MK3 clutch/gearbox mystery issue, urgent help needed!

[Bakas]

Hi all, greetings from Vilnius Lithuania!

After living in China for 5 years I decided come back to Europe and make a long roadtrip. I love cars and stuff made in the 80' so I got myself a very clean MK3 Westfalia camper.

The gearbox at first was a bit hard to work and sometimes it would not release first or reverse gears. Clutch pedal pressed in all the way and the van would be still pulling until I turn off the engine. Basically the clutch is not disconnecting the engine. We changed clutch pedal, cable and the whole clutch. It helped at first but after 2000 km the problem reappeared..

We were supposed to head out to Carpathian mountains a week ago but cant find solution to this.. !

Anyone has ANY thoughts on this? Can it be a faulty gearbox or some of the new parts came from a bad batch maybe? Any ideas are VERY appreciated!

Thanks and best from east side,

Bakas

[Bakas]

I should have noted that its a 2.5 diesel engine thats been upgraded with a turbo + intercooler.

[dumptruck]

Clutch release arms can bend / flex and sometimes break. When they are at fault, the arm does not give enough movement to operate the clutch fully.

The later Mk5 arms with the heavy weight on the end are more prone to this problem, the earlier more simple mk3 / mk4 design are more robust in my opinion.

Are you still running the original engine / box with turbo upgrade? or a later turbo engine and / or box?

Gearbox oil is another place to look, level ok? recently changed? Had issues getting my old box into 1st when cold but improved when warmed up, checked level and was really low. Filled up with approx 1.25 litres or MT75 gearbox oil and was as good as new!

[Bakas]

Thanks Dumptruck,

Clutch release arms can bend / flex and sometimes break. When they are at fault, the arm does not give enough movement to operate the clutch fully.

Is this the place where the other end of a cable plugs into?

The later Mk5 arms with the heavy weight on the end are more prone to this problem, the earlier more simple mk3 / mk4 design are more robust in my opinion.

Are you still running the original engine / box with turbo upgrade? or a later turbo engine and / or box?

The engine seems original, not sure about the gearbox.. It has some sealant around it indicating someone has worked on it recently..

Gearbox oil is another place to look, level ok? recently changed? Had issues getting my old box into 1st when cold but improved when warmed up, checked level and was really low. Filled up with approx 1.25 litres or MT75 gearbox oil and was as good as new!

Gearbox was full of oil and not leaking.

[dumptruck]

Clutch release arm is where the end of the clutch cable is attached, gearbox end.

Search previous forum posts for ' clutch arm ' and you'll find more info and pictures of that part.

[dumptruck]

viewtopic.php?f=4&t=78638&hilit=clutch+arm+snapped+release

[Bakas]

Clutch release arm is where the end of the clutch cable is attached, gearbox end.

Search previous forum posts for ' clutch arm ' and you'll find more info and pictures of that part.

Yup, we checked that part, it was fine. The problem only happens when it heats up and its irregularity really annoys me. Id drive the garage, the mechanic would drive it around with no faults and then it would come back next day in traffic or backing up when parking.. Also, when cold the clutch pedal starts to react half way and when warmed up its almost right at the bottom, not sure if that has anything to do with it.

[BROWNYS V6]

when you replaced the clutch, did you fit a new spigot bearing in the end of the crankshaft ?

[Bakas]

when you replaced the clutch, did you fit a new spigot bearing in the end of the crankshaft ?

Yes sir, the whole kit was replaced. Leaves only the gearbox right? So far we have drove 2000 km on some very bad Ukrainian roads and the problem has slightly intensified but only occurs when operating reverse or first gear in traffic, so are keep going towards Moldavia.

[chasnjess]

when you replaced the clutch, did you fit a new spigot bearing in the end of the crankshaft ?

Yes sir, the whole kit was replaced. Leaves only the gearbox right? So far we have drove 2000 km on some very bad Ukrainian roads and the problem has slightly intensified but only occurs when operating reverse or first gear in traffic, so are keep going towards Moldavia.

Had a similar problem with our mk3 Autosleeper Flair had a cheap clutch fitted same problem, replaced again with same make clutch but with new spigot bush. it helped but again after very very short time same problem occured After a lot of frustration and wondering what could be the problem a different garage said it was probably a cheap clutch giving me the problem. We replaced with a LUK clutch and spigot bush and have now driven a few thousand miles without a problem (fingers crossed).
apparently this was a problem on black cabs using cheap clutch GOOD LUCK.....Bruce

[BROWNYS V6]

have you checked the clutch cable ?

[Bakas]

So after 3 solid years of gearbox acting a little funky and not releasing the reverse gear sometimes - it finally got worse. Gearbox developed a HUGE knocking noise and need urgent repairs. I have tried to find a replacement but it seems all the mk3 non aluminum gearbox are gone together with the MK3's..

I really love my camper and want to keep ride and ride it.

Anyone has an idea if these boxes are repairable? Is it a huge big job?

Thanks!

[gotgcoalman]

Is it a type 9 box?

Look for a MT75 box and prop

[cherniy_chack]

Bakas,do you understand Russian?
I'm on the eastern side, from Ukraine.

[Bakas]

Yes it looks like a type 9 box. Fully extinct here in Lithuania..