2G Transmission in a 1G Issues

[fourgsixthree33]

Posting for a buddy of mine.

Friend was driving a couple months ago (92 TSi FWD 6 bolt 5 speed). He heard a bolt fall to the ground. Stopped at a stop sign. Accelerated, car bucked and he pulled over. Car was towed home.

He pulled the tranny out, the pilot shaft for the throw out bearing had snapped off from rubbing against the input shaft. Got a new tranny installed. Wouldn't go into gear without slamming gears. He thought it was the clutch alignment causing the problem.

Bought a new tranny because this one had broke from slamming gears. So now we have this 97 GST tranny. Did all the mods to make it work in a 1G. Installed tranny. Bleed the clutch system, car wouldn't go into gear with clutch pedal pushed in. Upon more bleeding, we discovered the master cylinder was leaking into the cabin. Replaced the master cylinder.

Bleed the clutch 15,845 times (all methods including using a rubber hose from the bleeder screw to a cup full of brake fluid). Same outcome, car will not go into gear while running.

We noticed a faint grinding noise with the car running and clutch pedal pushed in. It feels like the pressure plate isn't disengaging the clutch.

The bolt that snapped with the first transmission is still inside the block where the lower transaxle to engine bolt right above the slave cylinder. There is about 1/4" or less gap between the engine and transmission where this bolt is. Could that be the problem?


All bolts were torqued to spec.
Clutch system was bleed properly.
Replaced master cylinder.
Replaced slave cylinder.
Clutch was properly lined.
All necessary mods for the use of the 2G transmission on a 1G were completed.

Thanks in advance.

 

[19Eclipse90]

The bolt that snapped with the first transmission is still inside the block where the lower transaxle to engine bolt right above the slave cylinder. There is about 1/4" or less gap between the engine and transmission where this bolt is. Could that be the problem?

Yes.

 

[DSM Jeff]

Yea, there should not be any kind of gap between the engine/starter plate and the transmission. You need ALL of the bolts holding the trans and engine together or you'll run the risk of ruining the bell housing, clutch, flywheel and starter, and even the block. (I know this because that's how I bought my last 1g, which made it very cheap, )

 

[fourgsixthree33]

Thanks for the replies guys. We are pulling the engine out with the transmission so it will be easier to drill out the snapped bolt and to bolt the transmission to the engine.

We will update.