Will not go in gear when running and clutch feels soft?

Hi guys,

I took the 5-speed 020-box of my old 1,5 JB engine, where it ran perfectly with a 190mm clutch and flywheel.

The box is now mated to a 2 litre AGG engine and fitted with a brand new 210mm Sachs cluth and new 210mm flywheel.

It is possible to get it in all gears when the engine is turned off, but when engine is running, then I cannot select any gears.
Also the clutch feels very soft and it is very easy to lift up the release arm by hand at the gearbox.
There is no noise when pressing the clutch or releasing.
I tried putting it into gear and starting the engine and when lifting the clutch the car instantly took off flying and stalled…

I spoke to a mate who is a mechanic and he said that it would either be clutch release bearing or clutch plate installed wrong.
I did not change the release bearing. I would be surprised if the clutch was fitted wrongly, but cant be sure.
Would this cause the issues described above?

I am thinking about trying to pry of the end cap and having a look at whats behind and of course changing the release bearing.
Would a damaged bearing result in a soft clutch?

I also suspect the clutch cable as it is a non oem and difficult to adjust, but the soft arm tells me that the problem must be inside the box.

Hope anyone can help.

Thanks!

Just read this:
TO Bearing

If i cant get the release arm to more than 9:00 or horisontal, does it mean that the clutch fitment is OK?

At what point is the clutch released by the release arm? By 9:00 or further up?

Ps. The box oil was also changed before box fitment.

Thanks again.

I had this problem once on an old mk2 Polo, it turned out the the clutch cable arm was starting to shear. It hadn't totally broken, but was enough to stop me getting it in gear. It might be worth a close inspection of the arm?

mike.d1979 said

I had this problem once on an old mk2 Polo, it turned out the the clutch cable arm was starting to shear. It hadn't totally broken, but was enough to stop me getting it in gear. It might be worth a close inspection of the arm?

Hi Mike,

Thanks! Every input is welcome.

Did it shear inside the box or outside on the arm? Do you remember whether you were able to get the release arm horisontal to the 09:00 position with this errror?

I will have a closer look the next time i will go to the car.

It sheared where it met the casing, if that makes sense. I can't really remember about the arm position. It was a few years ago now

Sent from a phone, please excuse all the medium steaks. Stupid autocorrect!!