getting stuck in reverse

MostlyMonki · Posted: Sat Aug 02, 2008 3:07 pm Post subject: getting stuck in reverse

need some help with this one guys...

whenever i put my bug (ej20, bus box, shift rod over the tunnel) into reverse it gets stuck there. if i pump the clutch fast i can get it out (with a bit of a crunch) but not otherwise. my other gears are better, with 3rd and 4th being fine, and 1st and second ok but a little tricky to find/get in sometimes.

does anyone know why this might be happening (specifically the reverse thing)? i'd have thought that if it were a clutch problem then all gears would be effected rather than just reverse.

obviously i have a hydraulic set-up, using rjes belhousing/slave bracket, with t25 slave cyl and the rest of the stuff is from a Saco hydraulic clutch kit.

the system is properly bled with fresh fluid.

need some ideas here please as i'm stuck!
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'72 Ratty Bug - Subaru EJ20 Turbo motor.

13 window deluxe · Posted: Sat Aug 02, 2008 3:34 pm Post subject:

sounds like the clutch is dragging from what your saying with the pumping up bussiness is the slave cylinder the same bore as a stock t25? might be to same need a few stokes to move enough fluid?
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1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,

previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi

MostlyMonki · Posted: Sun Aug 03, 2008 4:29 pm Post subject:

not sure what bore the master cyl is to be honest. but if the other gears are engaging ok i'd have thought that was ok? the weird thing it that even if i turn the engine of, i still need to pump the clutch to get it out of reverse...

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'72 Ratty Bug - Subaru EJ20 Turbo motor.

rjes · Posted: Mon Aug 04, 2008 5:48 pm Post subject:

I imagine 13 window's suggestion could be right, although if it is clutch drag, it must be very slight as you can't tell in other gears. Remove the inspection cover on the bottom of the bell housing while someone else holds the clutch right down (without having pumped the pedal), with the engine off. Does the pressure plate move clear of the (uncompressed) disc by a reasonable amount (at a guess, 0.5mm or more?). If so, it's not clutch travel related. If not, it may well be.
Whatever the bore and used stroke of your master cylinder, it needs to give a slave cylinder stroke of around 20mm (or 10214mm^3 fluid displacement) according to my notes from when I designed the bell housings.
Also note any master cylinder will give a fluid displavement of slightly less than 'used stroke x piston area', due to the internal valving.

Pumping the clutch shouldn't give an increase in travel. If it does (try it while watching from underneath, as above) I'd suspect the master cylinder piston seal.

Assuming you've not used the box before installing it in the Beetle, it could also be a gearbox fault, or it could be the shift linkage binding on something.
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Richard,

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ElusiveStranger · Posted: Mon Aug 04, 2008 10:37 pm Post subject:

10214mm3... just over 10cc then Wink

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