Gearbox / Clutch woes Mk1 16v with a mk2 8v gearbox

Hi there. I'm having difficulties with my mk1. Its currently running a 2.0 16v abf on twin dell'orto 40s. I have just replaced the clutch with a black diamond cerametallic uprated clutch (210mm), a very good mk2 8v gti flywheel and attempted to fit a low mileage mk2 gti 8v gearbox. This has been a complete pain so far. I finally got round to fitting the gearbox yesterday and after trial fitting the box it appears the clutch push rod isn't long enough to disengage the clutch. Is this a known problem and what are the options?
It was running a campaign close ratio box with a 190mm clutch plate but it threw the oil seals out, contaminating the clutch.
Any help will be gratefully appreciated.

I've had this problem once before on a mk2 with an 020 box after fitting a new clutch and box, couldn't figure out the problem after fitting the box so we took the endplate off the gearbox and adjusted the operating lever for the push rod, involves filing out a new groove in the part where it connects as it's keyed and only supposed to fit one way, worked fine after we did that.

might be a daft question, but have you adjusted the clutch cable to take all the slack out?

Nice one, i took the end plate off and the push rod isnt contacting the centre plate until just before it hits the stop so it seems too short. The rod seems to move about 23mm so going to get a guy at work to knock up a longer rod and see what happens cos i dont want to change the angle the lever works at.

how much longer?

The ends can wear with time, so maybe a just a new std one will do you.  I believe they're meant to to be hemispherical, so if it's flattened then it's worn.

Its got a slight flat on one end but would probably be no more than 1mm off the end. By my reckoning the rod needs to be at least 20mm longer. I tried C&R Enterprises and TSR conversions and they just suggested to use a KR 16 valve box as the input shaft is different.

Just seen this, ive been having exactly the same problem, just fitted my 16v kr and 1.6 gearbox with a 210mm Sachs clutch and flywheel, it was running a 190mm which was fine (other than slipping).

When i push the clutch lever its very easy, like the pushrod isnt connecting anything….  and the clutch doesnt disengage, cant believe if this is a common problem it wasnt mentioned in any of the guides  :roll:

So by the sounds of it i can remove the cover and end plate have a play and be back in business    anyone actually done this?

Im suposed to be driving over to the nurburgh ring in 4 weeks so need it sorted asap!

Any advice much appreciated

Right finally got the new rod made up and it was too long, a few slight modifications later and the box is back in and were back in business with everything working just as it should. There was a similar problem on vwvortex and nobody had a decent resolution for it except modifying the clutch release arm to make it work at a different angle. I'll keep you posted as to how long it actually lasts for.

Dan,

See the link below, it looks to me like there are different size clutch release bearing carriers, im guessing that the set up ive got requires the 24mm bearing and ive got a 19mm one which would make my shaft 6mm short.  Suspect yours could be the same.

I will have to investigate further but my thoughts are to shim the bearing with a 6mm spacer or get hold of the thicker bearing anyone any thoughts?

TO Bearing

Ste

Bit more info today, took my release bearing out and its 17mm added a 7mm spacer (nut) behind it and its all working good oh…..  next plan is a trip to vw to see if i can get one of the 24mm release bearings as mentioned in the artical above, hopefully this will sort it.  If i cant get one i was thinking of either a longer shaft as youve done, getting a shim machined up to fit behind the bearing of rotating the trigger a couple of splines?