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Vw 1.9 tdi - Car goes into gear but will not move!! - Roy Brown

Hi,I had a thread up here a few weeks ago where I had considered changing the engine in my Vw Jetta 1.9 Tdi. All went quite smooth for a first attempt, however I have now encountered a problem....

The car got a new clutch kit with flywheel about 1000 miles ago and I had no issues regarding the transmission. However now that I have everything back together and the replacement engine in, I went to reverse the car out of my garage and it wont go anywhere!!

Gears 1,3,5 and R don't really slot in as good as 2+4. Whenever I put the car in gear I just hear a grinding noise

Edited by Roy Brown on 24/05/2020 at 15:30

Vw 1.9 tdi - Car goes into gear but will not move!! - Oli rag
From you saying that some of the gears don’t slot in as well as others, plus the grinding noise you have, I would suspect that the fault lies with the gear linkage.

Not sure if you have rods or cables but have a thorough check of it all for something amiss.
Vw 1.9 tdi - Car goes into gear but will not move!! - gordonbennet

We assume you double checked all dimensions on the new engine and its clutch flywheel and spigot bearing before fitting.

Assuming everything matches then i agree, something is probably out of line in the gear linkage, if you undo a clamp on some designs of linkage instead of say popping a roll pin out it can take a long time to get the linkage adjusted correctly again, what feels like a long movement up at the gear lever translates to micro adjustments of a friction clamp or cable adustment at the gearbox end, both fore and aft and twist motions to think of.

A good poke nose at the linkage for signs of disturbance might provide an answer, and get an assistant to go through the gears (engine off safely blocked) whilst you watch the linkage, hopefully you'll see the problem.

When you say the car doesn't move, does that mean when you engage the clutch in a gear it will select you have no drive at all, if that is the case something isn't right because the clutch isn't locking the engine to the input shaft.

Edited by gordonbennet on 25/05/2020 at 08:40

Vw 1.9 tdi - Car goes into gear but will not move!! - Railroad.

Have you had the driveshafts out? If so have you checked to see if they're both pushed firmly home? If one of them is not correctly engaged into the final drive then you will have no drive.

Vw 1.9 tdi - Car goes into gear but will not move!! - Roy Brown

Cheers for the replies

Its got 2 main cables under the battery tray but ive seen some videos online regarding adjustment so will try it tomorrow

The replacement engine is the exact same code from a car of the same year etc so im not concerned its an issue with sizes of the replacement flywheel - The flywheel only went on the one way and the pressure plate, 'if' I happened to put the clutch in back to front would it cause this issue?

I did have the driveshafts out and took quite a while to refit the longer driver side one so again I will double check that tomorrow but im pretty sure they are within the hubs correctly along with the cups on the gear box

Edited by Roy Brown on 25/05/2020 at 22:56

Vw 1.9 tdi - Car goes into gear but will not move!! - Roy Brown

Should also add I remove the slave cylinder from the gearbox but did not open any lines etc so refitted it without bleeding

Vw 1.9 tdi - Car goes into gear but will not move!! - Big John

It sounds like the clutch isn't fully dis-engaging . I'd suggest looking at the hydraulics first as it sound like they have been disturbed or damaged - first call try bleeding.

What happens if you try and start the car already in gear with the clutch down?

If even gears better than the others (or vice verse) the as above comments gear linkages could be out of allignment.

Edited by Big John on 27/05/2020 at 00:34

Vw 1.9 tdi - Car goes into gear but will not move!! - John F

Gears 1,3,5 and R don't really slot in as good as 2+4. Whenever I put the car in gear I just hear a grinding noise

Is the noise the same with the clutch engaged as when you still have your foot on it? If the engine, clutch and drive shafts have been interfered with but not the gearbox, the fault is unlikely to be in the gearbox, unless the selector mechanism isn't moving far enough to mesh the cogs properly. Did this mechanism have to be disturbed? If the noise only occurs when you engage (take your foot off) the clutch, that's possibly it.

Vw 1.9 tdi - Car goes into gear but will not move!! - blindspot

have an assistant put into gear,while you watch whats happening

Vw 1.9 tdi - Car goes into gear but will not move!! - Roy Brown
So had a look and seen that the outer cv joint on the drivers side wasn’t into the shaft correctly. I have now put that back together with a new cv boot kit etc.

I have watched a video online and adjusted the linkage. It is now spotting into all gears perfect.

However, when the car is IN gear I can still push it which is Definitely not right....

The grinding noise inky happens when I’m at the biting point on the clutch, doesn’t happen when off the clutch or on startup etc.

Going to get an assistant now to try whilst I look around
Vw 1.9 tdi - Car goes into gear but will not move!! - gordonbennet
The grinding noise inky happens when I’m at the biting point on the clutch, doesn’t happen when off the clutch or on startup etc. Going to get an assistant now to try whilst I look around

From your previous post ''( 'if' I happened to put the clutch in back to front would it cause this issue?)'', i'm beginning to wonder if this might be where the problem lies, in the clutch/flywheel area, maybe if the clutch was fitted back to front the clutch driven plate is at the very edge of the spigot shaft splines at biting point...this is only a suggestion so don't go removing the gearbox to check, but similarly don't keep letting the thing grate and grind whilst diagnosing the problem...yes i know easier said than done.

What you have to establish is if there's suitable locking of the engine to the transmission all the way to the road wheels, and to make double sure that as Railroad suggested pertinently above that the drive shafts have locked fully home in the final drive.

Maybe get the front end up in the air and the car safely blocked up, then remove both wheels (so you can see what's going on), try and pull the drive shafts out of the final drive by gripping the inner CV joints, there should be no appreciable movement.

Then put it in gear and turn one wheel hub (large screwdriver levering on the wheelbolts not bare threads), the other hub should turn the opposite way due to standard differential, try this both sides, then block the opposite hub and try to turn the free one, do this both sides, now the car being in gear it shouldn't be possible without the engine also turning over...by doing this you've 'proved' the final drive and driveshafts are in order, if after 'proving' the transmission you can turn either hub by hand with the opposite hub locked then there is definately no fully engaged clutch on its splines or the flywheel somehow isn't connected to the crank....is there an inspection hole so you can see the clutch pressure plate or flywheel turning or not as the case may be, be easier to whip the starter motor out if no inspection plate available.

One or two other remote possibles, i'm not sure how the slave cyl works on these, but maybe the lever if it has one is misplaced so even with your foot off the clutch its still partially disengaged, and was there a correct size spigot bearing in the end of the crankshaft?

Hopefully when your mate turns up and you can see what's happening all will be revealed.

Edited by gordonbennet on 30/05/2020 at 17:18