Re: problems cont (long)

["Calimus" <calimus@techography.net>]

Joe,

    I'm new to the list and kinda new to water cooled VW's.  So with what
I'm about to say, if it's not a possability, please excuse me for my lack of
knowledge on VW tranny's.  From the sound of it, it almost sounds more like
a syncro issue then a clutch problem.  I have a similar problem with my 88'
16v rocco when trying to downshift into first.  If I'm not at close to a
dead stop, the gear grinds, then grabs.  However, all my other gears are
smooth.  I've figured on it being a syncro issue, and from your post, I'd
say it the same issue to a point.

I haven't gotten a book on my tranny so I'm not positive what would be
involved in fixing it, or if syncro's would even be the problem.  Maybe
someone else on the list is a bit better versed in this area.

Hope this helps,
William Snyder
----- Original Message -----
From: "Joe Doty" <rocco2nr@hotmail.com>
To: <scirocco-l@scirocco.org>
Sent: Sunday, September 16, 2001 8:03 PM
Subject: problems cont (long)


> i know everyone is tired of hearing about this, but i am running out of
> ideas...many, many thanks go out to the person who can figure this one
out.
>
> first off, i have a rebuilt 9A with a kraftswerk rebuilt 4K w/.71 5th
gear.
> redline MTL, velocity (clutchnet) dual fiber disc, stock 16v pressure
plate,
> velocity lightened flywheel. all with less than 15k miles.
>
> only thing weird i ever noticed is that when i installed the exhaust cam
for
> an intake, i had a knocking noise when it was in neutral and the clutch
> pedal was out. thought nothing of it, as everything worked perfectly.
>
> the problem started out with being a little difficult between shifts, it
> sounded like it was still catching teeth when shifting out of a gear. it
got
> worse and worse, until i could no longer shift unless i revved the engine
> between shifts. then it got the point of where i couldnt get it into gear
> when the car was stopped. at all.
>
> replaced self adjusting clutch cable with manually adjusting one to no
> avail. adjusted it until there was no freeplay whatsoever in the cable.
the
> arm on the transmission was going up so far it was hitting the motor
mount.
> yet, the clutch still grabbed way at the end of the pedal travel...???
>
> pulled trans, inspected all components, nothing was broken, no bolts
> floating around, everything looked perfect. input shaft looks great.
> regreased it. reinstalled, problem still there.
>
> pulled trans again to replace thrust plate, throwout bearing, clutch
> pushrod, and the little clutch pushrod arm inside the 5th gear housing.
none
> of the parts i took out looked very worn at all. worked for a bit it
seemed,
> and then same problem came back. knocking noise from cam install is gone.
>
> checked crankshaft axial play...there is very little. moves no appreciable
> amount when the clutch is pushed in or a prybar is put on the crank
pulley.
> pulled thrust bearing, there is a .002" difference between the two sides.
> the babbit is worn off on the clutch side, but still...
>
> clutch cable has been adjusted to the point of being ridiculuous, yet the
> pedal still grabs at the end of its travel. i can actually drive it if the
> car is moving, which would suggest a problem with the clutch still turning
> the input shaft on the trans. but it will still be difficult to shift.
> reverse grinds if i try to shift into it...
>
> could it possibly be a transmission problem at this point? i babied the
> shifts as much as possible, not wishing to have to pull the transmission
for
> a long time. never raced, no rude clutch dumps. the fact that the problem
> came on gradually suggests that something became worn out.
>
> i am very confused and frustrated, and advice or ideas at this point will
be
> very appreciated.
>
> thanks
> Joe
>
>
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