Hoping some of you guys can suggest what the problem is:
I'm rebuilding a 1985 90 with 300tdi & LT77 box.
The gearbox/transfer box were reconditioned almost a couple of years ago.
A new HD Valeo clutch was fitted along with an alloy housed HD clutch release bearing and HD clutch fork (I welded a plate onto the back of it to stop the pushrod punching through).
I was very methodical when I fitted it all. I would estimate that was nearly 12 months ago when the clutch was fitted and gearbox bolted back in.
The clutch was bled after fitting new slave & master cylinders.
I finally got the engine running this week.
No wheels are fitted and it currently sits on axle stands under the front/rear axles.
I thought I would try out the gears/transfer box whilst on the stands with the engine running.
Initially it all seemed to do what it should.
I then got slightly more travel on the clutch pedal and it started getting a bit odd.
When I now push the clutch in, I can select a gear but when I release the clutch it stalls the engine.
I can select neutral on the gearbox and have the transfer box in high or low range and the hubs still spin.
I have rebled the clutch, no air present, the master & slave cylinder isn't leaking.
The clutch pedal sits at the correct height to the floor (140mm).
The pedal does have the double springs on the arm. There is some initial freeplay and then a lot of movement against the pedal springs before I feel the clutch being depressed but the movement against the springs also visually moves the shaft of the master cylinder in.
I don't know what the problem is. Please tell me I don't have to have the box out again as that just doesn't bear thinking about!
So in summary, when transfer box is in neutral, I can select a gear on the gearbox and let clutch out.
When transfer box in high or low range, I can select a gear on the gearbox but when I let clutch out it stalls the engine.
Heeeeelpppp!
I'm rebuilding a 1985 90 with 300tdi & LT77 box.
The gearbox/transfer box were reconditioned almost a couple of years ago.
A new HD Valeo clutch was fitted along with an alloy housed HD clutch release bearing and HD clutch fork (I welded a plate onto the back of it to stop the pushrod punching through).
I was very methodical when I fitted it all. I would estimate that was nearly 12 months ago when the clutch was fitted and gearbox bolted back in.
The clutch was bled after fitting new slave & master cylinders.
I finally got the engine running this week.
No wheels are fitted and it currently sits on axle stands under the front/rear axles.
I thought I would try out the gears/transfer box whilst on the stands with the engine running.
Initially it all seemed to do what it should.
I then got slightly more travel on the clutch pedal and it started getting a bit odd.
When I now push the clutch in, I can select a gear but when I release the clutch it stalls the engine.
I can select neutral on the gearbox and have the transfer box in high or low range and the hubs still spin.
I have rebled the clutch, no air present, the master & slave cylinder isn't leaking.
The clutch pedal sits at the correct height to the floor (140mm).
The pedal does have the double springs on the arm. There is some initial freeplay and then a lot of movement against the pedal springs before I feel the clutch being depressed but the movement against the springs also visually moves the shaft of the master cylinder in.
I don't know what the problem is. Please tell me I don't have to have the box out again as that just doesn't bear thinking about!
So in summary, when transfer box is in neutral, I can select a gear on the gearbox and let clutch out.
When transfer box in high or low range, I can select a gear on the gearbox but when I let clutch out it stalls the engine.
Heeeeelpppp!
Take the hand break OFF !
