another notchy box

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  • mike74
    S2Forum Maniac
    • Apr 2014
    • 615
    • Country: Scotland

    #1

    another notchy box

    Morning guys,

    As title suggests, the 6 speed box in my '95 ABY coupe with 146k miles is generally notchy all the time although gets slightly better when warm. It never grinds but, you can feel something almost catching/baulking when shifting during normal driving and have to shift slowly so it changes ok. This is most noticeable on R, 1, 2, 3 & 4; 5 & 6 seem ok. When cold, it changes gear ok but after a couple of minutes starts getting notchy and second gear becomes difficult to downshift into. After a couple more minutes the second gear downshift issue is almost gone and when warm is fine. When giving it beans it changes gear quickly at high RPM's cleanly and without any noticeable issues.

    I've gone to great lengths to ensure that the linkage is tight from the stick up to the box with virtually zero play anywhere. The gearbox oil was replaced a few months ago with Castrol GL-4 Syntrans (75/90) stuff which helped slightly but hasn't quite sorted it.
    I changed the clutch master cylinder last year but not the slave although since I have no records of this ever being done, might be getting replaced next week. FWIW, the clutch has always felt a bit heavy but has always worked *touches wood*
    The clutch biting point has been adjusted so its as high as I can possibly get it without pre-loading the release bearing and admittedly, is still only a couple of inches off the deck. I don't think its dragging but I haven't ruled that out completely.

    I'm reluctant to go spending money on things unless I have a good idea whatever it is will actually help (already changed box oil twice in last year!).

    So whotcha think guys:
    1. try changing the slave and see how it goes
    2. change the gearbox oil again (maybe Fuchs Titan Sintofluid 75/80?)
    3. live with it
    4. box is old and probably borked (see no.s 3 & 5)
    5. drive it like a chav everywhere so it changes gear properly

    Any suggestions greatly appreciated

    cheers,

    mike

    edit: I don't know if its relevant but I'm sure when the box oil was replaced it was filled up to the hole rather than Xmm below. Is that an issue?
  • simon20vq
    S2Forum Extremist
    • Dec 2010
    • 1379
    • Country: United Kingdom

    #2
    Option 3 or Sounds like the clutch could be knackered either the pressure plates gone week or the plate is shot as well. Lets see what the general consensus is! Hope you get it sorted.

    Comment

    • popdemonic
      S2Forum Extremist
      • Dec 2007
      • 1304
      • Country: Thailand

      #3
      try it with the engine off if it's still notchy.
      whilst you're trying to shift into R,switched the engine off to see if the gear can kick-in.if yes,i think the problem is the clutch engagement point is off.
      one of a few I5 from Asia.

      Comment

      • popdemonic
        S2Forum Extremist
        • Dec 2007
        • 1304
        • Country: Thailand

        #4
        *disenagagement point is off..
        one of a few I5 from Asia.

        Comment

        • mike74
          S2Forum Maniac
          • Apr 2014
          • 615
          • Country: Scotland

          #5
          its still notchy when engine is off. thing is, its been like this since I got the car ~6000 miles ago...if it was a knackered clutch, wouldn't it have died by now?

          Comment

          • simon20vq
            S2Forum Extremist
            • Dec 2010
            • 1379
            • Country: United Kingdom

            #6
            Yeah maybe but if its the fingers on the pressure plate maybe not. Does it stick in 1st so that its hard to take out and put into second when your driving? Is it easier to change gear with the engine off as popdemonic is saying?

            Comment

            • popdemonic
              S2Forum Extremist
              • Dec 2007
              • 1304
              • Country: Thailand

              #7
              how was the symptom when try shifting the gears with engine off?better ?yes it's probably slight notchy for some gears without depressing the clutch that's normal.
              one of a few I5 from Asia.

              Comment

              • mike74
                S2Forum Maniac
                • Apr 2014
                • 615
                • Country: Scotland

                #8
                Its hard to describe but, with the engine off it just feels clunky and notchy (even more so). I'm starting to think its clutch related now as on the way home I was intentionally pressing the pedal down harder and faster and it seemed to help! Maybe the end of the slave cylinder rod has split or worn off? Maybe the slave is just downright goosed altogether? Maybe I'm deluding myself...who knows!
                Keep the suggestions coming guys

                Comment

                • popdemonic
                  S2Forum Extremist
                  • Dec 2007
                  • 1304
                  • Country: Thailand

                  #9
                  try this,depressing the clutch several times maybe upto 5-10 and try shifting the gear again.
                  i doubt it's not the clutch if it's still notchy with the engine off.any crunching?
                  one of a few I5 from Asia.

                  Comment

                  • mike74
                    S2Forum Maniac
                    • Apr 2014
                    • 615
                    • Country: Scotland

                    #10
                    Ok I just tried this. Engine off, pump pedal a number of times and tried the gears; went in pretty easily with minimal notchiness. Also tried it when engine was running and reverse also went in no problem. Does this point towards clutch hydraulics or something more sinister?

                    Comment

                    • Error404
                      Super Moderator
                      • Mar 2007
                      • 19789
                      • Country: United Kingdom

                      #11
                      Sounds hydraulic to me. I'd try a really thorough bleed first.
                      They can be a pain in the *** to bleed, try jacking the rear of the car a few inches higher than the front, it helps
                      Panthero Coupé quattro 20vt
                      Indigo ABY coupé
                      Imola B6 S4 Avant

                      Comment

                      • bertman
                        S2Forum Extremist
                        • Apr 2007
                        • 1173
                        • Current: United Kingdom

                        #12
                        Reach down and put your finger into the slight hole in the bell housing and feel around the side of the box(engine off) and see if your finger gets any oil residue on it
                        Rob

                        Ragussa green avant RS2+ spec
                        Racing blue Octavia VRS mk2 estate-Remapped now to 250 bhp
                        Audi coupe gt-slow as hell but loads of character-sold

                        Comment

                        • 220bhp
                          S2Forum Fiend
                          • Nov 2004
                          • 2578
                          • Home: United Kingdom

                          #13
                          Check the oil, or better still change it. Worked for me

                          Comment

                          • mike74
                            S2Forum Maniac
                            • Apr 2014
                            • 615
                            • Country: Scotland

                            #14
                            I've bled it at least twice, if not three times with a pressure bleeder after I replaced the MC. I'll have a more in-depth look over the next few days and report back, cheers guys

                            Comment

                            • macspring
                              S2Forum Zealot
                              • Mar 2005
                              • 6371
                              • Home: Ireland Current: Wallis & Futuna

                              #15
                              As Error says, as the next step definitely bleed the fluid between the reservoir and the slave cylinder on the gearbox.

                              Rarely done and should benefit most cars.

                              Post your results either way.

                              Thanks.

                              Comment

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