ive just fitted a second hand gearbox in my astra 1.7tdi 53 plate..

the last one ended up with a hole in the bell housing whoops, but it still drove for the last 6 mile to my unit lots of noise but got in to all gears fine..

new gearbox fitted no problem with clutch it was new in june last year, got correct oil then on for the test drive,

gears feel tight, lets try reverse crunch no it will not go in tidy try all other gears there not perfect, so i used the factory set up advice locate 5mm pin in the gear stick and lock the pin on top of the selector on the box it should be perfect but no it isnt now i cant get reverse first or second tidy,

if i go 1 2 3 4 5 then in to reverse its fine, the guy i got the gearbox from said its the clutch but how can it be when it was perfect before i took the last one out and its o.k going in to 3 4 5 but not 12 and reverse, it only crunchs in reverse,

 

does sound like it could possibly be the clutch even tho its not all gears as ive had this before, however sometimes the unit on top of the gearbox that the cables go onto can become overly worn and require replacing, i think they are the same on mk2, 3, and 4's if i remember correctly so should not be a problem picking one up

 

Did you fit your slave cylinder/thrust bearing to the new gearbox?
Im just wondering if you have used the one thats attached to the box rather than the original one that was fitted to your box. It may be possible the difference between manufactuers that its not the same size and therefore possibly not engaging the clutch correctly?
Its possible and seems weird how the clutch was fine before hand.

 

give it a good bleed out mate and reset the linkage!

 

thrust bearing out of the last gearbox and the linkage...

ive just found out now if i do 4mph put the clutch in and put it in first or second it goes in like its a new car very smooth,

botters i was thinking the same thing about the unit on the top of the box i was going to change that on sunday re set using 5mm drill bit etc and see what happends

is it true the unit on the top off the box can or has a screw to adjust if so this may be incorrect for the set up on my car or have i been given a 1600 box ???????

mechanic 28, shall i bleed the brakes aswell or wouldnt it affect the clutch if there is air in it after all its using the same fluid from the same pot...

cheers for the help guys

 

anyone ???

 

na dont worry about the brakes as it wont get that low to effect them!you need to use dot 4 just the same as you would for brakes!

i dont get what you mean about all this 5mm stuff?did you reset the linkage after refitting the box?

 

What does the clutch pedal feel like? Whats the first few inches of pedal travel like?

If it feels soft or spongy there is air in the clutch system and the clutch will not be disengaging fully.

As mentioned above, give the clutch a good bleed to make sure no air is present.