Not Selecting Gears.....

[ORB 227 1 Cars]

So, I put a GTI6 in using my existing 1.9 BE3 box.

 

I used a new clutch (215mm BX GTI 16v)

 

Tonight I ran in and decided to shunt it forward a little to get some crap in the back of the garage.

 

It appears it won't select the gears at the top of the shift. 1st 3rd ant 5th

 

Now it's late and I had done enough tonight so I just killed it, turned garage lights off and went for a shower.

 

What do you suspect? Clutch adjustment? Linkages hitting something?

 

Go on, answer my question and make it easy for me tomorrow night!

[dcc 855]

Im sure this used to happen if you let the selector arm drop. Did you take the pin out of the top selector?

[ORB 227 1 Cars]

Nope. Not touched it. I took box off 8v and straight onto 16v

 

I'm PRAYING that I just need more adjustment on the cable

[pug_ham 244 3 Cars]

Will they all select with the engine switched off?

 

 

Im sure this used to happen if you let the selector arm drop. Did you take the pin out of the top selector?

 

That's when you've lost two gears at one end of the travel, usually fifth & reverse.

 

g

[ORB 227 1 Cars]

Will they all select with the engine switched off?

 

 

No

[ORB 227 1 Cars]

To elaborate, I went out this morning but only had 30 secs as had to get the kids to school.

 

It goes so far up the gate and then stops dead.

[Tom Fenton 1,542]

First thing would be to pop off the selector rods and then operate the gearbox selector levers manually to see if you can get all gears.

That will rule out a gearbox problem.

Is this a new issue or have you only just done the conversion?

Have you got one of those stupid "quick shift" modified quadrants? I've seen these hit the block before now.

[ORB 227 1 Cars]

Its a fresh issue Tom - the gearbox was working fine with the previous engine. Everything is standard and as it was on the XU9 engine except for the clutch obviously.

 

All I have done in essence is drain it, remove it from the XU9 and bolt it up to the XU10 with a new clutch (as I said, MI16 215mm)

[Tom Fenton 1,542]

Like I say, remove linkage rods first and check movement manually.

[ORB 227 1 Cars]

Will do Tom - have to wait till tonight though. Stupid work does get in the way of the more important things in life ......

[pug_ham 244 3 Cars]

Silly idea & not sure if it would work at all but have you connected the linkage rods in the wrong place?

 

Short one goes from quadrant to arm on top of box & longer one to the arm which comes out of the back.

 

Short linkage correctly positioned in pic below;

 

 

g

[ORB 227 1 Cars]

Hmm, i dont think so, but, I have done more stupid things in the past - so I better have a look!

 

In thinking about it, if memory serves me correct, the 1st&2nd Synchro are common (shared) thus it SHOULD in theory be a linkage issure rather than a box issue? (I think this is correct anyhow?)

 

Worse news, the daughters new bunk-bed/desk/wardrobe/playhouse thing has just been delivered to home, so the wife will have me removing cot/chest of drawers/wardrobe and building that tonight

[pug_ham 244 3 Cars]

How did you disconnect them, gearbox end or subframe end?

 

I had a look on my car earlier, I really think you'd struggle to connect them up in the wrong order tbh, something would be obviously wrong when you tried but if you had the gearstick position would be completely wrong imo & instantly noticeable.

 

g

[ORB 227 1 Cars]

Thanks Graham, I just (literally) walked in, straight to garage.

 

Without engine running I can hear it hitting something metallic!

 

I guess it's the L linkage hitting manifold preventing full selection of gears?

 

After I do my evenings DIY I shall jack it back up and investigate further!

[ORB 227 1 Cars]

Hmm, had a brief poke about earlier and I could not see anything obvious. Need to jack it up after work and have a better look.

 

Unless you gents have any pearls of wisdom?

[pug_ham 244 3 Cars]

Have you got a quickshift fitted or still using the standard subframe quadrant?

 

g

[welshpug 1,661]

Did it work with the other gearbox?

 

If so and nothing has been changed on the linkages then i woud check you have the correct mounting stud in both new and old box, and that you have them in the correct drilling (later boxes have two holes)

[ORB 227 1 Cars]

No Quick shift fitted G

 

It's the same box that came out of the car when it was a 1.9, nothing's changed bar the clutch and the motor.

 

Still in the same mounting point too WP

 

It has to be linkage, I'm sure of it. I hope

[ORB 227 1 Cars]

Rather worryingly, I got the wife to try to select gears while I lay under the car with a lamp. Although I could hear metallic sound at the top of the throw to first, I could not see any physical interference.

 

I will have to strip out a load of crap to see if I can get a better view. Typically I have no time to do so....

[ORB 227 1 Cars]

Figured out the problem later last night.

 

I removed battery & box/ecu to get a better look:

 

In neutral:

 

 

Trying to select first:

 

 

As you can see the long linkage is hitting the downpipe bolts and stopping gears engaging.

 

After work tonight I'll have to figure out how to sort it

 

Wondering if a bit of bending/straightening to one of these would help

 

 

???

[pug_ham 244 3 Cars]

You might be able to bend the short arm down a bit to give you more clearance depending on free space between the two.

 

It might be easier to trim the exhaust manifold bolt tail down as well to get more space between the two.

 

g

[Liquid_106 97 1 Cars]

Could you reverse the bolt so the spring is on the other side of the manifold flange??

[ORB 227 1 Cars]

 

You might be able to bend the short arm down a bit to give you more clearance depending on free space between the two.

 

It might be easier to trim the exhaust manifold bolt tail down as well to get more space between the two.

 

g

 

 

 

I was sondering if just straightening the right hand (shorter) leg of the L linkage would give it the effect of extending enough to push the linkage away from the manifold/downpipe?

 

I have the spare one on the bench at the moment so would not be a big issue?

 

 

 

 

Could you reverse the bolt so the spring is on the other side of the manifold flange??

 

 

 

I thought that, but the stupid manifold joint bolts have them cups that are fitted to the top end of the joint, and they are enough of a tw@t to put in!

Edited March 17, 2013 by ORB

[welshpug 1,661]

is the engine on standard mounts?

[ORB 227 1 Cars]

yup, standard mounts and standard angle (no stupid extended fork)