Lost Reverse And 5Th Gear :(

[huwjones 0]

After an epic 12 hour shift putting my 309 back together today (it's been off the road for over 12 months), two things went wrong. First the new cylinder head had a very loud tap in it (VTS engine) but thankfully has started to sort itself out (tappet I hope!). The other, I can't figure out just now and I was wondering if any of you lot have come across it before. My brain is a bit frazzled and I'm sure it will have happened to someone else before!

Some background...

 

The engine, box and subframe have been out. The old box was a VTS and worked fine. I've fitted a replacement VTS box and have fitted an LSD myself. I've swapped the linkages over as per the old box.

 

Have I messed up the selectors while swapping linkages?

 

There are three holes on the subframe for the 'ball' where one of the linkages clip onto. This was all apart for blasting, so I couldn't see which hole I removed it from! I've got it in the middle hole.

 

When in neutral, I can only seem to move the lever across one half of the gate. This is the same if I disconnect the linkages (worryingly). The linkage on the box that is a 90 degree swept bend seems to behave differently to the old 'box. It's almost as if it's one position out of sync. I'm sure this is the problem but can't think how to fix it.

I'd appreciate any help. Once this is sorted, it's MOT time!

[welshpug 1,661]

sounds like the shaft dropped into the box when you swapped the arm.

[huwjones 0]

Balls. I'll have a go at it this morning to see if I can persuade it back into place. Is it a full stripdown otherwise?

[Anthony 1,003]

Shouldn't need to completely strip it - with a bit of patience you can normally do it from the top after removing the selector arm, otherwise if you remove the diff you can get your finger up inside to sort it that way (apparently, I've never yet needed to).

[huwjones 0]

Sorted. Removed the linkage, dropped the shaft. Found one of the missing gears. Selected it. Pulled the shaft back up and refitted everything. Works a treat. PHEW!

 

The feeling of dread when I noticed the problem after so much work was not nice!

 

I was rewarded today with a shakedown drive before the MOT. I forgot how good the car feels and goes! Good to be back on the road.

 

Cheers for the replies.

[205dj 0 1 Cars]

I have a similar problem can someone help. Im in the process of a GTI-6 conversion and notice that I only have 1st 2nd 3rd and 4th. The gear stick will not move across to 5th and 6th and reverse. When I pop off the linkage the lever sprung loaded towards the passenger side 10mm or so but only one position. I did have issues when swapping over the lever from the 205 box, the shaft did drop. I now have the lever off again, not and easy job now everything is installed but pushing the lever down it only pulls fully back up in one position. Do I need to select a gear before pushing down ?