · Postby **JBT** » Wed Mar 14, 2007 8:46 pm

Check for leaks at the slave cylinder (squeeze the rubber boot and check for fluid) and also see if you're getting full travel (vs small movement) of the clutch release lever when the pedal is pressed down.

Andrew · Postby **Andrew** » Wed Mar 14, 2007 8:58 pm

I had a similar thing happen last year, and when they drained the gearbox oil this is what they found -

I also thought my clutch had failed.

adamjp · Postby **adamjp** » Wed Mar 14, 2007 9:58 pm

It might be hard to judge, but does the rattle from the 'clutch' change in pitch or frequency as you increase the revs of the engine, but without having the engine in gear?

If so, then the clutch is probably broken. Possibly broken a plate spring, or more likely a finger on the pressure plate. Only way to tell for sure is to drop the box out and have a looksee.

Craig · Postby **Craig** » Wed Mar 14, 2007 10:01 pm

Trade in time! :mrgreen:

JSE · Postby **JSE** » Wed Mar 14, 2007 10:58 pm

adam...i have a feeling that is exactly what happened. there has been a rattle on decelreation for the past month or so...i just never got around to fixing it...i'm pretty sure a spring has come loose and mashed up in there somewhere...

so do the 1.8 boxes fit in the 1.6 without any modification...how much do master cylinders cost brand new? i know slaves are about $90. i might as well replace everything and make it strong again since its all going to be out.

JBT · Postby **JBT** » Wed Mar 14, 2007 11:10 pm

The clutch pedal feels mushy and soft not as it would normally feel.

Your gearbox could be full of banana skins but that will have no effect on the feel of the clutch pedal. That description above is of failed hydraulics or a disintegrated clutch/pressure plate. If the clutch and/or pressure plate have disintegrated, it is most unlikely that it will recover as stated below .....

a few seconds later I thought I'd try my luck and start it again. and then it was all back to normal -> although the gears did feel really rough

Rough shift/changes are also indicative of incomplete clutch disengagement from the possible failures raised above.

Have you checked the slave and release lever travel yet?

adamjp · Postby **adamjp** » Thu Mar 15, 2007 9:02 am

JSE, I'm with JBT here.

Based on the limited information that you have passed us, your gearbox is probably fine.

However you will need a new clutch kit, 4 axle stands, a trolley jack and a socket set with 2 extensions, 1 knuckle and 14 and 17mm sockets. Around 4 hours work with a friend and you will be fixed.

A PBR clutch kit will set you back around $200. They will want your old pressure plate though. The little bearing in the middle of the flywheel is another $5 or so. Unless you have a desire to spend money without good cause, continue to use the slave cylinder until it is kaput. Same for the gearbox.

Check the slave cylinder throw, but I think the problem is inside the bellhousing.

JSE · Postby **JSE** » Thu Mar 15, 2007 11:31 am

Funnily enough just last week I purchased an Exedy Sports Tuff clutch. Mania reckons its just the pressure plate from the clutch. Just a pain in the ass now to try fix. I will check the slave, lever and leaks today in the bright daylight. Thanks for all the help guys.

JBT · Postby **JBT** » Thu Mar 15, 2007 6:52 pm

Did you buy the clutch kit a week ago or did you have it fitted a week ago :?:

JSE · Postby **JSE** » Thu Mar 15, 2007 9:47 pm

I just bought it, not fitted. I checked for leaks and the master and slave are both perfectly fine. It's got to be the pressure plate or somethin glike that

JBT · Postby **JBT** » Thu Mar 15, 2007 11:02 pm

Hmmm. If the release lever is moving properly then I guess it is down to a stuffed pressure plate. I'll be interested to see the outcome of this. Did you drive the car today? If so, how was it?