Second Coming...

[blakey]

Finally got around to taking some more pics....

[blakey]

Been doing bits 'n' bobs over the last couple of weekends - full service & cambelt, discs & pads, replaced instrument panel & heater motor and fitted inertia reel belts in the back.
Still got a lot of cleaning and cosmetic stuff to do - when the weather improves. I think it's almost water tight, so will be replacing the carpets soon

[mark1gls]

Tidy looking car you have there.

[blakey]

Last weekend I had 'clutch failure' with no warning, which was strange as the clutch operation felt good. Anyway, it turned out to be release bearing failure. Having taken the green gearbox end cap off, I found that the release bearing was completely broken up and burnt out, and the top of the bearing had friction welded itself to the release finger. Once I'd free'd it off I then found that pushrod would not come out, so figured the other end was damaged too.
So if the gearbox was coming out, I thought I'd better put a new clutch in it too. I replaced the clutch and release mechanism today, and changed the gear oil, a little worrying as less than a litre came out... and found one of the drive shaft cup plastic sealing caps was missing resulting in gear oil in the inner CV joint...hmm. The pushrod was indeed mushroomed and burnt, so had to be cut off.
I can only assume that at sometime in the past it has been driven with no free play in the clutch cable or by a driver that liked to rest their foot on the clutch pedal.

[mark1gls]

Sound like you have been busy...

Don’t know if you have the box back on or what you did as the pictures don’t seem to work expect 1 but did you check for play in the brass bush just inside the input shaft?

You can see the brass bush in this link.

https://www.ebay.co.uk/itm/VW-Volkswage ... XQMXRQ7c3x

More info here.
http://www.brokevw.com/020seal.html

When I changed mine I treaded in a long bolt into the bush when I tapped a thread into the bush and used some washers and a nut to screw down so it pulled the bush out as I did not have a slide hammer.

I had the same problem with gearbox oil in the inner CV boot when my seal seemed to of fell out, I re greased the CV joint and it’s been fine for the last couple of years.

[blakey]

Thanks for the info, it's back together now and you've got me thinking...
I can see how that could cause the issue. I didn't notice any issues with the bush when I replaced the button seal and fitted the new pushrod, so fingers crossed. A least a thrust plate can be bought without buying a new clutch if I do have to change the bush in the future (provided gear oil doesn't get past the button seal).

Sent from my ZTE BLADE A512 using Tapatalk

[mark1gls]

Mine had a lot of movement in the push rod so if you did not notice it you may be alright.

I guess the last owner must of rested their foot on the clutch pedal when driving as I’ve not seen a push rod that bad.

I do now check my gearbox oil at least every year just to be on the safe side.

P.s pictures now working

[blakey]

Yep, got my fingers crossed on the bush and hoping the low oil in the gearbox hasn't done too much long term damage.

[mark1gls]

The gearbox usually starts to jump out of 5th gear if oil is to low, fingers crossed it’s ok as the gearboxes are fairly bullet proof.

[blakey]

Well I used to be able to hear the diff a bit on overrun, so hoping that has quietened down. I got it back now, so will find out, my missus has had it all week due to a couple of issues with her Mk2 Golf...