203 Gear DIAGNOSIS

[James Gelido]

Hey guys,

Recently replaced the barrel that holds the 'clutch operating rod'. The thing was worn beyond belief and was not getting a direct pull on the thrust bearing fork. I filed out the holes on the Jackshaft lever and used a bolt of slightly bigger diameter to form a new barrel (see attached).

Checked clutch bearing and has 5mm worth of carbon on it.

Clutch feel much better and actually springs back now.

Also tightened the adjuster nut on the steering column for linkages, not much difference

Got a slight issue though. The old girl will not go into and gear whilst engine is running, although, when I put it into 1st gear with the engine off, then start it with the clutch down, it starts and doesn't creep or jump forward. I then slowly release the clutch and the the car will drive in 1st gear. I give it a slight rev, then I can change it out of gear into neutral, but once in neutral will not go into any gear again. Same as reverse.

The fact that it starts in 1st with the clutch down and doesn't move until I release the clutch tells me that the clutch is engaging and disengaging.

The fact that it doesn't go into gear when started in neutral makes me wonder ....

Is this an issue with worn linkages or clutch operating rod out of adjustment? The gears change fine when engine is off and linkages seem to do what they are supposed to but I guess when the engine is on, possibly there is more pressure to shift?

Thanks guys

 

[stew]

Your clutch is dragging which means it is not releasing from the friction faces. That carbon thrust seems below tolerance. My suggestion to you is to find a workshop manual.


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[Boydie]

Hey guys,

Recently replaced the barrel that holds the 'clutch operating rod'. The thing was worn beyond belief and was not getting a direct pull on the thrust bearing fork. I filed out the holes on the Jackshaft lever and used a bolt of slightly bigger diameter to form a new barrel (see attached).

Checked clutch bearing and has 5mm worth of carbon on it.

Clutch feel much better and actually springs back now.

Also tightened the adjuster nut on the steering column for linkages, not much difference

Got a slight issue though. The old girl will not go into and gear whilst engine is running, although, when I put it into 1st gear with the engine off, then start it with the clutch down, it starts and doesn't creep or jump forward. I then slowly release the clutch and the the car will drive in 1st gear. I give it a slight rev, then I can change it out of gear into neutral, but once in neutral will not go into any gear again. Same as reverse.

The fact that it starts in 1st with the clutch down and doesn't move until I release the clutch tells me that the clutch is engaging and disengaging.

The fact that it doesn't go into gear when started in neutral makes me wonder ....

Is this an issue with worn linkages or clutch operating rod out of adjustment? The gears change fine when engine is off and linkages seem to do what they are supposed to but I guess when the engine is on, possibly there is more pressure to shift?

Thanks guys

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You can strike this problem if the clutch plate has had a "lot of oil" on the facing and tends to stick to either clutch face or flywheel. If the gearbox has been allowed to hang off the clutch plate when being re-installed you can distort the clutch plate enough to drag. If the pilot (spigot)bush is very dry in the crank, it can also drag. All of which sounds like engine or gearbox out, the carbon thrust appears as good as new to me.

 

[James Gelido]

You can strike this problem if the clutch plate has had a "lot of oil" on the facing and tends to stick to either clutch face or flywheel. If the gearbox has been allowed to hang off the clutch plate when being re-installed you can distort the clutch plate enough to drag. If the pilot (spigot)bush is very dry in the crank, it can also drag. All of which sounds like engine or gearbox out, the carbon thrust appears as good as new to me.

Thanks Boydie!

I managed to find out the issue. The ajusters for the fingers on the pressure plate were loose as a wizards sleeve :joker: Measured the distance of the centre piece from another pressure plate I had. Was 21mm from face to back of fly wheel. Adjusted the fingers up. Worked a treat and brought the centre piece up closer to the thrust bearing making for a much better engagment and disengagment. Clutch is also nice and springy.

 

[James Gelido]

Your clutch is dragging which means it is not releasing from the friction faces. That carbon thrust seems below tolerance. My suggestion to you is to find a workshop manual.

Thanks for the suggestion. Already have a workshop manual. Couldn't have rebuilt the motor without it. Manual is 403 specific, which our motor is. Also have a 203 workshop manual for adjustment rod specs.. Unfortunately, the manual doesn't mention anything about loose finger adjusters on pressure plate or tightening specifications for that matter. Thrust bearing however is according to spec. Plenty still on it.

Cheers

 

[lo203404]

Some pics that should be of use.

Thanks Boydie!

I managed to find out the issue. The ajusters for the fingers on the pressure plate were loose as a wizards sleeve :joker: Measured the distance of the centre piece from another pressure plate I had. Was 21mm from face to back of fly wheel. Adjusted the fingers up. Worked a treat and brought the centre piece up closer to the thrust bearing making for a much better engagment and disengagment. Clutch is also nice and springy.

Hi James, I'll put up some images that should be of use to you on this. Any questions, give us a hit back.

 

[lo203404]

Hi James, I'll put up some images that should be of use to you on this. Any questions, give us a hit back.

More images on the subject.

 

[lo203404]

More images on the subject.

Last few.

 

[Steven King]

please admins - could this lot become a 'sticky' for future reference ?

 

[lo203404]

Go hard James...

please admins - could this lot become a 'sticky' for future reference ?

Thanks for that Steven, I thought sending what info I could think of on the subject of the clutch and gearchange issues that James is having or had, with images and postscript the most straight forward way to hopefully help James out.

 

[Steven King]

all i could think is join Amoureux 203 403 for their searchable archive of FAQs and (being without french) look at threads with paperclips, i.e. pictures ... 'tringles' look promising.

 

[James Gelido]

Hi James, I'll put up some images that should be of use to you on this. Any questions, give us a hit back.

Wow, thanks for going to all that effort mate! Amazing stuff! Apologies for the late reply. This will become much use to alot of people I reckon. Clutch is okay now. The depth is crucial and not sure what happened to my pressure plate but was way too under-adjusted and because I didn't have any specs I then proceeded to over-adjust the fingers, which then caused the clutch to slip, the opposite. Engine was out again.

Luckily, I was able to find an original pressure plate that hadn't been tampered with, and measured the correct depth centre of the bearing face with a set of vernier callipers. Worked a treat and got the correct distance.

Cheers again mate! Legend