Clutch adjustment / box problem

  1. Administrator Joined: Dec 2002 Warrington Posts: 20561 Blue Saxo VTS Turbo/White Megane F1 R26
    #1
    Myself and danny fitted the replacement 1.1 gearbox to my vts this evening, in preparation for FCS. My old box had suffered the ongoing crown wheel slippage problem, so I had planned to replace it before it died.

    After fitting the replacement box, I took the car for a spin and it was slipping much worse than before. Now, this could be due to the replacement box being screwed, but as this is from a 1.1, I doubt this.

    Instead, I think it sounds like the clutch is not releasing properly. SOmething looked odd with the clutch cable setup, so Ive taken before and after pics... but that doesnt seem to show up too much different? Before on the left, after on the right.

    I seem to rememebr the rubber block alignment being pretty important, to the cable is pulled in the correct orientation.

    THe clutch arm can be pulled approx. 10mm towards the front of the car, suggesting that the clutch may not be biting fully?? Or this free play could be normal? I cant remember.

    Basically, I have a couple of hours tomorrow evening to try and sort this, else my saxo won;t be going to FCS... as I still need to MOT and tax it!

    ANyone got any words of wisdom? COuld there be any other reasons other than the clutch cable setup, which is stopping the clutch from biting properly?

    Ive tried tightening and slackening the cable adjustment and tbh, its now almost undriveable. Ive put the cable back to how it was and still it doesnt feel like the clutch is dis-engaging properly... as soon as i try to accelerate at all, it just slips.

    ideas to try tomorrow??

    The AP clutch usually bites extremely hard... so im sure its something to do with the clutch. It was left on the car.. and only the box changed.

    When fitting the box with this clutch, a small amount of metal needs to be removed from the inner gearbox casing to allow the clutch fork to swing properly... on this replacement box, more metal was taken away than usual, which may allow the fork to swing back more... dont think that would be an issue though?
  2. Infrequent Poster Joined: Dec 2003 Ireland (Republic of) Posts: 208
    #2
    Did you face off/skim the flywheel when you took the clutch off to fit the 1.1 box?
  3. Administrator Joined: Dec 2002 Warrington Posts: 20561 Blue Saxo VTS Turbo/White Megane F1 R26
    #3
    I didnt remove the clutch or flywheel.. simply bolted the box over the assembly.
  4. Saxperience Post Whore Joined: Aug 2004 Kunt & Sorrey Posts: 5763 Rep mobiles & Joes ma
    #4
    release bearing/fork

    get that box back off again...
  5. Infrequent Poster Joined: Dec 2003 Ireland (Republic of) Posts: 208
    #5
    Quote:
    Originally Posted by Simo View Post
    I didnt remove the clutch or flywheel.. simply bolted the box over the assembly.
    Ok, thought it could've been slipping due to the hard material on the flywheel face created due to the hot spots caused over time by the AP, however if it was engaging fine before hand then i dont see it being this. It does look like a release bearing problem if you can feel something up with the clutch engagement/disengagement itself.

    Maybe by removing that extra material from the box it allowed the fork swing back too much and separate from the "clips" on the release bearing, maybe then when you press the clutch the forks dont sit back properly on the bearing. Just a thought... Only way of knowing is to split her again unfortunately...

    I never removed any material from the box when i was using the AP and it seemed to work ok
  6. Administrator Joined: Dec 2002 Warrington Posts: 20561 Blue Saxo VTS Turbo/White Megane F1 R26
    #6
    When the box was offered up, the arm was moved and the bearing moved forward. This was pushed back, but I suspect the bearing is NOT located properly... which will then be putting pressure on the cover fingers.

    Its gotta be this after having a think about it.

    Gutted... and likely Im not gonna be able to get it sorted and MOT'd and taxed in time for FCS now!
  7. Saxperience Post Whore Joined: Jan 2005 somewhere on this planet, doing something..... around northumberland or in the middle of the sea Posts: 8774 Mk2 VTS track mk1 turbo vts scooby engined 2CV
    #7
    you still using the realase bearing from ap?
    they have a larger front area on them for the clutch.
    i had to butcher a new standard one and apply the ap bearing and bond it in place to work on mine.
  8. Saxperience Forum Bum Joined: Oct 2004 South Posts: 3638
    #8
    may i ask why your using 1.1 boxes and not get a stronger box?
  9. Frequent Poster Joined: May 2006 Posts: 691 Mk 1 VTS poseidon blue
    #9
    Is that a rigid clutch plate you're using?? Got any pics?
  10. Administrator Joined: Dec 2002 Warrington Posts: 20561 Blue Saxo VTS Turbo/White Megane F1 R26
    #10
    OK, so we are a few months down the line and Im now trying to get my car ready for TRAX. MOT is booked for 9am tomorrow... but think its oging to miss it!

    I removed the box at the weekend and re-fitted it along with the existing release bearing. I made extra sure the bearing was aligned, even checking it with the box semi-mounted in place.

    Before I fitted THIS gearbox the clutch was biting perfectly... but as soon as I fitted this box (both times) the transmission is slipping as sson as I apply any acceleration.

    My thoughts : -

    - release bearing is mis-aligned (again?!!?)
    - clutch has somehow died?
    - this 1.1 box is mechanically knackered??
    - too much metal has been removed from behind the release bearing which is mis-aligning the forks/bearing.

    Im currently favouring the box itself being to blame.


    Id like to think the clutch isn;t dead.. and it seems suspicious that its started slipping much worse since fitting THIS box. When the material was ground from behind the release bearing too much definately was removed, as I remember commenting at the time.

    Any thoughts... dont think the car's gonna make it to TRAX now. Arse.