Help please-no clutch!

[meowdmucker]

Fitted a new 2110 engine with a kennedy stage 1 clutch and new release bearing, to a 71 bay . Things seemed fine but after approx 30 miles i noticed a rattling noise if I depressed the clutch to the floor. Thought I'd got too much of a bend in the conduit tube so removed 2 spacer washers and things were better with no noise. However 30 miles later as I pulled into Tescos the clutch pedal made a clunk and possibly dropped a little. I couldn't get any gears with the engine running but could without. Had to select 2nd , start the engine and drive home very slowly .
When the pedal is depressed the lever on the gearbox moves so don't think the cable has snapped.
Any ideas? Am thinking that the release bearing has come adrift but before removing the engine to check would value other opinions please.

 

[pete nice]

The clutch may of been over adjusted.

It sounds like the release bearing clips have come off. I had this on a mates beetle last week.

Engine out again.

 

[meowdmucker]

Thought i'd followed the bentley manual with clutch adjustment but obviously am doing something wrong. I used a ruler to get 2cms of pedal freeplay but had to tighten the wing nut to nearly the end of the threads and this seeems to pull the lever forwards which I presume should not happen?
Any advise on clutch adjustment would be much appreciated as I want to get it right this time! Thanks

 

[Todster]

Hi,
Are you sure that when originally fitted back in, the conduit tube was correctly seated? If it wasn't, the clunk could have been the conduit seating correctly and therefore the adjustment would be out, it will still be moving the lever on the 'box but not far enough. Don't know, just a thought before taking the engine out??
Cheers
Mark

 

[meowdmucker]

Yes the conduit tube was ok, have tried readjusting the freeplay but still cannot get any gears with the engine running.

 

[richbaker78]

my moneys on the release bearing.....
its fallen off due to clips breaking / not being fitted properly so you are not disengaging the clutch when changing gear. hence why you can select gears without engine on and can with it off.

whatever it turns out you need the engine out to be sure.

 

[pete nice]

The clips are crap for an early release bearing, I have had them come off before for no real reason. You may have adjusted the cable right, I just leave a bit of play at the pedal end.

The Kennedy is a tough bit of kit & will put extra load on the bearing. I have one in mine with an early bearing, it will work ok, when you clip it back in.

 

[meowdmucker]

Thanks everyone. How much play do you leave at the pedal ? By leaving more than the 2cms advised does this put less strain on the bearing to hopefully stop the same thing happening again or is this just wishful thinking!? ps mine is the later style bearing.

 

[meowdmucker]

Right, engine out, bearing snug as a rug but brand new 'heavy duty' cross shaft has failed. One of the welded arms obviously not welded very well and is swinging freely on the shaft. Had it put in when a well known vw gearbox company remade the gearbox with 2 litre bits less than 100 miles ago so not a happy bunny. Not sure if I fancy removing gearbox and taking it 70 miles to be fixed and then putting it all back together again but what choice have I got!?

 

[marcher]

Sorry to hear your worries m8, I have the same problem at the moment :x :x :x

BoL in getting it sorted.

 

[pete nice]

Sod taking the box out. Speak to the gearbox builder & seek advice. I would replace the shaft in situe & try again.

I didn't realise it was a late release bearing, they never really fall off.

At least you know what it is, the shaft isn't too bad to change, all the bushes would have been done, so you should get away with slipping the new one in. You could fully weld the new one before fitting it, I guess Mr Kennedy gave it a hammering.

 

[meowdmucker]

Sorry to hear your worries m8, I have the same problem at the moment :x :x :x

BoL in getting it sorted.

Thanks Marcher hope you're not as stressed as me! Was your cross shaft a 'heavy duty 'one too?

 

[marcher]

No m8 mine was just an old standard one. still well fooked.

http://forum.earlybay.com/viewtopic.php?f=4&t=14950" onclick="window.open(this.href);return false;

 

[meowdmucker]

You could fully weld the new one before fitting it, I guess Mr Kennedy gave it a hammering.[/quote]

Can you weld the broken one whilst still in the bellhousing? The arm is just spinning on the shaft so if it is possible would save me a lot of grief even though I would have to find a mobile welder as tI cannot weld!

 

[meowdmucker]

No m8 mine was just an old standard one. still well fooked.

I would advise you weld up a 'welded' heavy duty one when you fix it!!

 

[pete nice]

I would fit a new one, I don't think it's worth risking a repaired one. They are not that hard to change.