• Registered: 2011-07-27
  • Posts: 5

Topic: '68 Bug Won't Go Into Gear

Within the last week I noticed that it was getting harder to get my '68 Bug into 1st and reverse while the engine was running.  I had to shove real hard.  A few days ago I couldn't get it into gear without grinding.  Soon after I couldn't get it into gear at all (while the engine was running).  I got a high speed whirling sound whenever I tried to put it into gear...like metal skimming on metal. To make it home, I had to turn off the engine, then put it into 1st, then start the engine and let out the clutch.  I assumed that my clutch cable was fraying.  I took the cable out this morning.  There was nothing wrong with it?!  How can I tell if I have a clutch assembly problem or a bad synchro?  By the way, it has never popped out of gear.  Should I just put the clutch cable back in and tighten it more?   Somehow I think it is more than a clutch cable adjustment problem...unfortunately.

Mo Lee

  • From: Cincinnati, Ohio
  • Registered: 2005-09-10
  • Posts: 2,336

Re: '68 Bug Won't Go Into Gear

First of all regarding the clutch cable...when you reinstall it you adjust it so that there's around 1" of free-play in the clutch pedal.

Regarding the shifting issues:

- If you don't know the last time the clutch disk, pressure plate, and throw-out bearing were replaced...it may be time for at least an inspection (drop the engine) and/or replacement of some or all of these parts..
- There's a "shift rod coupler" (shift rod to transmission) under an access panel under the rear seat.  Make sure this isn't loose...or that it isn't worn out.
- Make sure the transmission fluid is at the correct level.
- there is a small amount of adjustment you can make with the shifter where it bolts to the "tunnel".  Sometimes "tweeking" things a bit can solve hard shifting problems.
- Lastly...manual transmissions are very very durable.  But even on a 68 Beetle (43 years old)...eventually things wear out.  So something could be worn out in the tranny.

HTH,

- Nick

1979 Super Beetle Convertible
  • Registered: 2011-07-27
  • Posts: 5

Re: '68 Bug Won't Go Into Gear

Thanks Nick.  I replaced the clutch assembly and installed a re-built tranny about 3 years ago (<20K miles).  Even so, I recognize that I may have a problem in either the clutch assembly or the tranny.  I am just hoping to get some assistance in what the problem could be.  When I replaced the tranny three years ago, it would pop out of gear.  It is not the case this time with this re-built tranny.  Does the whirling sound  (metal skimming metal) when I try to put it into gear suggest a tranny or a clutch problem?  What are the symptoms of a bad synchro?

Thanks,
Mo Lee

  • TomB
  • Moderator
  • Offline
  • From: Austin, TX
  • Registered: 2004-03-27
  • Posts: 1,095

Re: '68 Bug Won't Go Into Gear

Could be the pilot bearing in the flywheel that centers the end of the tranny shaft. If it drags enough the tranny shaft turns even with the clutch in, overtaxing the synchros when you try to shift. That's what your symptoms sound like to me.

  • From: somewhere over the rainbow USA
  • Registered: 2006-07-26
  • Posts: 1,889

Re: '68 Bug Won't Go Into Gear

Welcome
First how much freeplay was in the pedal before you pulled out the cable? It would help with diagnostics if we know this?
Could be a TO bearing clip fell off, seized needle bearings in gland nut, wore out pressure plate fingers.

Last edited by burrhead (2011-07-27 11:01:39)

burrhead

A wise man makes his own decisions, an ignorant man follows public opinion.
  • From: Cincinnati, Ohio
  • Registered: 2005-09-10
  • Posts: 2,336

Re: '68 Bug Won't Go Into Gear

TomB wrote:

Could be the pilot bearing in the flywheel that centers the end of the tranny shaft. If it drags enough the tranny shaft turns even with the clutch in, overtaxing the synchros when you try to shift. That's what your symptoms sound like to me.

Nice additional idea Tom! smile 

I've replaced those...a bit of a pain to get them out...but they can definitely be noisy when they go bad.

- Nick

1979 Super Beetle Convertible
  • Registered: 2011-07-27
  • Posts: 5

Re: '68 Bug Won't Go Into Gear

Thanks for the great ideas!  However, can anyone confirm the symptoms of a synchro gone bad?  Is popping out of gear always the case?... (because it is not popping out of gear).

Mo Lee

  • From: somewhere over the rainbow USA
  • Registered: 2006-07-26
  • Posts: 1,889

Re: '68 Bug Won't Go Into Gear

Bad syncro usually means it is hard to shift up or down into the gears with out it grinding. Reverse does not have one.
Answer about the free play please.

burrhead

A wise man makes his own decisions, an ignorant man follows public opinion.
  • Registered: 2011-07-27
  • Posts: 5

Re: '68 Bug Won't Go Into Gear

Burrhead,

I can only guess about the freeplay because I did not actually take out a ruler and neasure it. (Now I wish that I had).  The exgagement point did not feel like it had moved (loosened) significantly.  The pedal play felt normal when I tried to put it into 1st or reverse.

What causes a gear to pop out?  (That was my problem before replacing the tranny).

Mo Lee

  • From: Cincinnati, Ohio
  • Registered: 2005-09-10
  • Posts: 2,336

Re: '68 Bug Won't Go Into Gear

Mo Lee wrote:

What causes a gear to pop out?  (That was my problem before replacing the tranny).

Are you saying that this "popping out of gear" happened before & after you replaced your tranny?

As far as popping out of gear...when does your Beetle pop out of gear (under what conditions)?  Accelerating, braking, uphills, down hills, just randomly, etc.

And the clutch cable.  Yes it would have been good to know what the free-play was before removing the cable...but at this point all you can do is reinstall the cable, set the free-play around 1 inch...and see if you still have the problem of popping out of gear.

You've gotten a lot of suggestions:

- inspect/replace clutch, pressure plate, and throw out bearing
- inspect/replace the pilot bearing
- inspect/replace the shift coupler
- adjust the shifter
- check manual transmission fluid level
- maybe replace the clutch cable if it's worn out

...time to stop talking...and get dirty! wink

- Nick

1979 Super Beetle Convertible