Reverse gear reluctance.

[kevtherev]

It has recently become impossible to select reverse gear with out horrendous grinding.
It used to be a little crunch but now it's hopeless.
It can only be selected (smoothly) with the engine off.
First gear is ok but does sometimes need an effort to select.
Second is ok as is third and fourth.
Is this an internal issue?
I have renewed the linkage support and bellows, a few months ago, but it was ok then and selected fine.
Is there a method of setting up the linkage to be sure it's not this?

[Mocki]

Haynes has the set up procedure, and the wiki
http://wiki.club8090.co.uk/index.php/Ma ... o_front.29" onclick="window.open(this.href);return false;
But really, speak to Aidan ....

[multisi]

Sounds more like a clutch problem.

[937carrera]

Sounds more like a clutch problem.

+1

There's no synchro on first & reverse on most gearboxes too

[weimarbus]

+2 , definitely sounds like a dragging clutch, or seizing needle bearing in the crankshaft ( behind the flywheel), it always starts with reverse first then 1st gear later.

[DoubleOSeven]

Clutch. Pull that gearbox - 4 nuts, not too challenging and change it. 2 hours.

[kevtherev]

Ok I'll take the advice and look at the clutch dragging.
I'll come back with my findings.

[937carrera]

Simple stuff first, start by bleeding the system, just to make sure there's no air in there, check for fluid leaks from the master & slave cylinder. If they have internal problems the clutch will not have the full movement requred

[itchyfeet]

2 hours.

Maybe on a ramp or with two people and experience but never on your own or on the ground.

Last time I pulled my gearbox was because I had just refitted it and the clutch bearing had slipped off the arm ( make sure you don't make this mistake) So I knew what I was doing, had all the tools at hand and it still took me 3 1/2 hours with no cleaning up or any extra work.

[937carrera]

Have a read here too

http://forum.club8090.co.uk/viewtopic.php?p=8042010

[kevtherev]

Update.
I think I do have a very very light drag.
Not enough to affect the engine rpm but enough to disrupt the gearbox changes.
Reluctant in reverse stiff into first and second unless the van is moving and a little crunch into 3rd plus a notchy 4th.
I would appreciate some thoughts on that.

I have bought an ASM code 5 speed box with the gate and stick. (88,000m)
This code was fitted to later DG vans so it has a very tall first same ratio 5th as my old 4th.
I might utilise it to fit a bigger tyre diameter.
Killing two birds...

[Mocki]

Clutch. Pull that gearbox - 4 nuts, not too challenging and change it. 2 hours.

4? Not bothering to undo the starter, , gear linkage , driveshafts , slave or nose mounting then?

It’s a four hour job if everything comes undone easily .... if

[937carrera]

Update.
I think I do have a very very light drag.

...but why...... is the friction plate sticking, the needle bearing holding or the clutch lever movement insufficient due to a hydraulic issue ?

I have that box in my van. 1st becomes a bit of a crawler gear, or is used for snappy getaways around time, with a long pause up to second. If you put bigger tyres on you might just end up changing down more when you are going up hills

[kevtherev]

Update.
I think I do have a very very light drag.

...but why......

I don't know yet.
I suspect a worn arm.
As for the bigger tyres, I aim to incease the diameter by 3% to allow the DJ to be liberated from DG gearing.
Having the power to do so, and retain a snappy start.

[937carrera]

Just rechecking, I actually have the 3H box in my A/S, very similar gearing to the ASM though.

I'll say it quietly, but the DK box from the 2.0 a/c has the longest top gear, about 3.7% longer than the ASM and the better change. Bags of torque with a DJ to pull that.