more "tranny" issues for Ed

[Smokey Eddy]

Oh I know. It doesnt. The problem now is 100% for sure the pressure plate or the pusgrod plate.

[rs899]

I have got to examine my ball and plug thing.  I thing mine may need replacing.  Just unscrews? no surprises?

[Smokey Eddy]

Yes, it just unscrews but make sure you are not in any gears and the stick is right in the middle of neutral. If you have one, i would put a very strong magnet on it or on your ratchet in precaution. The ball inside mine had completely come out and I would imagine can possibly get loose in there. I saw mine luckily and plucked it out with needle nose pliers.

[Smokey Eddy]

Here is a short clip of the travel on my push rod. Does this seem normal? the clicking has since gone away. This video was taken after the manual cable and new pushrod/bearing had been installed.
Here

[Smokey Eddy]

So the pushrod had gone through the plate.

[burn_your_money]

Now hopefully that fixes it.

[Smokey Eddy]

Because the clutch I bought in November was under warranty the place I bought it gave me one that is $100 less and they claim better quality. So I got an entirely new clutch and $100 refunded on my visa! Unfortunately not all stories are fairy tales and with the transfer apart I decided I would use the final. Drive seal kits I have and tear the thing apart. Not by choice, I ignorantly pulled out a shaft that holds the shifting forks together so I've got the split the trans in half. I'm almost there, just the 5th gear wont come free so I need a puller with hooks on it. The steering wheel puller I was loaned wont do.
Brian at brokevw.com is a VW hero. Even for those not wanting to do any work on their transmission I suggest looking at his site. Incredibly educational.

[theman53]

yeah broke is awesome. If you email him he will get back to you very fast and usually has the correct answer first shot. Good luck with your trans.

[Smokey Eddy]

I would have been in the clear if I had my own gear puller but RadoTD is coming to my rescue tomorrow. Due time for some hang out anyways I reckon!
So my mistake will be relatively costless since i already had bought the seals about 2 years ago and all the special tools I was able to borrow.
OH! I lied... today i had to buy a 6mm triple square for $9 and I broke a circlip ill likely have to buy from the stealership - and I also donated $25 to brokevw.com which i thought was pretty stingy of me considering a shop was going to charge around $600 just to take the trans apart...
I'm also looking forward to pulling all the red bits from past speedo gears out. I've already pulled about a nickle amount out just froom what was lying around behind the 5th gear housing.

[theman53]

broke says for whatever reason most grime and deposits are left in that 5th housing/green cap area. Hopefully the rest of your quest continues as cheap as it has been going.

[Smokey Eddy]

From the design I can't imagine that area sees too much flow of oil... im sure oil  gets in there (clearly it does) but i dont really see an in/out system.

[Smokey Eddy]

I got a used replacement clip for free from the local private VW shop (not stealership) and the casing is all back together with the gears shifting beautifully. Now I just need to find a shim for the final drive spring (only on one side!). Does anyone have any sources or ideas to use for a shim for say a 20% (30ft.lbs) increase? It would have to be pretty high grade. There is a ton of spring tension in there...

Just to boast my efforts and make my self feel better for having such filthy hands for the last few days, I changed the intermediate shaft seals, the cam shaft seal that had been stuck on there (due to not having a gear puller to get the sprocket off) for many years, water pump gasket which was leaking like CRAZY! and I put in an 80 degree T-stat instead of my 87 that I like to use in the winter. I had loads of fun testing them on the stove
Im also changing the timing belt but i can't time it until i have the bellhousing back on to set the flywheel to TDC. I'm not looking forward to the bench press fight with that thing trying to get it back in there.

[R.O.R-2.0]

dont bench press it then. stick it under the car, then reach thru the bay from above, pick up the trans off the ground, then slide it on the engine. its way simple..

bench pressing the trans is a royal ***. lifting it up to the flywheel is much easier. i do it that way on all mk1/2/3 cars..

when all my cars were still 4spd, i did the bench press method because the trannies were alot lighter. the 5 spd was considerably harder to bench press, thats why i came up with the method of setting it under the car, and lifting it to the engine.

[Smokey Eddy]

Wow don't you just shred your back doing that?

[R.O.R-2.0]

Wow don't you just shred your back doing that?

not even the slightest..

i have a bad back to begin with, so im all about doing things the easiest way possible..

doing it the way i described, is the easiest method on my back..