Right, as I had a couple of hours spare today, i thought i would fit the refurbished 020 gearbox onto the engine. Torqued up the flywheel after fitting the bolts and on went the gearbox. I thought all was good so went to try the clutch release arm and it was solid.... would not lift up!! Damn So I took the gearbox off and the arm works fine. Put the gearbox box back on and same problem So I took the gearbox off and the flywheel and all looks correct. The clutch is facing the correct way. Last time, put it all together and still solid Walked away I know I need to take the box off again, but was hoping to get the lot back in the car this weekend. Anyway, what are your thoughts? Pushrod too long ! Or have I done something wrong . Like cricket, bad light stops play
From recollection, so check I'm right... If you mean lift the arm up further than the 9 o'clock position... it'll be nigh on impossible to do it by hand with the 'box mated to the engine. It takes the combined power of your foot/clutch cable to do it when it's all connected up and even then the travel's maybe only up to the 11 o'clock position.
The arm will not move at all when the gearbox is on the engine. It is at about 7oclock and solid.....
The black plastic thing, it stops the arm dropping passed a resting point cast into the metal of the bell housing. Removing it / pulling the arm back a little allows it to drop right down (when changing the release bearing for example). Is it on while the arm is below that point, preventing it from rising back up?
Think you got your 'box done at a VW specialist? Really grabbing at straws here and don't think it's your issue as the guy's obviously good, but for the sake of covering it... Guy that did mine got the release bearing clip and spring wrong when refitting, only realised something was amiss when a small dent appeared from the inside, out on the new green end cap. The finger on the arm was travelling too far back, picked up on it early, don't know if it'd have resulted in your problem if not. Your obviously reading BrokeVW as you go and his measurements for the rod etc. Wish I could help more, but don't know enough beyond my own problems recently. Sounds like you're being methodical, all you can do...
If you can get the cable attached, try it, possibly the new pressure plate needs to bed into the new disc, and let the fingers settle.
All sorted, thankfully. Can I say what the cause was...... I don't actually know. I took all the measurements to check against the Broke info and all seemed correct. Maybe I had the pushrod the wrong way around. All i do know is it worked fine off the car and i kept checking the lever would move as i put the bolts in. The bolts are in and the lever moves with a hard tug. Putting it in gear it moves the flywheel and the drive flanges and if i pull the lever as if i was engaging the clutch, it releases the flanges from driving So happy days But it did annoy me earlier today Time for a beer
