Hi guys,

 

91 Legacy 1.8 with 5spd Dual-Range MT (cable clutch) and 370.000km on the clock:

 

Clutch was done 20.000km ago incl. throwout and pilot bearing (all parts OE).

Yesterday within a 500km drive I noticed the gear shifts getting more difficult and suspected a problem with improper clutch disengagement.

 

I had checked the cable adjustment and it was fine but to be sure I had tightened it up a little more to the point of maximum possible clutch fork movement (fork touching a metal bracket sitting behind). 

Gearshifts were still difficult.

 

What is odd however is that putting it into reverse while the car is stationary is still going smooth. Only forward gears require to double clutch. Also with a gear engaged and the car standing still I can't notice the car crawling.

 

It may be imagination but I also feel the trans (probably input shaft bearing) got noisier within the past time. Can a bad trans bearing cause shifting difficulties similar to bad clutch disengagement?

 

I have a spare trans available in case.

 

 

Any idea folks?

 

 

Thank you

Georg

Edited January 8, 20188 yr by Georg

From your description , I would have to say your trans is shot. Triple check the throwout fork for cracking / bending but.... I'm thinking its DOA

weird - will the engine stall if you dump the clutch in top gear?

 

what kind of gear oil is in the trans? should be NON-synthetic GL-5 I think (I'm not sure about soobs that old)

 

sure seems like a clutch problem, or a shift linkage issue...????

Edited January 8, 20188 yr by 1 Lucky Texan

I was thinking too.... make sure your shift linkage does not have excessive play....  

 

    If  vehicle is not moving...  and in neutral..  if you push clutch in.... will it shift into gears?  all the gears(keeping clutch pressed to floor)?

Hmm in the end it was the transmission itself. Along it's last days there was an audible bearing noise coming up with the clutch engaged.

Runs as good as new again now with a spare trans

I'm glad to hear that it was an easy fix since you happened to have a spare transmission laying around haha, I have a spare engine that came in handy like that once.

Would replacing the input shaft bearing be easy?

Replacing the bearings requires to split the case. I've never done it before but I guess if you replace only the roasted bearing it won't involve any rocket science.

However if I'll decide to repair it in future to have a spare trans again I'll replace all bearings and balk rings which probably will require some shimming.