jerky

bit of advice needed on my 16v caddy sport, it is hard to pull away in and drive slowly in any gear, if rolling forward in first at idle it jerks like there is play in the drivetrain. also if its jacked up and you rotate one of the wheels back and forth the diff knocks :dontknow:

 ive put a new clutch cable in and i welded the bulkhead before i fitted the engine as it pulled through.

 i didnt drive the car the engine and gearbox were from and didnt fit a new clutch. on the pedal the bite point is high but it doesnt slip going up hills. i do get a whine from the gearbox but its not chrunching in to any gears. changed the oil but no better

would this be the clutch that needs changing or the gearbox also?.

what would i need to put a new box on, 3 piece clutch kit?. got a tourque wrench and it still has 90 mm shafts on as i changed the flanges on the 2y kr box

 i have a 1.6 gti gearbox that i know is smooth as it was fitted when i got it, and also got the original 1.8 sport gearbox but not sure on condition. i think the 1.6 would be a closer match to the 2y thats on there but i have found that both of these boxes are not great for cruising at 70 say (3.5k rpm in 5th) would the 1.8 sport gearbox be any better or would it ruin it.

if there is lots of slack in the diff that would suggest the bearings are toast unfortunatly, i had one the same and it was awefull for jerking about like you say.

in tyour shores i would buy a new clutch kit and fit the mk1 1.6 gti gearbox as its known good. with the 1.8 and 1.6 8v boxes you would have to fit a mk1/2 1.8 gti clutch kit, the 2y box uses a 16v clutch kit as the input shaft is bigger.

if you're worried about the short ratio 5th in the 1.6 box you can swap in a taller 5th from another box, check out brokes site Welcome to BrokeVW.com

oh and check the code of the gearbox, you may have to swap the speedo gear to suit. my 1.6 gti box required a white gear. i loved the way my 16v cabby pulled with the 1.6 box, though as you say motorway driving was a bit buzzy at speed. but saying that you cant drive too fast in them anyway since the hood starts inflating like a balloon

thanks for that, i was starting to think it is the diff.

i think i will remove the 1.6 gearbox and have a look. so i need a 1.8 8v gti clutch, is that 210 mm?

yup, get a sachs one:
AVS Car Parts - [The VW - Audi - Seat - Skoda Parts Specialist]

the kr flywheel will swap straight on as they're the same as 8v gti ones. just the friction disc that differs on the 16v kit so you could just fit 8v one and keep the pressure plate if you like, but id just swap a new clutch on unless the 16v kit is nearly new and good make

after a bit of a drive today i think i may try and swap the 5th gear on the 1.6 box, it looks like something i could do in that link. what would be the best to go for?

i have the sport box but not sure if that will be any good

also

could i have fudged the diff bearings when i swapped the seals and flanges

have a look at the box codes on the 2 you have, compare to brokes ratio chart and Gear Up!
then see how the 5th ratios compare in them all.

checked the codes and the one on the 1.6 gti engine is an FH and the sport box is a 4S so either will have 4th gear the same ratio as 5th on the 2y i think the fh is a later one as its on a 1982 engine, the full code is FH08042. the fh is alot cleaner and i know its smooth so i wont bother swapping 5th as its a good ratio.
i think the best option would be to swap the 5th gear onto my 2y box but the diff is on its way i think as its knocking when changing gears.

according to that page it will be at 2850rpm at 70 and 158mph at 6500rpm with the fh box but not sure if this is gonna make it too long ratio to drive about.

would prefer best of both worlds, according to the gears page it would be at 105mph at 6.5k in 4th and would drop to 4k rpm when put into 5th with a 2y close ratio box and a 0.71 5th gear and would be at 168mph at 6.5k rpm


i have a mate who says he has a 16v box but unsure on condition and i would need to swap the flanges again or fit 100mm driveshafts

id stick the fh in, you can always swap the 5th gear later with box in situ if you really want to. as i say mine was a bit buzzy on the motorway but not enough for me to be bothered about swapping it

thanks gonna get the box swapped and look out for a close ratio one to build up with a better 5th
 
yeah i think the fh will be fine on the motorway but wont accelerate as well. would be ok if it had a bit more torque… thats it i need a 2.0