Gearbox Issues After Clutch Blow Up

[futura 3]

The other day I blew up a 3 month old clutch, seems that it was a combination of play in the clutch fork bushes and the fact that the throw out bearing was a bit loose from the clutch plate (not enough tension on clutch cable).

 

During a 3 hour trip I started getting vibrations, which got worse, then gears became harder to change until I couldn't change them at all unless the engine was stopped. A few miles down the road the clutch gave up and I obviously couldn't get the car to move. When I took the stuff apart the clutch disks were broken into pieces because a bit of the throw out bearing went through the plate.

 

I have fitted new clutch fork bushes and a new clutch, but now almost every time I stop at a traffic light and go to neutral, I can't get back into any gear unless I stop the engine, engage the gear with foot down on clutch, and start the engine to get going. People may think I have an automatic start-stop system

 

Any ideas on what to look into and which replacement parts I should get? I have never opened a gearbox before.

Edited March 24, 2015 by futura

[Anthony 1,003]

It sounds like the clutch isn't fully disengaging and the resulting drag is stopping you getting it into gear.

 

Assuming that's the case, are you sure that the clutch cable is adjusted correctly and the gearbox properly attached to the engine block (notably the single fixing at the lower rear) and with the dowels fitted?

 

Also, are you sure you got the correct bushes for the fork fitted?

[futura 3]

Hi Anthony,

 

I fitted the same bushes (yellow) as were in place, and had checked various sources before ordering them so I am sure they are the correct ones.

 

I ensured there was no play in the clutch cable so it's nice and tense at the fork lever.

 

All three fixings are in place, but the rear dowel is actually missing because when taking the gearbox apart, I found the rear stud broken inside the block (to my surprise). I tried drilling and taking it out cleanly but working under there resulted difficult and I ended up enlarging the first centimeter deep of the hole quite a bit, which means the dowel would be no use and I didn't fit it back. Would just this missing dowel cause all that trouble? Also where can I source these dowels?

Edited March 24, 2015 by futura

[futura 3]

Just to add, I have no problem to change gears while driving. It's only when I stop in neutral that I have problems.

[Mattr5uk 20 5 Cars]

I would agree with Anthony, was there any damage to the clutch fork from the bearing failure?

[futura 3]

Nope, I inspected the fork after giving it a good clean and it looked fine to me.

D

Damn I don't feel like taking it all apart again!

[welshpug 1,661]

whats the height of the pedal and where is the bite point?

 

did you remember gear oil of the appropriate grade?

[futura 3]

It's pissing down here today, I'll check that on Friday and will report.

 

I bought the recommended grade 75W something for a 1992 BE3 gearbox.

[futura 3]

The height of the clutch pedal was 18cm, I set it down to 14cm and the gear changing problem is gone.

 

Thanks for your help.