Gearbox/clutch Problems

[lando9000 2]

Hi all,

 

Long time lurker and first time poster here. I'm having problems with a 1989 205 GTI 1.6 with ~80,000 on the clock (no history to prove). The car has a BE1 box (reverse over first incase I'm wrong). The problems are (always a good start) that the clutch pedal feel really stiff compared to other GTI's, the box itself seems to crunch in all gears and the bite point is to the floor. The box can also be very tight trying to get it back out gear a lot. Say you're in fourth, you can have to push back the lever toward the handbrake and then move into another gear.

 

When we bought the car we decided we were going to do a few things to try and remedy the problem but it hasn't done anything yet. We've replaced the clutch kit and the clutch cable with a genuine Peugeot one. We have put two cables in the car now as the first cable got stripped. I'm wondering have we not fitted the clutch properly (alignment issue), is it possible all sychros in the box are just f***ed cause it to crunch into every gear or is there a problem with the clutch fork mechanism (the pin between the clutch fork and the cable sometimes won't stay in)? It seems improbable (with my small amount of knowledge) that the syncros would be f***ed and crunching in all gears.

 

Any help or insight would be great as we're at our wits end! Thanks, Andy.

Edited October 15, 2015 by lando9000

[Tom Fenton 1,542]

When you replaced the clutch did you inspect the lever arm that goes through the gearbox casing and pushes on the release bearing? This has a ball type joint, if this is stiff or seized, or the nylon cup worn out, it can all make the clutch heavy.

Bite point being low should be an adjustment issue, shorten the cable to move the bite point upwards. This also will be why its hard to get in and out of gear and the box crunches, the clutch is not fully clearing when you press the pedal.

Also on the outside of the gearbox is a bellcrank which transmits the cable movement to the lever arm. Check the bushes in this are intact and greased up so it can freely rotate on the mounting pin.

 

Edit; also double check all the engine to gearbox bolts are in and tight. They can work loose if not tightened properly. I loctite them in. Especially check the lower bolt near the driveshaft that goes from the gearbox to the engine.

[steve@cornwall 100]

BE 1 have a tendency to bend the arm that the cable connects to on the box and not giving enough throw. (At least I've had it happen a couple of times)

Edited October 15, 2015 by steve@cornwall

[lando9000 2]

Thanks for the answers lads! We're going to get the box out soon and have a look at all that's been suggested. Cheers for such a quick reply!

 

Any other suggestions are welcomed as well. It'll be a week or so before the box comes out!

[Tom Fenton 1,542]

I wouldn't remove the gearbox yet. Check everything else first.

[lando9000 2]

I wouldn't remove the gearbox yet. Check everything else first.

Probably a good idea, Tom. Cheers!

[Crescent205 11 1 Cars]

surely if the connecting pin is falling out its simply an adjustment issue? I agree with Tom check everything first before you take it out.

[Capa 0]

I'm having precisely the same issue as described above with the clutch. I figure it needs some adjustment; I don't suppose anyone has a fool-proof guide on how to adjust the clutch cable? If it has pictures all the better...

 

Cheers

[scbond 15 1 Cars]

I'm having precisely the same issue as described above with the clutch. I figure it needs some adjustment; I don't suppose anyone has a fool-proof guide on how to adjust the clutch cable? If it has pictures all the better...

 

Cheers

Search...there's loads on adjusting the clutch. Also view the procedure in the Haynes.

[Deckysw 0 1 Cars]

Guys I know this is on an old topic but here is my problem. I have removed engine and box as one unit to paint the engine bay and now I have refitted. Engine etc all running no problem but my clutch doesnt seem to work now ie wont let me engage a gear when it is running. I have adjusted the clutch cable to the point that it is sticking up in the air inside the car and still no engagement. It is a 1600 gti 89 model with a BE1 box. The engine and box was never seperated while it was out of the car. As far as I can see the gear linkage rods only fit on one way so that shouldnt be a problem. I have the gear cable etc fitted to the top of the box. Everything is back on the correct way I hope. Am I missing something silly or has anyone else had this problem. Everything was working before I removed it so I know the clutch was ok. I really dont want to take it out again. Help!!

Edited July 3, 2016 by Deckysw

[jackherer 543]

Have you fitted the approx. 1 inch long pin between the clutch arm and the paddle sticking out of the gearbox?