NO DRIVE!

I've just fitted a new 5 speed gearbox to my caddy. All went together smoothly, put a new clutch on there as well.
All the linkages have been adjusted, and (it seems) that all 5 gears and reverse are slotting in nicely.

The only problem is, when I try to move off, the caddy just stays where it is?  :dontknow:

Any ideas or solutions would be great, and the sooner the better, because I need to get to work Friday!!!!!!

Any noises?
Does the clutch feel ok?
Adjustment in the cable maybe but if there's no clutch at all I doubt its that.
Everything refitted yeah??
Could it be possible the clutch is fitted the wrong way, can't remember if this will atop the clutch from working.
is the new box a recon? Could have a pushrod/release bearing/release fork fault, located behind the green cap at the end of the box

possle said

Any noises?
Does the clutch feel ok?
Adjustment in the cable maybe but if there's no clutch at all I doubt its that.
Everything refitted yeah??
Could it be possible the clutch is fitted the wrong way, can't remember if this will atop the clutch from working.
is the new box a recon? Could have a pushrod/release bearing/release fork fault, located behind the green cap at the end of the box

The only noise I get is a slight squeal when I put my foot on the pedal.
Free play in the pedal is fine, feels good on the pedal as well.
Everything went together nicely, I got the friction plate all centered up. As for fitting the friction plate, the boss bit that projects from the middle is pointed towards the gearbox.
The gearbox itself was in full working order when it was taken off the donor so I don't have any worries there.

The only thing I didn't do was change the pressure plate; as the manual said, if there's no damage or scoring, then leave it? Could this be where I've gone wrong? Either that or I've got the wrong clutch on there. I just bought a replacement for a 1.6D Mk1 caddy (it's a 210mm). Maybe I should have bought the clutch for the gearbox?

What engine is fitted?
What is the gearbox from?
yeah as far as I know you match the clutch to the gearbox

The engine is a 1.6D
The box came from a 1.8 8V petrol

I've done a quick check and if I were to order one from say, eBay; the part numbers for clutches, so therefore the clutch itself are the same.

Nope, that's wrong. Just had a proper check and the part numbers between the 1.6d clutch and the 1.8 8V clutch are different so turns oh thats the likely cause of the problem, wrong clutch!!

Schoolboy error

You beat me to it mate!
Haha, best get cracking pal!
Should be an easy fix though!

Yeah, now I know what I'm doing. Just a pain in the backside I have to do it all over again purely because I didn't check before hand.

Happens to all of us at some point,
Should be nice and easy now!

either clutch will work, the difference is in the diameter of them. all you need to do is make sure the flywheel is the same diameter as  the clutch you buy. you bought a 210mm clutch kit so the flywheel must be too otherwise it wouldnt have gone over it!

what it could be is the clutch kit you bought actually had a mk3 2.0 8v or mk2 16v friction disc in it, these have a larger spline in the middle. so if you fit an 8v box it just rattles around!

Okay, just dropped the box AGAIN. had a look at the clutch plate and it turns out the center boss splines don't fit the main shaft splines. The clutch plate boss is slightly too big!!

turns out you were right Rubjonny,  I've been sent a MK2 16V clutch, but thankfully, got the correct one coming out today on a 24hr.

boom! i wonder if someone did a cheeky swap and return job, ive heard of people buying 8v and 16v kit  to get the 16v pressure plate and an 8v friction disc, then returning all the unused stuff.

16v pressure plate is stronger see, but that only applies to genuine vw kits sachs and the like use the same pressure plate for everything

rubjonny said

16v pressure plate is stronger see, but that only applies to genuine vw kits sachs and the like use the same pressure plate for everything

From “NO DRIVE!”

I'm having a problem here with my Sachs clutch, the pushrod doesn't seem to push the pressure plate off the clutch enough. It's a brand new Sachs clutch kit. It works but its hard to get into gear and bite point is about 10mm off the floor. 

It seems as if its not pushing the release plate and pressure plate far enough away. Could it be that the Sachs pressure plate springs are slightly (a few mm) further back? Making it hard to disengage the clutch? Or is it the wrong release plate, slightly deeper? Causing the same problem?

I'm thinking of just taking it all back off :-( and re fitting the genuine pressure and release plates. And just using the new Sachs friction discs. Could I be a victim of this 16v/8v buy and return thing?? 

check the release arm, release bearing and pushrod are all ok:
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