Dudgy clutch/box Mk1 Golf

[Trunkie]

Ok here's the problem. I have a Mk1 Golf GTi Karman from 1984. Recently the clutch cable went through the bulkhead. I bodged a plate over the hole as an intermediate solution. This weekend I made up a 'proper' plate to reinforce the bulkhead, however when trying to move the car last night the (5sp) box seems to jam. I've had a problem selecting reverse for a while - basically it keeps jumping out and refuses to move under strain. I'm wondering if the box is now shot or the clutch simply isn't releasing properly?

Any clues and ideas of cost to repair? Basically I don't have the time, tools, space or inclination to do it myself (unless it's dead simple) as I'm trying to sell it, move house and drive the Elise!

[spnracing]

You should be able to feel if the clutch is releasing by the pressure on the pedal. If not just get someone to watch and make sure the lever on the side of the gearbox is the bit that is moving and not any other part of the cable up by the bulkhead etc.

I also welded a patch onto my bulhead to hold the clutch cable, it works fine.

My gearbox also stuck in gear once. It was at Snetterton, 2002. I thought I'd try and race the car in third gear, on the green flag lap the problem cleared itself just by driving at relatively high speed. Then the engine cut out on lap 2...

So if it is stuck in gear - try taking it for a bit of a run and keep dipping the clutch and trying to dislodge it. If the box keeps jumping out of reverse its on its way out anyway, another one will be £50-80 from a breaker and a couple of hours to fit.

[Trunkie]

Sorry I forgot to add this bit! If the clutch isn't depressed when turning the engine over the car jumps forward, even in neutral - ok so that sounds like the clutch isn't releasing properly, however even if I slaken the cable so the lever is flopping all over the shop it makes no difference. If I engage reverse and come off the clutch the engine takes up and appears to want to move both backwards and forwards at the same time! The engine strains but the car doesn't move and I cut the engine because I'm scared of somethign snapping!

I rolled the car off the drive last night and tried to drive up the hill. First wouldn't engage so I tried second, same problem. Tried to take off in third but the whole thing seemed to jam. then couldn't select neutral (the car was on a hill so resistance held in box by lack of release?)

Does this sound like the box has fallen or is lose or something? I'm just a bit stumped as to why this has suddenly happened whilst the car has been stationary for about a week?

[chris_n]

Sounds weird, only time I have experienced something a bit like this it was down to a clutch pressure plate having started to disentegrate and some of the bits having got wedged between the flywheel and the clutch friction plate. Scored the face of the flywheel in the process unfortunately. This wasn't on my Golf so may or may not be a likely scenario. Good luck!

[iains]

I've had this on a Mk2 - when the clutch was totally knackered - the plates melt mesh together when they get hot once all the material on the plate has broken down. This would explain you lack of availity to select gears and the damage to the bulkhead as the plates become harder to release.

Iain

[Trunkie]

Excellent thanks Iain. So basically I'm looking at the cost of a new clutch plus labour?

>> Edited by Trunkie on Thursday 30th October 14:48

[iains]

Hopefully! Although it might not be that simple - you might be in for a flywheel skim / rebalance if it has completely worn through.

I am a little concerned by the information re: the 'box. Have you checked the oil in the recently? You will need a 17ml hex stud (on 02 boxes) to undo the filler. Mr Haynes should have the necessary info on this. The output seals on the drvieshafts on them are notorious for weeping oil.

As for the box itself, second gear syncro is always crunchy on them, but should never have the problems you are experiencing.