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Author Subject: high boost gearbox issues
russbez

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Post #1
i believe i have damaged my gearbox

was driving in anger and now i struggle to get into gears anything above 2500 revs - just feels like clutch isnt down
never made any obvious noises that anything was wrong

i can blip the throttle and get them to go into gear, sometimes crunches a little - all six gears feel smooth right up rev range

i changed my gear linkages back to old ones which i knew work okay - had hoped the heads off the linkages had came loose and adjusted them selves incorrectly - this doesn't seem to be the case

firstly

does this sound like its the Gear Syncro Hubs are damaged?
its all my gears that are doing it

secondly has anyone ever ran a standard diff, is this a good idea??? - i have my old gearbox i want to fit in hurry for a road trip to Orkney on Friday

Cheers
Rus.

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Posted 9th Sep 2013 at 11:07
superchargedblack1997gti6

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Post #2
Sounds to me more of a clutch problem Russ Does it engage into all gears when the engine is off dude?
Just strikes me that the issue is occurring over 2.5k only leading me to believe more Likley a clutch problem than a transmission issue? have you got a spare standard clutch? buzzbirghtyear is still using standard diff with his superhighboost with no issues.

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Posted 9th Sep 2013 at 11:22
russbez

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Post #3
iv got a spare new standard new clutch sitting in garage Yes
been so tempted to fit it for around town driving

yes the gears engage when engine is off

the Helix clutch plate has been making a lot of noise when car is out of gear/sitting idling - when getting remapped Wayne didnt think much was wrong so never really though much of it... he said that some paddle clutches are noisy

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Posted 9th Sep 2013 at 11:38
superchargedblack1997gti6

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Post #4
I just think that sounds more of a clutch issue! I'm sure that the car will be fine with standard clutch I'm sure RichW only changed to a paddle clutch for the superhighboost!

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Posted 9th Sep 2013 at 11:39
russbez

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Post #5
yeh suppose, anyone else agree?

because the car drives fine when gears are engaged.... i guess see your point

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Posted 9th Sep 2013 at 11:42
superchargedblack1997gti6

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Post #6
I think that the noise you told me about was clutch release bearing.Im sure that Rich told me when he had the full helix kit fitted it only lasted 8-900 miles. which is why he substitutes the clutch cover for something else. Uses the helix paddle with a different cover.

________________________________________

Super high boost Completed, destroyer of gearboxes and 160mph club
Posted 9th Sep 2013 at 11:50
russbez

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Post #7
it wasnt the clutch release bearing

replaced the clutch cover + bearing before i went for my remap Whistle
and that noise didnt go away

i am using 6 paddle helix and sachs clutch cover

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Posted 9th Sep 2013 at 12:10
superchargedblack1997gti6

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Post #8
Very odd mate not to sure then! but sounds like a clutch issue because of the way you can engage normally. but only over 2.5k revs means in my mind that the clutch is struggling to disengage enough for you to select gear?

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Posted 9th Sep 2013 at 12:19
russbez

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Post #9
yeh but clutch plate is still the same Helix clutch plate that had been making noises

Wayne agreed that the noise was the Helix plate, but id already replaced my Sachs Clutch cover + bearing by then Doh

got home fine after remap wasnt intil i drove it hard did this start happening - guess it could of been on its way out?

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Posted 9th Sep 2013 at 12:34
superchargedblack1997gti6

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Post #10
To be fair it may be the issue of it being a six puck rather than 4?

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Posted 9th Sep 2013 at 12:34
russbez

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Post #11
i would hope not, cars done hardly any miles before that noise started (end of last year iirc)

when i took the Helix out before my remap, it didnt "look" damaged or loose in any way

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Posted 9th Sep 2013 at 14:31
superchargedblack1997gti6

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Post #12
Just stick the standard clutch back in and see what happens?

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Posted 9th Sep 2013 at 12:43
russbez

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Post #13
planing that tbh, mates taking his Yamaha R6 up to Orkney so i am buzzing wanting to take my Rallye and not a 1.9d 306 estate LOL

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Posted 9th Sep 2013 at 12:47
armzsc6

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Post #14
Sounds like the clutch is dragging to me causing it to be very difficult to get into gear. Check the cable is ok and the fork moves fully when the pedal is depressed and if all ok then box out. Had this caused a few times by one of the 3 springs round the outer edge of the clutch cover snapping causing the cover plate to move in on one side and drag against the clutch.

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Posted 9th Sep 2013 at 13:46
dcc

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Post #15
sounds like synchros are dying

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Posted 9th Sep 2013 at 13:49
russbez

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Post #16
good shout - ill recheck cable and fork
clutch cable is 2/3 years old

i had a look at clutch plate when it was out the springs all looked the same and nice and tight

was really hoping it was not the synchros, got a spare gearbox but would need to switch the LSD into the spare box

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Posted 9th Sep 2013 at 14:30
mechanical_repairs

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Post #17
I had this issue with my rallye and it turned out the Valeo clutch fitted had broke a rivet on the pressure plate, got a new one under warranty and all is well.

If you are using the standard pressure plate I would say this is the issue, Sachs and Valeo like to use the same parts, I have had many Sachs clutches with Valeo parts in the box. I would get someone to lever the clutch lever over and see if it makes any difference, if its still the same and bulking when trying to get gears, above will be your issue.Thumbs up

Carl

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C.G.Cars of Leicester, Peugeot/Citroen/Renault specialist Tel: 01162 624498/07799 405184 WWW.CGCARSLEICESTER.CO.UK
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MOT station now open, tests £35 with a free retest.
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Posted 9th Sep 2013 at 16:20
russbez

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Post #18
mechanical_repairs wrote:

.... I would get someone to lever the clutch lever over and see if it makes any difference, if its still the same and bulking when trying to get gears...

Carl


i might be reading you wrongly, but how do i that Unsure
i can get an unsuspecting friend to help easy enough

________________________________________

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Posted 9th Sep 2013 at 16:35
mechanical_repairs

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Post #19
russbez wrote:
mechanical_repairs wrote:

.... I would get someone to lever the clutch lever over and see if it makes any difference, if its still the same and bulking when trying to get gears...

Carl


i might be reading you wrongly, but how do i that Unsure
i can get an unsuspecting friend to help easy enough



Basically when you press the clutch get someone to look at the cable on the gearbox and make sure the lever is going all the way, get a lever bar in there and see if it will move more, if not its at the limit and the box will need to be removed to inspect.

It just rules out the cable pedal etc.

Carl

________________________________________

C.G.Cars of Leicester, Peugeot/Citroen/Renault specialist Tel: 01162 624498/07799 405184 WWW.CGCARSLEICESTER.CO.UK
36 narborough road south, Leicester LE3 2fn

MOT station now open, tests £35 with a free retest.
Recovery available with a recovery unit, for those not so local jobs

Also offer the loan of a free courtesy car 306 dturbo
Posted 9th Sep 2013 at 16:38
russbez

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Post #20
thanks mate will have a look tonight

________________________________________

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My Rallye project thread
Posted 9th Sep 2013 at 16:41
russbez

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Post #21
right iv tried levering the clutch arm more when my mate has his foot on clutch

cannot seem to budge it over any more Sad

took a few pictures cannot tell what is a "normal position"

clutch left up


clutch pressed down

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread
Posted 12th Sep 2013 at 10:16
russbez

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Post #22
using washers i compensated for any stretching of the clutch cable.... didnt make any difference

probably going to take gearbox off and inspect the clutch, most likely stick standard clutch plate in there

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread
Posted 9th Sep 2013 at 20:54
armzsc6

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Location: Crowborough

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Post #23
Yup either something's gone pop in the cover or the plate. Impossible for every synchro to die at once lmao. I've heard standard valeo clutches hold high boost anyway? Obviously not as well as a paddle would but due to linear power they do ok.

________________________________________

Black power baby! SUUUUUPERCHARGED Superman
Seat Leon FR TDI 190BHP 300lbft daily gti-6 killer :p
12x 306's owned so far

Cambelts, clutches, service work carried out on All makes and models, Peugeot Citroen / mitsubishi specialist.
Pug planet / Citroen Lexia diagnostics / code reads available.
Posted 10th Sep 2013 at 10:19
russbez

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Registered: 19 Dec 2005

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Post #24
armzs16 wrote:
Impossible for every synchro to die at once


a mechanic friend mentioned that last night actually!

started taking it all apart, have to take whole front end off to get intercooler and pipes out the way Thumbs down

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread
Posted 10th Sep 2013 at 10:30
mechanical_repairs

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Location: leicester

Registered: 10 Jan 2005

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Post #25
Get the box out, we putting money on the problemThumbs up


Carl

________________________________________

C.G.Cars of Leicester, Peugeot/Citroen/Renault specialist Tel: 01162 624498/07799 405184 WWW.CGCARSLEICESTER.CO.UK
36 narborough road south, Leicester LE3 2fn

MOT station now open, tests £35 with a free retest.
Recovery available with a recovery unit, for those not so local jobs

Also offer the loan of a free courtesy car 306 dturbo
Posted 10th Sep 2013 at 14:10

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