WELL I DONT KNOW WHAT IT IS WITH ME AND VOLKSIES BUT I SEEM TO RUN INTO PROBLEMS THAT NO ONE HAS A IDEA HOW TO HELP ME....GGRRR

LETS JUST SAY IVE DONE A IRS CONVERSION AND NOW INSTALLED A IRS BOX "PAZZANS OLD BOX" WITH LATER STYLE THROW OUT BEARING..THE REAR OBVIOUSLY WAS A SWINGER WITH THE EARLIER T/O BEARING SO I TOOK THE RING AND SPIRAL WASHER OFF THE THE PRESSURE PLATE AND NO MATTER HOW MUCH I ADJUST THE CLUCH UP THE GEARS JUST WILL NOT INGAGE..EVEN IF I START IT IN FIRST WITH THE CLUTCH IN, THE GEAR GRINDS AND POPS STRAIGHT OUT WITH MY FOOT STILL DOWN...WTF????? THEN WHEN I SWITCH IT OF AND TRY AND GO THROUGH THE GEARS THEY JUST WONT BUDGE....

IT STILL HAS THE SQUARE COUPLING ON THE SHIFT ROD...

WELL HOPE SOMEONE CAN HELP,ITS BEEN A POOP WEEKEND, WEATHERS GREAT AND IM STUCK TRYING TI FIGURE THIS OUT.....NOT TO MENTION I INSTALED THE ENGINE YESTY THEN A PISTON OR TWO WAS HITTING THE COPPER HEAD GASKETS,SO OUT IT CAME THIS MORN...THEN BACK IN AGAIN...

bumpsy, thought id get some brains ticking...

anyways, a friend said maybe the hockey stick isnt aligned properly prior to instalation.... ????

its in my bug,and the box came out of pazzans race beetle ...

No, there’s something weird going on there mate. Sounds like you have a couple of problems. I like the hockey stick thing, perhaps combined with the stick and lockout plate position which may have to be re-set. The first thing is to get it going in and out of all gears nice and smoothly without the engine in, or running, then go for the clutch issue.
As for the clutch it seems you may not be able get the clutch to release for some reason. There are usually 4 reasons for this.
1 – The throw out bearing isn’t pushing the clutch diaphragm in far enough. (see below)
2 – The flywheel isn’t running true, something jammed between the flywheel and the crank on one side or the surface was ground out of square etc, makes the clutch plate drag, it happens.
3 – The clutch plate centre spline is “bent” so the plate runs out, usually from an “incident” during engine removal or install, again, causes the clutch plate to drag. Try putting the clutch plate on the shaft and spin it, you’ll see if it’s badly bent.
4 – The motor isn’t bolted up correctly, yes, that happens too, strange as it may sound I’ve seen them jammed out on one side.

Me, I’ll go with number 1. I’m no expert on IRS clutch setups but I suspect you’ve got one of the parts wrong somewhere. You are using the IRS throw out bearing and it’s carrier? Have a close look and make sure you’re using all the correct IRS stuff, not a combination. Then double check everything.
Good Luck

1500s, i have got the sleeve on,...

where is dangerous when u need him.......

i put the clutch and pressure plate on with a input shaft, check....

engines all the way in, check.....

bowden tube has correct bend in it, check.....

tried varies clutch adjustments and now have it adjusted up to one inch free play, check......

hockey stick isnt sitting in its groove properly,,hhhmmm...

is there such thing as different shift rod lenghts when going from swing axle to irs....????

and why could i get gears with the car off but not when it was on,,hhhmmm????

DANGEROUS.........WHERE ARE YOU.....

Another thought. Without trying to get into any gear, can the engine start and run when the gears are at neutral position or does it stall when you let the clutch out? By the way, what area are you in? Profile update could get help easier!

DH

engine runs fine....and .im in perth......

maybe ill try a bigger bend in the bowden tube.....

the clutch fork,t/o bearing and sleave havent been touched in the bellhousing...thats how pazzan had it and thats how i installed it....

confussing one......

ill have a play tomorrow arvy... thanks for the help so far....

I know you said most of it back in post 1 but better to run through it again to be sure!

NOW

Pull the engine and replace the pressure plate as there doesn't seem to be anything else you have modified (your words: took ring and spiral washer off). Also, what about the shift rod again. Is the coupler right home on the hockey stick and the set screw in place?

DH

okay thanks boys, ill check the things that dont involve the engine coming out first today in the arvo .then ill get back to you...

oh one thing,,when i was swing axle i kept turning diaghrams inside out even when i had factory spec and a bit less adjustment on the clutch.so i went to alot more free play and it seemed to fix that....dont know if that has anything to do with it....

I'm wondering if it got jambed in two gears at once during transport??? Seen it before.

You said the gearbox is grinding and popping out of gear even with you foot on the clutch. It shouldn't pop out of gear even with you foot off the clutch, sounds like something to do with the gearbox more so if you ask me. Not saying the clutch is disengaging properly either. I think you need to pull the engine out for starters :-(

Sorry I cant help anymore, Kev

bummer.

alrighty, everything will come out by the weekend and ill update then.....better not be the box....

thanks guys..........

everything is back in and running great...

anyways the problem was the input shaft, the gradual step up to the splines "part" was interfering with the gland nut bearing, so the input shaft was spinning with the flywheel...out came the sanding disc and off came the unwanted material....didnt need much though....

thanks guys for all the help, muchly appreciated....

Looks like the lolly pop goes to Dangerous. Good call Dave. I think we’ve all learned something. That’s what forums are for. Good luck cnfabo.

nice to hear he is enjoying the gearbox now running like a dream

yep, thanks paul....ratios are very fun,and the revs are not any higher on the freeway then when i had my stock box.. but i sold my street tyres and fuchs to afford the box,so now im running my semi slicks on on the street..: bad idea..