Clutch issue [Archive] - Saxperience

Jonathancilia

22nd April 2019, 14:12

Hi, my saxo is having trouble going into gears, particularly first and reverse lately. I already changed the clutch cable cause i have thinked that it was faulty. It was good for about 3 days but today its grinding reverse again and first is difficult to go in. I think its the clutch now. Car has only 85k kms. I think it has the factory clutch still. The adjustment in the cable is almost all the way back, does this mean its almost worn all the way?

I adjusted the clutch abit higher than the brake pedal for now and its a bit better but still grinds abit and when car is off gears go in smooth so i dont think its the gearbox. What do you guys think?

Jonathancilia

22nd April 2019, 18:43

Is CIS a good clutch brand?

Jonathancilia

22nd April 2019, 19:38

Is the saxo 1.5D mk2 clutch, 200mm or 180mm? Are there any other variances between?

MartinObviously

22nd April 2019, 22:12

Is the saxo 1.5D mk2 clutch, 200mm or 180mm? Are there any other variances between?

1.5D clutch is 180mm, they're specific to the diesel from what I can remember.

1st and reverse being difficult is normally a gear linkage issue, I'd be checking that system first.

A worn clutch won't normally give you a crunch because the wear gives more clearance.

Jonathancilia

23rd April 2019, 03:52

Linkages are all new. Is the flywheel bolts spaced evenly on the mk2 diesel?

Jonathancilia

23rd April 2019, 09:47

I can not fit a 200mm clutch instead of 180mm? Is the flywheel not big enough for the diesel to accept a 200mm clutch. The reason i ask is because i found a good valeo clutch on ebay and he says it fits my car. It has a pressure plate with evenly spaced bolts and a 200mm clutch disk

Jonathancilia

23rd April 2019, 12:36

I found a sachs clutch kit. Its 180mm clutch disk with the pressure plate evenly spaced. Are the release bearings all the same or are there any differences ?

Jonathancilia

23rd April 2019, 17:10

https://www.ebay.com/itm/Metro-115D-Citroen-AX-ZX-Saxo-1-5D-Peugeot-106-1-5D-Sachs-Clutch-Kit-NOS/153436496825?_trkparms=aid=111001&algo=REC.SEED&ao=1&asc=56922&meid=e81706af4f3040adbbf5e49457238f20&pid=100675&rk=1&rkt=15&sd=153436496825&itm=153436496825&_trksid=p2481888.c100675.m4236&_trkparms=pageci:459e3719-65ea-11e9-856d-74dbd180dccc%7Cparentrq:4b2aa6b316a0ace085205358ff facc0b%7Ciid:1&redirect=mobile

This is the clutch that im interested in buying but noone on ebay seems to know what fits the diesel

MartinObviously

24th April 2019, 22:11

Sorry for being slow

the 200mm clutch wont fit, the diesel clutch plate sits recessed into the flywheel.

To fit a 200mm clutch, you would need to fit the flywheel from a petrol engine.

Jonathancilia

25th April 2019, 16:08

Ok, i bought a sachs 180mm clutch kit, if it will give me trouble i will replace it

MartinObviously

25th April 2019, 21:29

Ok, i bought a sachs 180mm clutch kit, if it will give me trouble i will replace it

As long as it is a diesel 180mm kit and not a petrol 180mm kit then it'll be fine.

Jonathancilia

26th April 2019, 09:13

I bought the one with the holes evenly spaced around the pressure plate

MartinObviously

27th April 2019, 10:26

I bought the one with the holes evenly spaced around the pressure plate

the 1.5D clutch is its own clutch, the flywheel is totally different to the petrol.

The locating dowels are all evenly spaced across all years of 1.5d

Jonathancilia

27th April 2019, 12:51

Then its the correct one i ordered, thanks :) when the cable adjustment is all the way back almost, does this mean that the clutch disk is worn almost? I think the previous person slipped the clutch alot

MartinObviously

27th April 2019, 22:31

Then its the correct one i ordered, thanks :) when the cable adjustment is all the way back almost, does this mean that the clutch disk is worn almost? I think the previous person slipped the clutch alot

Yes I'd say so :)

could be a number of things though, cable stretch, worn nylon fork bush etc.

It will be good with the new cable and clutch I'm sure

Jonathancilia

27th April 2019, 23:08

Yes I'd say so :)

could be a number of things though, cable stretch, worn nylon fork bush etc.

It will be good with the new cable and clutch I'm sure

Haha i thought so
The previous owner was an old man i think he slipped the clutch alot but anyway i will change it when the clutch arrives.

Thanks for the help :)

Jonathancilia

5th May 2019, 12:45

This is an odd one, today i went out to investigate the linkages. And what do i find ?

I found the lower small linkage where it attaches to the gearbox ball joint, the welds knthe ball joint broke and its bent. Which i think in turn is making it hard to shift. Is this true?

And tk my surprise i found that the linkages have play in them already, they havent seen even 5000 miles. And they are of a good "sasic" french brand. Any advice on a good set of linkages ?https://uploads.tapatalk-cdn.com/20190505/cedfaaf2944288bfe47fdc2428d73c4c.jpghttps://uploads.tapatalk-cdn.com/20190505/839149abf972b76b48bae59694b29f60.jpg

Sent from my SM-T560 using Tapatalk

MartinObviously

7th May 2019, 21:07

Yes that being bent won't help at all

The linkages will always have a bit of play in them. just pop some grease on them an re-fit

Jonathancilia

8th May 2019, 12:10

Thats what i did. Now all gears go in good. But reverse still crunching abit, is this normal with saxos ? If you try to put it in revrrse immediately after pushing the clutch it will grind like hell but if you stay with the clutch pushed in for 4 seconds or 5 it goes in with just a slight crunch

Sent from my SM-T560 using Tapatalk

MartinObviously

8th May 2019, 20:30

Thats what i did. Now all gears go in good. But reverse still crunching abit, is this normal with saxos ? If you try to put it in revrrse immediately after pushing the clutch it will grind like hell but if you stay with the clutch pushed in for 4 seconds or 5 it goes in with just a slight crunch

Sent from my SM-T560 using Tapatalk

That's correct yes, there's no synchro on reverse.

Also when selecting reverse, you have to go to the right first, then pull it straight back. If you try to put it into reverse like a curve then it will crunch. There's a diagram in the handbook showing you how to do it :)

http://i68.tinypic.com/11c6vdt.png

Jonathancilia

8th May 2019, 20:32

Hehe thats neat! Never seen this handbook before

Sent from my SM-T560 using Tapatalk

MartinObviously

8th May 2019, 20:36

Yeah it's the manual for the MK3 106

https://www.dropbox.com/s/fkwex1oi6ii1b4z/2001-5-peugeot-106-64808.pdf?dl=0

Jonathancilia

9th May 2019, 15:44

Nice its interesting, thanks for sharing !

Sent from my SM-T560 using Tapatalk

Jonathancilia

23rd May 2019, 18:43

All was well for 2 weeks but today it went to being difficult to engage gears again, dont know why. Sent from my SM-T560 using Tapatalk

Jonathancilia

23rd May 2019, 18:47

Im thunking maybe i can try to install a set of solid gear linkages from constella, the gear lever seems abit sloppy, and the selector arm has alot of play in and out Sent from my SM-T560 using Tapatalk

MartinObviously

23rd May 2019, 20:29

Im thunking maybe i can try to install a set of solid gear linkages from constella, the gear lever seems abit sloppy, and the selector arm has alot of play in and out Sent from my SM-T560 using Tapatalk 

Don't install them, you must have another issue.

Have you checked the roll pin which holds the arm onto the gearbox?

Or the main selector (with the rubber ball)?

Jonathancilia

24th May 2019, 00:40

The roll pin is fine its not out of the hole at all its just moving in and out, and the ball was replaced just a few months ago, about 8 months or so Sent from my SM-T560 using Tapatalk

Jonathancilia

24th May 2019, 01:42

I read on here that someone just welded the selector arm to the shaft, is this ok to do? I tried to look from the passenger side wheeel arch and the extensions doesnt line up to the gearbox, the tearbox is more low on my car, or do i need to jack up the gearbox aswell? Sent from my SM-T560 using Tapatalk

Jonathancilia

24th May 2019, 11:48

https://m.youtube.com/watch?v=JqM-beEmGAE My selector arm has play like in this video. Sent from my SM-T560 using Tapatalk

MartinObviously

24th May 2019, 18:17

If it is just like in the video, then the pin has wonr the hole on the selector.

Yes you can weld it.

Jonathancilia

24th May 2019, 18:23

Its not that bad, mine only has a bit of play in and out and side to side. But the pin is all the way in the hole and doesnt move when i move the arm Sent from my SM-T560 using Tapatalk

MartinObviously

24th May 2019, 21:24

Its not that bad, mine only has a bit of play in and out and side to side. But the pin is all the way in the hole and doesnt move when i move the arm Sent from my SM-T560 using Tapatalk 

The pin doesn't wear the outside part, it's the inner part! It makes the hole in the actual lever coming out of the box larger.

Jonathancilia

24th May 2019, 21:26

Oh crap, the only problem i have with this is there is absolutely no good access to get the pin out. Everything is in the way. Sent from my SM-T560 using Tapatalk

Jonathancilia

24th May 2019, 21:27

So i would imagine that putting a new pin wont fix this as it still will be a larger hole on the inside part, i think you need to redrill the arm to fit a bigger pin right ? Sent from my SM-T560 using Tapatalk

MartinObviously

25th May 2019, 15:49

So i would imagine that putting a new pin wont fix this as it still will be a larger hole on the inside part, i think you need to redrill the arm to fit a bigger pin right ? Sent from my SM-T560 using Tapatalk 

Spot on, that's what you need to do :)

or weld it :P

Jonathancilia

25th May 2019, 16:08

Spot on, that's what you need to do :)

or weld it :P

I think ill weld it thats easier haha

Jonathancilia

26th May 2019, 07:34

So this is what i did today. I went out. Pushed the pin out from the wheel arch with an extension. Now the selector arm has one hole which is ovalised. The other is fine and measures at 4.5mm. the ovalised one is a bit bigger. The shaft on the gearbox has bigger holes. They are around 6.3mm. and the arm has around 1mm play in and out. The pin is damaged also. It is split on one part. Now this is the plan. Drilling the selector arm holes at 6mm. And fitting a bolt with a nyloc nut on it and do it very tight. Also im going to put a 1mm spacer behind the selector arm. What you think of this ? Also might aswell replace that leaking selector shaft seal now that i have the chancehttps://uploads.tapatalk-cdn.com/20190526/5c796eed2bc415885b4f5dea18140e34.jpghttps://uploads.tapatalk-cdn.com/20190526/a056ffaf3f7292856beba89d512817c9.jpghttps://uploads.tapatalk-cdn.com/20190526/6975dc808a420073f96983ae6d3dce53.jpghttps://uploads.tapatalk-cdn.com/20190526/3e245b02e2b3e02ba99857c0e48d848b.jpghttps://uploads.tapatalk-cdn.com/20190526/ffc49a595870dbd309e8adf3b70e24d3.jpg Sent from my VFD 510 using Tapatalk

Jonathancilia

26th May 2019, 09:18

Sorry my measurements were wrong. All holes are about 6.8mm or 7mm. The only problem is there is 1mm play between the arm and the gearbox So i probably need a 1mm spacer Sent from my VFD 510 using Tapatalk

MartinObviously

26th May 2019, 09:38

Don't worry about the in/out play. If you try and take up the slack it'll be stiff to get into gears. it's internal wear.

However drilling the hole is a good idea. You should drill through so both holes are the same size.

So if they're 6.8mm use a 7mm drill on both, then use a bolt with a long plain shank. If it's threaded all the way through they fill flatten and play will come back quickly. :)

Or you can get a bigger roll pin.

Jonathancilia

26th May 2019, 09:44

Ok i will drill it to 7 and get a 7mm pin I read somewhere on this forum that someone used a washer to take up the slack. Mine doesnt have play left and right. Only in and out Sent from my VFD 510 using Tapatalk

Jonathancilia

26th May 2019, 09:47

Yeah thats what i thought. I will get a bolt 7mm with a plain shank then and a nyloc nut Sent from my VFD 510 using Tapatalk

Jonathancilia

26th May 2019, 19:06

Also the selector shaft seal is not flush with the gearbox. Its recessed inside the hole. I think this is a part of my i have leaks from here Sent from my VFD 510 using Tapatalk

Jonathancilia

28th May 2019, 12:22

I fitted a 7mm bolt with a plain shank. And fitted a very thin washer about 0.8mm or so. Now there is no in and out play and i used a locknut to tighten everything. All is better now gears are so smooth and precise. No more grinding While i was there i greased up all the linkages and the ball also. Selector shaft seal im not sure how im going to remove it. Its in the hole pretty good. Only way i think i need to screw in 2 screws and lever it Sent from my VFD 510 using Tapatalk

MartinObviously

28th May 2019, 16:39

I fitted a 7mm bolt with a plain shank. And fitted a very thin washer about 0.8mm or so. Now there is no in and out play and i used a locknut to tighten everything. All is better now gears are so smooth and precise. No more grinding While i was there i greased up all the linkages and the ball also. Selector shaft seal im not sure how im going to remove it. Its in the hole pretty good. Only way i think i need to screw in 2 screws and lever it Sent from my VFD 510 using Tapatalk 

At least you can get into gear now though! :y:

Jonathancilia

28th May 2019, 16:58

Yeah thats the main thing haha thanks for the help mate ! Sent from my VFD 510 using Tapatalk

Jonathancilia

3rd June 2019, 08:53

I swear that this car has sworn in getting on my nerves. Today iwas at a stoplight and the gears became so stiff. I couldnt s3lect first gear, i had to slip the clutch to get going with second gear. Reverse doesnt stop at all when selecting. Grinds like hell. Could this be an issue with the clutch release or something ? Or is this something bad inside the gearbox?. Gears go in fine when car is off Sent from my SM-T560 using Tapatalk

MartinObviously

4th June 2019, 17:09

I swear that this car has sworn in getting on my nerves. Today iwas at a stoplight and the gears became so stiff. I couldnt s3lect first gear, i had to slip the clutch to get going with second gear. Reverse doesnt stop at all when selecting. Grinds like hell. Could this be an issue with the clutch release or something ? Or is this something bad inside the gearbox?. Gears go in fine when car is off Sent from my SM-T560 using Tapatalk 

Absolutely no idea man :/ it's weird

Jonathancilia

4th June 2019, 17:52

Yeah. I booked it to a garage to change the clutch next week. Will see then Sent from my VFD 510 using Tapatalk