Gear Box woes.

[Peter Jones]

Driving about today the MK1 stuck in 3rd gear. It was wedged in there solid. After pulling over and driving on for bit I could get 1,2,3 5 &R. 4th is completley out of the question. 1&2 take some convincing. 2>3 is an easy shift. R is difficult.

It's a bit dark and cold to do too much tonight.

A quick inspection shows all the linkages that I can see in the engine bay are ok. The engine mounts look OK too.

I suspect the shift forks in the box. Things just don't feel right between the gears. There were some noises too but those seem to have stopped.

Any thoughts anyone?

MK1 5 speed box (the tall ratio kind)

CHeers
Pete Jones

[gtimk5]

Wouldn't have a stray speedo drive gear in there, would it? I have seen that before.

[imported_brackie]

Good to see you back on the forum again, Peter. Looks like you're about to get your hands dirty. Probably not a good time to ask you about cutting some stickers :D

If the linkages are OK then unless Andrew's suggestion is the cause (and you'll knoe 'cos the speedo won't work!), it looks like selector forks.

[Golf Loon]

Yup Hoorah for Pete Jones, nice to have you back from the wilderness mate.

I`ve got a couple of gearboxes that I can zip down to you if it gets too messy :wink:

[Peter Jones]

I'm still here. Work been insane; they sent me to the US for a little while so I've been out of the loop. Before that we were flat out with the Commonwealth games.I've also got a beetle on the go so I've been trying to track down bits for that. The RC car club has been keeping me busy too. www.brccc.org

Traffic was pretty heavy so I didn't need to change gears too much on the way home.

I don't recall if the speedo was working, I'll pull the drive and check it out.



All in all a very busy time the last few months! Not a weekend free to play with the golfs.

I'll take the linkages off the box and try shifting it directly to eliminate the linkages form the equation.

I think a friend has a 5speed box down here I can use or just rat for bits.

I hope I can salvage this box apart from a diff whine it's been pretty good.

Are the shift forks a common breakage?

Do you mind stickers with greasy finger prints?

I think I'm in for a dirty weekend!

Pete Jones

[Golf Loon]

We love greasy stickers

Usually the self machining rivets inside those boxes, not the shift forks, but you never know.

Go the dirty weekend! :wink:

[Peter Jones]

The box is out. Took me 4 hours.. there were many "challenges" to overcome. There's nothing obvious and I can't get the main cover off 'cos I don't have te tools to get 5th gear off the end off the mainshaft. So it's off to my tame mechanic on Monday!


Meanwhile my other golf has been running way too hot. I suspect a blocked radiator but I was concerned about the head gasket too so I've just pulled that off and it all looks Ok. So tomorow it's back on with the head and swap the radiator over with golf number one. That way I can get the radiator looked at at the same time I get the box fixed, might as well drop off the heater core too.

Pete

[gldgti]

thats organisation...

respect mate

[Peter Jones]

Job's done, just beat the rain. I was moving a bit slower today! I think I spent about 50% of my time looking for tools, 30% looking for things I dropped and about 20% was the actual work!

No surprises, no left overs and it fired up on the first crank!

Next stop gearbox and radiator doctor!

Watch this space!

Pete Jones

[Golfwise]

Thermostats are the Golfs worst enemy.
Always look there first

[Peter Jones]

Yep the thermostat was stuffed but completley removing it didn't help.

Next step water pump! Perhaps the impellor has fallen off????

I picked up a brand new pump cheap on ebay last week so in it goes!

If that doesn't fix it I don't really know what else to do....My pet mechanic tells migh it may still be a cylinder head issue despite the head looking to be straight and sound.

Even very short trips of 5km/5min send the temp off the gauge and yes there is coolant in there!

(Despite this the heater has never worked and it's bloody freezing inside the car. I think I might have to cut some holes in the firewall to use some of that excess heat!)

Dropped the box radiator and heater core off this morning. hopefully I'll know soon what's up with the box.

Pete Jones

[Golf Loon]

Is the gague working properly? Is the engine actually overheating?
Compression test?

[Peter Jones]

I'm going to change the sender to be sure but the fan is kicking in at the right point on the scale so I'm fairly that's not it.

I'm wondering now if that steel tube that carries water from the back of the motor back to the pump isn't blocked with rust. That would explain the heater issue too. Because the sender is passed by the water going to this pipe perhaps it's just a local hotspot. Although the expansion tank fills the radiator ok.


Pete

[Golf Loon]

Take the waterpump and the metal hose off I reckon mate.

[worm]

Keep the updates comming, I am really keen to know the outcome..... My heater doesnt work either and my car runs hot enough for the fan to be on almost all the time and its freezing outside :?

[Peter Jones]

The pump's ok but the metal pipe is blocked solid between the pump and the expansion tank outlet.

When I pulled the pipe off the pump no water drained from the expansion tank until I undid the cap when it drained back into the motor and out of the pump itself.

With this pipe blocked no water can get through the manifold or the heater core and no water is flowing past the temp sender.

Tomorrow I'll bypass it with some hose and see how I go.

The bad news is that the head may still be cracked as a result. My mechanic told me the best way to check for water getting into the cylinder is to run the engine up to temp, then pull out the plugs and put a cold screwdriver into each plug hole. If there is any water in there condensation will form on the cold screwdriver. I got a wet screwdriver in no1!

I've pressure tested the cooling system with the motor both hot and cold and it holds 10psi no probelms.

No work on the gearbox yet.

Pete Jones

[Golf Loon]

Which golf is this in? You wont be fixing a 1.6 motor surely?

[Peter Jones]

Yep, it's the 1600. This is just the hack to get me to the station. This is second on the list of cars to go.

First we get both golfs reliable.
Then we sell the BMW (ongoing liability!)
Get the 59 Beetle on the road.
Then sell red golf.
Then I buy a split screen Kombi!

Of course the new VW diesel EOS could be pretty tempting along the way too!

SO I don't want to over invest in the red car. The clyinder head work won't cost me much, if anything at all. My "mechanic" owes me a lot of favours and now mostly specialises in cylinder head reconditioning.

Actually I quite like the way the 1600 drives, it's very civilised. It's pretty good around the 'burbs but it needs a 5th gear for longer trips.

One day it will be a good project car for an injected late model motor and box (for someone else). It's ex diesel so it's got the tank and no polution gear, chassis is straight. Rust in the usual spots.

As much fun as a 2.0L 16v would be, I'm trying to stay focused on the end game!

Pete

[gldgti]

i like that - staying focussed on the end game.

im kind of the same...a petrol gof would be/is great fun (thanks mollins for our numerous drives) but in the end, my diesel is going to be so much for practical fo os much longer... sad but true

[Golf Loon]

Yeah wise words, realism leads to a more finished car. One step at a time.

[Peter Jones]

Well the box is in bits. Turn out 3rd had been overselected and the one of the keys that keep the shift ring in place had poppee out and wedged itself in the selector. No harm done but it means the gear shift linkages in the car need looking at to make sure that I can't push the gearstick too deep into 3rd.

My mechanical friend John took 4 hour to get it apart 'cos it was stuck in gear and the box doesn't come apart if you cant get the selector out. It's sort of like one of those chinese puzzles, you play with it long enough it just falls apart.

So I guess that means that I'm in the market for 5 speed shift linkages to replace the dodgy modified 4 speed bits that are in there at the moment.

Oddly enough it's probably my fault for replacing all the shift bushings. With all the slop in the system it might not have happened.

We're just waiting on dif bearings now so it should be back together by next weekend.

Pete

[Peter Jones]

Well it's a couple of months on and the saga continues.

Car no 1
White 79

The gearbox went back in and after a few weeks I still couldn't get the linkages adjusted right and it was hard to shift out of 4th. Eventualy something let fly in there and now it's off the road again until I get get it to my mechanic to get it sorted once and for all. It can't be driven at the moment because it's raditor is back in car no 2.

Car no 2

The radiator and heater core were stuffed beyond repair. Hoorah, I thought, we're getting closer to the overheating problem now. Blocked tube, stuffed radiator. Nope, the head's bent too! So my friend reco'd the head (nice job too). I fitted it all back up with the radiator from car no 1 and it all fired up on about the second turn. Great! Problem solved? Guess again.

I drove it to the station for a week and it was all good, it's only a 5 min run after all. The very first time I took it for a 1/2 hour drive it boiled.

This is getting beyond a joke. I'm sorely tempted to trade the pair on a TDI EOS when they get here!

(The very nearly stationary)
Pete Jones

[worm]

Have u driven it without the thermo stat in... should run cool then.

[Golf Loon]

Sounds like a lot of pain Pete.
Sod trying to repair a stuffed gearbox, replace with a newer one. Just ask.
The other car could be thermostat or bottom end. If not thermostat, throw engine away and replace with 1.8. And you need a new radiator.
I wouldn`t even do a headgasket on a 1.6 1976 motor, its 30 years old, either rebuild it all, or replace with a newer, fresher, bigger one for less than the cost of the rebuild.
I wish I was nearer I`d come and give you a hand.

[Peter Jones]

The thermostat's long gone.

Thanks Loony it's just the time I'm short on. None of this carry on has cost me any money, it's just that I don't have the luxury of enough time to get it sorted.

I can exchange my time for my mechanics time but at this rate I'll be working off my debts forever! I can only spare Saturday mornings and it needs more hours than that to sort out.

So I'll book them in one at a time and get them properly fixed up. There's a few other issues with them both that I'll probably never get around to so I'll get them done too.

Funny thing is I drive these by choice. I have the option of salary sacrifice vehicles at work but I'd rather be driving the golf with all its issues than a new LPG Falcon with headlights you can't turn off. (They're hard wired on and you can't turn them off it's a "safety" thing).

Thanks everyone.

Pete

[Golf Loon]

You are a crazy man. New car, or 30 year old golf with issues. Not many would make the choice, but I understand. I know you like em, not many people would do a 1800km parts run in a weekend in a 30 year old car with no radio either.

[roccodingo]

Funny thing is I drive these by choice. I have the option of salary sacrifice vehicles at work but I'd rather be driving the golf with all its issues than a new LPG Falcon with headlights you can't turn off. (They're hard wired on and you can't turn them off it's a "safety" thing).



I understand this 110% pete, I am the same mate.. all the new stuff sucks cause it's designed NOT to last more than a few years...

I will go to the grave in one of my old rocco's..:)

.

[brackie]

I understand this 110% pete, I am the same mate.. all the new stuff sucks cause it's designed NOT to last more than a few years...

I will go to the grave in one of my old rocco's..:)

.
Yeah...My Mk1s don't get out enough. And probably will get out less for the next 3 or 4 months. You'll be hearing less from me on the forum too as 14hr days begin next week :-( Admin and moderator's duties only.

And I remember the days when people used to flash you if you had your headlights on during the day..."Wasting the battery!!!!" How times have changed.....

[Golf Loon]

I will go to the grave in one of my old rocco's..:)
.

Hopefully not literally. :)

[Peter Jones]

I will go to the grave in one of my old rocco's..:)

.

Perhaps it's time you replaced the brakes!

(Sorry couldn't resist!)

Pete

[roccodingo]

EEeek... maybe an omen :o

the brakes on the daily are a bit sad, along with the cv's...:(

[Peter Jones]

OK now I'm convinced. My red golf has lost the will to live. I've just abandonded it at the local train station 'cos it refuses to start. Spontaneous electrical problem - no spark. Combine that with a battery that goes flat in about 8 hours and the fact that it takes only 6 minutes of running to get the needle right off the temp gauge makes this vehicle a joy to own.

That LPG Falcon with the always on headlights is starting to look better every day. The dark side is calling............

Pete

[Golf Loon]

golf3 has a spare 1995 2L engine in Melbourne if you want to ressurect her. Or push it into Bass Straight. Dont you dare get a Ford.

[gtigrl]

golf3 has a spare 1995 2L engine in Melbourne if you want to ressurect her. Or push it into Bass Straight. Dont you dare get a Ford.
:evil: I've got a ford with headlights that turn off if you're looking for a cheap solution ....

[Peter Jones]

Couldn't revive it on the spot. So I've just towed it back to base for a looking at. Starting issue looks like it's just the points. I've cleaned them up and I'll see if it starts ok in 10 mins when the battery's had a chance to recover on the charger.

Jodie learnt how to drive a car being towed tonight. I'm all too experienced in that particular area of VW expertise I'm afraid.


I'll get back yo you in 10 when (If?) it starts.

Pete

[Peter Jones]

It lives!

It's sort of like giving a 110 year old multiple gunshot wound victim CPR now. It will only live if it wants to. If it's truly lost the will to live there's not much medical science can do.

Might have to talk the next of kin into organ donation at this stage.

Pete

[Edison]

than a new LPG Falcon with headlights you can't turn off. (They're hard wired on and you can't turn them off it's a "safety" thing).


It's a petrol thing in the big picture, same with bracks mention of people flashing their lights at you if you had yours on in the daytime. People become stupid when prices are down and then believe any crap and buy any crap and drive any..well you get the picture,.. Sooner or later the high prices force people to be educated or walk. during this process the oil companies gouge and laugh. It's a cycle. get a old paper from the 1920s-1980s and it's all exactly the same arguments as now. PRECISELY the same, you cannot date the letters at all.


Combine that with a battery that goes flat in about 8 hours
Disconnect the battery overnight or use an ammeter to see if there is more current flow than just the clock, also I noticed that when the connector from the alternator comes off, the alternator light won't light up so you will still think things are ok even though the battery is going flat..


It's sort of like giving a 110 year old multiple gunshot wound victim CPR now. It will only live if it wants to.
It just needs a bit of help from a friend or two. when you get to the end of your expertise (mine is electrical) you take it to a friends house and let them have a go at it, they find fixes to obvious problems and also old problems that aren't addressed over the years because they are not that bad. You drive back and I swear to you it is a different car. After all pictures on here show 110 year olds can be stripped back painted and be better than newborn, you don't want that much done, just back to a teenager and that just takes a friend or two and an afternoon or two.

Heater problems, maybe just a good methodical approach, like disconnect the hoses and use a garden hose to see if the engine, heater and whatever is blocked or not. would revving with the radiator cap off show if water is pumping through ? We use intuition to speed up diagnosis, but sometimes it is wrong assumptions, so simple methodical checks might help out.

Or push it into Bass Straight.
Most of the time Loon is helpful, sometimes I need to hunt him down and kill him j: