S3 Intermittent can't engage gears with engine running
05-31-2016, 12:49 PM
#1
Racer
Thread Starter
S3 Intermittent can't engage gears with engine running
So my early '86 needs the clutch release arm cup replaced. Been putting that off while I got some engine issues corrected. Finally fixed my high idle (ISV replaced) and erratic idle/stalling (MAF replaced). The clutch seems to operate just fine, apart from the expected vibration. Although, once it's warmed up a bit, it doesn't even do that.
Went for a spirited drive on Sunday with some hard pulls in 1st through 3rd gear, carved up lots of curves. It was awesome, of course. I had one bad shift. Didn't quite push the clutch all the way in and heard some brief grinding. Shame on me. But I still had a long ways to get home, and made numerous shifts without issue.
However the next day, I started up the car in neutral with the parking brake engaged, and found that I was locked out of all gears. Pumped the clutch several times, and it made no difference. Turned off the engine, and now all the gears engage, and it feels totally normal.
The day after that, I got the idea to try it again. Made sure all the gears were still engaging, started up the engine, and now it works just fine. Backed up and moved forward just to make sure it worked after moving the car, and it was all normal.
Anyone have a clue what's going on here? Thanks. The only thing I did different from my normal routine when I had the issue, is that I ha parked it in neutral with the parking brake. Normally, I just leave it in gear.
Went for a spirited drive on Sunday with some hard pulls in 1st through 3rd gear, carved up lots of curves. It was awesome, of course. I had one bad shift. Didn't quite push the clutch all the way in and heard some brief grinding. Shame on me. But I still had a long ways to get home, and made numerous shifts without issue.
However the next day, I started up the car in neutral with the parking brake engaged, and found that I was locked out of all gears. Pumped the clutch several times, and it made no difference. Turned off the engine, and now all the gears engage, and it feels totally normal.
The day after that, I got the idea to try it again. Made sure all the gears were still engaging, started up the engine, and now it works just fine. Backed up and moved forward just to make sure it worked after moving the car, and it was all normal.
Anyone have a clue what's going on here? Thanks. The only thing I did different from my normal routine when I had the issue, is that I ha parked it in neutral with the parking brake. Normally, I just leave it in gear.
05-31-2016, 05:32 PM
#3
Burning Brakes
Went through the same thing with my '82 - had to start the car in gear. Adjusted the clutch over and over and replaced parts one at a time. Turned out that the intermediate pressure plate was no longer holding adjustment. A new intermediate pressure plate solved the problem....
If this turns out to be your problem, do a search, there are posts on how to modify the intermediate plate. A new one is an expensive option (if they're even available). IIRC I paid about $500 for a new one about 12 years ago.
If this turns out to be your problem, do a search, there are posts on how to modify the intermediate plate. A new one is an expensive option (if they're even available). IIRC I paid about $500 for a new one about 12 years ago.
05-31-2016, 05:37 PM
#4
Rennlist Member
could be intermediate plate out of adjustment. very easy to check, but you have to drop the lower bell housing 8 bolts.
see if you have greater than a 1 mm gap...if so that could definitely be the issue.
leaving it in gear or parking brake has NO bearing on the phenom you experienced.
did you say, after you couldnt get it in gear, you shut it down and put it in gear and then started it up or then just restarted it and it operated normally?
whats happening, is the driveshaft is spinning .. when it spins, the synchros cant slow it down to get a gear change. (wheels not spinning, driveshaft spinning and it has to slow and almost stop before gear slection can happen)
so, what is keeing the driveshaft spinning. something rubbing on the discs and flywheel.. grit or dirt. when you shut it down and pushed in the clutch, maybe it fell out. or the INT plate is not adjusted, and its not releasing the clutch discs and they spin the drive shaft (because they are attached at the splines)
see if you have greater than a 1 mm gap...if so that could definitely be the issue.
leaving it in gear or parking brake has NO bearing on the phenom you experienced.
did you say, after you couldnt get it in gear, you shut it down and put it in gear and then started it up or then just restarted it and it operated normally?
whats happening, is the driveshaft is spinning .. when it spins, the synchros cant slow it down to get a gear change. (wheels not spinning, driveshaft spinning and it has to slow and almost stop before gear slection can happen)
so, what is keeing the driveshaft spinning. something rubbing on the discs and flywheel.. grit or dirt. when you shut it down and pushed in the clutch, maybe it fell out. or the INT plate is not adjusted, and its not releasing the clutch discs and they spin the drive shaft (because they are attached at the splines)
05-31-2016, 08:27 PM
#5
Racer
Thread Starter
Thanks guys. I forgot to mention a long while back, when I was just browsing, I did see an old post by somebody who had a similar issue, but now I can't find it. Intermediate plate adjustment rings a bell though.
Brakes and clutch have not been bled in who knows how long. I've had the car for a year. But the fluid is crystal clear. Entirely possible there's air in there, but in the absence of other symptoms, and with such a sudden and complete onset of the symptom I did have, I kind of doubt that's the issue.
Just to clarify, after I had the problem, I shut it down, put it in gear, took it out of gear, started it, and now it shifts normally.
I like the theory that something got stuck between clutch and flywheel. I have found little screws and injector plug clips and the like that previous owners dropped in the V. So there's a good chance something fell in the clutch release arm hole. I have the clutch inspection hole plugged, but who knows how many rocks bounced up inside there while it was open. Guess I better at least have a look inside the bell housing. I suppose the release arm bushing being obliterated makes it easier for debris to get in there too.
Brakes and clutch have not been bled in who knows how long. I've had the car for a year. But the fluid is crystal clear. Entirely possible there's air in there, but in the absence of other symptoms, and with such a sudden and complete onset of the symptom I did have, I kind of doubt that's the issue.
Just to clarify, after I had the problem, I shut it down, put it in gear, took it out of gear, started it, and now it shifts normally.
I like the theory that something got stuck between clutch and flywheel. I have found little screws and injector plug clips and the like that previous owners dropped in the V. So there's a good chance something fell in the clutch release arm hole. I have the clutch inspection hole plugged, but who knows how many rocks bounced up inside there while it was open. Guess I better at least have a look inside the bell housing. I suppose the release arm bushing being obliterated makes it easier for debris to get in there too.
06-03-2016, 03:21 PM
#6
Racer
Thread Starter
Darn. Problem came back. It seems to know when I'm actually gonna drive it, and it gives me a warning that I'm about to get myself stranded by refusing to engage gears right away. This time I could engage 4th and 5th with some heavy resistance, but the other gears were locked out. The clutch doesn't seem to be stuck, because I can engage gears without stalling or lurching, and the car doesn't creep forward in 4th and 5th until I start lifting the clutch pedal. Does this still point to intermediate plate? Or gearbox?