engine and drivetrain 1976 2002 Won't Shift Into Gear

[aaziz99]

So i just started by 2002 after about a year sitting idle.  My car does not seem to shift into gear when the car is on.  When I put it in reverse it makes a horrible grinding sound.  The car is able to shift with the car off but not with the car on.  Any suggestions?

[esty]

your clutch is rusted...stuck to the flywheel....jack up both rear wheels, be safe, start the car in gear and rev the engine...it'll spin the 2 apart

 

or on a downhill slant, no traffic, start the car in gear and drive it

 

 

[Dabliz02]

+1

 

it is a good practice to somehow  set up the car to keep the clutch pedal down so this wont happen upon storage.

[aaziz99]

thanks for the tips, this helps a lot!

[TobyB]

Might also be the hydraulics have leaked out.  If you can get help, have someone press the clutch

while you watch the slave underneath.  If it moves, your clutch is stuck.  If it doesn't, the hydraulics need work.

 

Unsticking is fun- you get to start the car in gear, holding the pedal in, and try to get it

to break free.  It often does...  but be careful!  Make sure your brakes are good!

 

t

[DaveyG67]

I'd like to resurrect this thread, as I have a similar problem. Just completed a auto to 5 speed conversion on my '75. New clutch, pressure plate, throw out bearing, master & slave cylinders (lines bled), resurfaced flywheel to spec. Getrag 245 was purchased from a vendor at the Bay area '02 show last month, & is supposed to be good, (replaced all seals). Gear box shifts fine when car is not running, but when started in neutral, can't shift into reverse, horrible grinding. Can engage gears 1 to 5 while car is running. If I put the car in reverse when turned off, start the car in reverse, can't engage gears 1 to 5. I did this test with the rear of the car elevated on jack stands...Would this be an issue with the clutch, or something else?

 

Thanks in advance,

 

David

[Hans]

For first problem I agree with stuck disc. Start car in gear, punch gas a few times or apply brakes hard.

For David and 5 speed, which throw out bearing did you use?

[DaveyG67]

Hans, I used the Sachs SN3759 or 21 51 7 521 471. That is what I was sent from the Ireland 215mm Clutch Kit which is correct for my flywheel.

[Simeon]

Check your hydraulics (harder to determine if the clutch is working on a 5 speed). Clutch is not disengaging and from the sound of things it won't be because the plate has rusted to the flywheel. Not that familiar with the 5 speed - any chance the throwout lever inside can be displaced from its pivot?

[dang]

Do you know for sure that the lines are completely bled?

[jimk]

Hans, I used the Sachs SN3759 or 21 51 7 521 471. That is what I was sent from the Ireland 215mm Clutch Kit which is correct for my flywheel.

The info I have is:

 320i bearing, for 215mm clutch: 21 51 1 225 168, but the one you got supercedes the 168, so it should be ok.  The 228mm uses a different one from a 323.

 

Edited June 18, 2015 by jimk

[Hans]

In both cases, another thing to look at is the rubber hose. They swell shut on the inside over time. So check to see if the push rod is moving when the peddle is pushed.

On the 5 speed, and I'm working from memory here, I think the bearing needs to be 30mm thick. But maybe just with 228mm. So the question for IE is: does that one work with 215mm and 5 speed. There is a procedure for checking push rod movement on the 5 speed in the shop manual, or in previous posts. I recall one from Hack Mechanic went on for 8 or 9 pages and covered every possible clutch problem known to man. If your bearing is too thin, the clutch won't release. Ask me how I know. But it could be something else.

[DaveyG67]

I mentioned my problem to a co-worker who is our fleet mechanic for USPS, & he thought it could be the slave push rod is not fully engaging the clutch fork, or the clutch fork is worn or worse case a bad reverse gear syncro… Yikes, hopefully not the latter.  

I think tomorrow I'll actually try to take it out on my street and do some more testing, staying very close to my house of course!

[Hans]

Reverse is not synchromesh. It would appear clutch is not releasing completely. I suggest you get under the car and check arm movement.

[DaveyG67]

Ok, thanks Hans. My buddy is coming over tomorrow to help sort it out. He's waaaaay more knowledgeable than I, so hopefully we will figure it out.