1.8 20V APT gear selection issues

[johnwintle]

Hi all,

I hope that someone can help me before I pay a lot of money for something that I may not require!

My car is a 1999 1.8 20v B5.5 with the APT engine and DWH 5s gearbox, 71000 miles.

I am experiencing quite a lot of trouble engaging 1st and reverse gear, sometimes to the point of turning the engine off in order to get the gear in. If I can get the gear in without resorting to this procedure, it is very hard to engage, and you can feel it grating and then it will push past and engage.

I normally have to make sure that I engage 1st gear before coming completely to a halt. The it will engage cleanly.

I also have some clunkiness in going from 1st> 2nd at times, and also a notchiness into 3rd on occasions.

The gear oil was changed a few months ago but that hasn't made much difference. Also some Moylslip gear oil additive was also introduced but no difference.

As far as I am aware the clutch is the original.
Clutch slave cylinder was replaced a few months ago.

Has anyone experienced anything similar or has any suggestions. All are welcome before I go and source a replacement gearbox!

TIA,

John

[fingers mclean]

I'am experiancing the very same issues..I was looking for the answer on here when i saw yours (LOL)

[Crasher]

Do the gears select OK with the engine not running and the clutch depressed?

[fingers mclean]

Do the gears select OK with the engine not running and the clutch depressed?

Yes when the engine is off mine selects fine..Mine only has the issues stated above in 1st and reverse?? very strange

[Crasher]

More than likely a clutch issue then, the plate is not clearing the flywheel so dragging and still transferring a little torque which makes the gears difficult to engage.

[fingers mclean]

More than likely a clutch issue then, the plate is not clearing the flywheel so dragging and still transferring a little torque which makes the gears difficult to engage.

I thought the same but the clutch isnt high or low which i would of thought would also of been the case??

[johnwintle]

Mine engages fine when the engine is off, but can have issues when the engine is turning. Sometimes this happens sometimes it doesn't. When it does you can almost be locked out of 1st or reverse.
Problem with these cars like a lot of others is that when you change the clutch you will really have to do the dual mass flywheel also as they muck about and fail. There is a clutch/flywheel kit available from ECP for this engine/gearbox combo. I guess that if the box is coming out for the clutch plate, for about 10mins more labour you can change the flywheel at the same time, saving time later on, but with a bigger bill initially.

A new DMFW is around £300-£450 depending on source, and add to that the cost of the clutch pressure plate, around £130-£180...+ labour to remove the box, old clutch, and refit all back again...! Ouch.

I am replacing the gearbox mounts to see if that helps as they will also be getting tired, then move onwards and do the clutch. Question also is, is the box knackered, cos if it is I might as well change that at the same time as I remove the old one!

[johnwintle]

With the hydraulic clutch, the bite point should stay the same, not change as the clutch wears.

[Crasher]

To a certain extent yes but the depth of the bite changes, difficult to put into words but you probably get what I mean.

[johnwintle]

Well it's going in on Thursday for the DMF + Clutch to be changed, and am doing the gearbox mounts at the same time, as they may well be a bit tired also. Will let you know how it feels afterwards.