Really Werid Electrical Problem?

[fatony1 17]

I fitted a lightened flywheel and VTS gearbox to my 205 GTI-6 over Christmas, all good so far. Then the other morning, i turned the key and the starter clicked but wouldn't turn, a few more tries and it still wouldn't go, then after 8-10 turns of the key it fired, i thought nothing of it, until it happened again the next morning, and has been happening on and off ever since.

 

Then tonight on my way home from work while sat in traffic, i noticed when i move the gearstick from netural into gear, all of the cars electrics get a surge of power (headlights/dash cluster/interior light etc etc) all brighten up..??? Once in gear, the electrics dim again, but if i push the stick forward while in 1st for example, the power surges again??

 

Thinking the two might be related, i went back out about 20 minutes ago and turned the key. As usual, it clicked but didnt fire, so i held the key turned and moved the gearstick and sh*t me, it fired!?!

 

Now the old BE3 gearbox i removed over Christmas had a threaded stud in the top that i connected my main earth cable to, the other end of the cable is bolted to the battery tray. The VTS box didnt have this threaded stud, so i swapped it from the BE3 box to the VTS box. Im thinking this earth cable bolted to the gearbox can be the only link between gearstick/electrics getting brighter/starter not turning over, does anyone have any ideas?? I've checked this main earth and from what i can see by torch light, its complete (not split/frayed) and its bolted tightly at both ends.

 

Please help!

[rallysteve 22]

Check the brown multi-plug that sits just above the gearbox first

 

Steve

[Daviewonder 533 3 Cars]

Check the brown multi-plug that sits just above the gearbox first

 

Steve

 

I don't think a GTI6 loom has one?

[rallysteve 22]

I don't think a GTI6 loom has one?

 

Fair point

 

Wasnt sure wether it was retained when you join the looms

 

Steve

[welshpug 1,666]

would imagine that main earth wire could have a break in some of the strands.

[mickie 3]

sounds like everytime you move off its pulling the earth on the box

[large 33]

I would check the bolts on the gearbox and the earthing point on top of the box.

Also check the earth clamp to the battery post as it sounds like you have a bad conection.

 

Did you remove the battery tray when fitting the new box? If so check the 4 bolts have not worked loose.

Edited January 31, 2011 by large

[fatony1 17]

Well i checked tonight and the top 3 gearbox/engine bolts were loose!! Any idea how this could have happened? I KNOW i tightened them up when the box went in, im 100% sure of it!

 

None of the battery tray bolts were loose. Can't see any breaks in the earth cable.

 

[GLPoomobile 958]

I kind of feel a little smug for myself as I was reading this earlier and I thought it might be the gearbox that was loose, but then I dismissed the idea as I would have expected you to have had problems engaing gears etc.

 

So presumably it was making a poor earth due to the gearbox not being in full contact with the block. When you were pushing forward on the gearstick it was pushing on the gearbox causing it to go back in to contact with the engine and make a better earth.

[fatony1 17]

I suppose that does make sense but I tightened the bolts back up tonight and it's still the same I've also noticed it's doing the whole electrical surging/lights getting brighter if i move the shifter around in neutral??

[smithy 1]

have you checked to make sure gear linkage is not fouling the eart lead making it work loose?

 

If that is ok then I would run a new earth from battery engine/trans and see if that makes any difference.

[fatony1 17]

I forgot to say, my battery is in the boot in a box, could this make any difference? Im going to try running a new earth cable between gearbox and battery tray and see if that makes a difference.

 

Also does anyone have any idea what could have made the gearbox bolts work loose?