AW11 shift problem?

[AW]

OK I have scoured around for similar problems but because I'm unsure of what exactly is going on I'm all out of guesses.

I'll describe the background to this problem and I'm hoping someone with a clue will be able to point me in the right direction...

At the end of January I fried the clutch (exploded actually, don't ask..).

Got together another clutch, pressure plate and flywheel and with a friends help got it all in. The flywheel was fine but the pressure plate was looking pretty cooked so replaced the clutch and pressure plate, just in case.

All went well, took it for a test drive down the road, shifted OK at first then started slipping a bit in third and fourth. Third had always been a little delicate and had been advised there'd possibly be some clutch slip while it settled in. Got back popped the engine cover and noticed my friend had put the shift cable too close to the manifold and it had melted the sleeve down to the wire sleeve. This inner sleeve looked fine and I asked him if it'd affect the shift to which he said probably not. We were running out of time so I pulled it away from the manifold and wired it against the firewall until I could move it properly.

The problem got worse over time and even after moving them back to their original position it remains rooted.

I am thinking the cable is $&#$% and has been stretched or perhaps the shift assembly bent or something similar? I have take it apart and put back together now a few times trying to see what might be wrong with it but no dice.

Any ideas appreciated, TIA.

[AE86less]

Over time the cables do stretch, that's quite possibly it.

[AW]

Yea I'm beginning to wonder if it got yanked when we dropped the gearbox out although from memory that went smoothly as everything was detached.

I would expect it to wear overtime but this was quite sudden. A before and after difference.

[AW]

Hmm well after everyone I have talked to swearing it must be the cable. It aint.

Just replaced the cables with no change whatsoever.

So, I really need some decent advice here because I can't afford to keep buying unnecessary parts.. What else could it possibly be?

The symptom is it doesn't change into 3rd or 4th. Ideas?

[Adamal]

Thats odd..... 3rd and 4th are the neutral position for the left/right cable.... How about 5th and reverse? Any problems there?

[AW]

Nope 5th and reverse are fine as are 1st and 2nd.

[Malcolm]

could be damage to the box itself, worn/damaged syncros, selector hub or selector fork. I assume that with the cables disconnected from the box the problem still exists, i.e. you can't shift into 3rd or 4th just using the shift arm on the gearbox?

[Adamal]

Have you had someone watch the gearbox end of the cables while you shift it to see if operation appears normal?

[AW]

Select assembly itself? I have checked it against diagrams to see if it's bent but it seems fine. Without another one to check against it is difficult to be sure however.

[AW]

could be damage to the box itself, worn/damaged syncros, selector hub or selector fork. I assume that with the cables disconnected from the box the problem still exists, i.e. you can't shift into 3rd or 4th just using the shift arm on the gearbox?

Yea the box is on its way out however does it seem likely it would have shat itself so suddenly? Is it possible the selector fork was $&#$% when the clutch exploded?

I have checked the gears at the assembly only by moving them through their possible positions until they clicked into place. Everything seemed fine however I'll have another check noting the actual gear change.

[Truenotch]

So is the problem that the gears are slipping or that it won't shift into the 3rd and 4th gear positions?

And I know you said don't ask, but how did you blow the gearbox? It might help with diagnosis.

[AW]

So is the problem that the gears are slipping or that it won't shift into the 3rd and 4th gear positions?

And I know you said don't ask, but how did you blow the gearbox? It might help with diagnosis.

The gearbox was fine other then 3rd being fragile and 5th starting to occasionally pop out. Never felt close to dying completely.

It was the clutch that exploded. The carbon stuff was burnt/ripped off the flywheel side.

[mr30%jr]

ive never had a clutch "slip" while settling in, new or second hand

check the cable C clips sometimes people forget them and the cable just flops about it will go into the pull gear properly but not the push one.

[AW]

ive never had a clutch "slip" while settling in, new or second hand

check the cable C clips sometimes people forget them and the cable just flops about it will go into the pull gear properly but not the push one.

Thanks man yea the perils of second hand information I suppose..

So the C clips holding the rubber bushing thing onto the lever? If so, they're both on and reasonably secure although there is a little play.

edit: You mean the clips holding the cables in at either end? They're in place also.

[AW]

check the cable C clips sometimes people forget them and the cable just flops about it will go into the pull gear properly but not the push one.

Looking at my reply I really didn't read that properly the first time, did I lol..