YAAAAAAAAAAA!! gearbox/clutch/engine is 90% undrivable now!

[The Monk 50]

Hi all. I apologise if this comes across as long winded but I'm going to describe the problems and pick your brains.

Vehicle

'95 Golf VR6.

OBD2

98,000 miles

Problem

1) Severe difficulty engaging gears and crunching

2) Constant grinding noise from rear of engine with or without clutch pressed.

3) Gears engaged with clutch pressed, creates severe vibrations on gearstick, clutch pedal and engine lumpyness.

4) High pitched fast grinding when gear selected and foot off the clutch.

5) Keeping foot pressed on clutch, 2/3rds up, no grinding or vibrations at all with engaged gear.

6) When changing gear, press clutch fully and wait 2 or more seconds to mesh in with new gear.

Diagnosis/ Repairs done already

1) New timing chains, tensioners, guide rails ect ect...to replace old timing bits with only 11k of use.

2) New clutch, release bearing, spring plate.... appropriate places greased and rid of rust.

3) New gearbox oil.

I've pretty much thought about the problem lying within the gearbox itself right from the start but covered the less pricey basics first.

I've checked that there is no excessive wear on the tappets.

No noise coming from crank case/sump to suggest bearing damage/crankshaft slide.

I'm at the end of my teather. The car is now so bad, I can't actually drive it properly.

I did think about the unbalanced flywheel idea, however, unless ben cut parts of the flywheel off before transport, I can't see how that would happen. Besides, I've already checked that everything was fine, secured ect ect.

Just wanderd if anyone wanted to put their 2 pence worth into the mixture?

[VR6Pete 1,455]

sounds similar to what I had when my slave cylinder went

have you checked your selector cables too?

[dman78 1]

sorry mate dont mean to hijack your thread but im having a hard time getting mine into 1st and 2nd also,could it be a similar problem?

[The Monk 50]

Yours could be sycros in the gearbox or the upper selector cable loosening at the selector.

Pete, my slave cylinder was changed when the engine from ben went in. As for the selectors, I can't imagine they would create severe vibrations with or without the gears being selected.

I will check however. Thanks.

[dman78 1]

cheers mate i'll have a look at that,sorry i cant give any advise on your problem im kinda new to all this vr6 stuff

[VR6Pete 1,455]

Yours could be sycros in the gearbox or the upper selector cable loosening at the selector.

Pete' date=' my slave cylinder was changed when the engine from ben went in. As for the selectors, I can't imagine they would create severe vibrations with or without the gears being selected.

I will check however. Thanks.

[/quote']

I got through 2 slave cylinders in a matter of months, on I got from GSF ended up going faulty, the seal had a small slit in it..

[legvw 0]

Have you taken the box off yet the engine yet to see if its something in the bell housing (clutch/flywheel/slave) or in the gearbox? Might be worth a try big fella :-)

[The Monk 50]

Looked at slave pete, all is well.

Noise is coming from inside the gearbox at rear and toward diff.

Only thing that has changed from my old car other than the engine...is the gearbox.

I can only assume that the gearbox is the culprit.

I really can't be bothered changing it over again. Atleast not for a while anyway. So I've stripped the engine bay and taken the front of the car off. All I need to do now is remove the driveshafts and unbolt the gearbox and mounts.

That can wait for a good while as my back needs a rest from the amount I've done in the past 2 months.

If I find that it isn't the gearbox and it is an internal engine issue then I'll be breaking the car. But that's in the worst case scenario.

Paul, I removed the gearbox when ben bought the engine up. After installing the engine and gearbox, I heard the noise and removed the gearbox. I replaced the clutch, spring plate and release bearing. I had the timing go while checking for the grinding noise again, removed gbox again to do timing, retimed, gearbox back on...grinding still there so I'm now taking the gearbox out later this week again. Will be putting my old gearbox on this time and see if the grinding is still there.

I hate gearboxes.

Fingers crossed this time anyway.

[vr6stormt 0]

what has this all happened since that noise at the pod?

[The Monk 50]

Yes Barry.

Got worse after I left you all on the island to the M1. By the time I hit the M6 I had serious vibrations and grinding. Got to my parents and spent about 10 seconds crunching reverse trying to engage it. Nursed her home to the garage and I couldn't get any gear. Had to use the starter motor to pull her over a bump and rolled into the garage.

Not brilliant really.

[Pearsy47 1]

sounds like what im going thought hopefully getting all the parts this week then one weekend bang all off then bosh all back on wish it was that simple lol

[The Monk 50]

Yea I do too.

My only problem is with putting the gearox back on. I've hurt myself doing this quite a few times, most recent was breaking my finger and taking a large chunk out of the back of my hand.

It will get done. Just need to build up some enthusiasm.

[Pearsy47 1]

sounds nice lol ah i ve got my way of getting the gear box back on done it once and it worked lol its just such a long job !!! i just wanna get mine done so i can drive it again !

[VR6Pete 1,455]

best way ive seen is to jack the box into place

[Pearsy47 1]

best way ive seen is to jack the box into place

yer iv e seen that way my way is a bar and some rope lift the cunt up and someone to guide it on lol

[The Monk 50]

Yes pete, that's how I've done it all times other than last, where I lifted it in myself.

Just a pain in the bum.

[bungy 2]

On a lighter note, all this practice will make you a gearbox change guru. Hope you get somewhere with this soon. Shame team south is too far away....

[J5KE F 0]

On a lighter note' date=' all this practice will make you a gearbox change guru. Hope you get somewhere with this soon. Shame team south is too far away....

[/quote']

many hands and all!! U should move down fella, better weather also

[The Monk 50]

Yea, tis a shame. I may move to get a job as a mechanic..... but that could be anywhere.

I have almost 100% certain the gearbox is the problem. The MAF needs to be replaced, new oil, spark plugs, HT's. Going to cost a bit in march.

[Bigjobbo 0]

Alright dude, just read your post on the other thread and it sound's to me like the input shaft bearing's are screwed, but if your gonna strip it, you may as well do the output and diff bearing's. At least i hope it is anyway. Rather the box than the block. Good luck.

[The Monk 50]

Thans for the info bigjobbo. I pretty much figured it was that last night after looking around for gearbox innards last night.

Cheers buddy. Luckily I have another gearbox to put on it from my old car.