03 Vectra , new clutch = sticky gears

CSU

Have had the clutch replaced on my 03 Vectra and as above, when cold it's very hard to select reverse & 1st... everything is fine when she's warmed up though

I've bled the clutch and everything looked normal with good pressure etc and the clutch did improve for a day but then returned to horrible sticky selection (I do have to swing out of the stick to select reverse in the mornins')

Anyone any idea of whats goin on please?

Greyfoot

Have you replaced the clutch yourself? Also have you changed the whole lot, ie friction, pressure plate, release bearing? Have you checked your flywheel before replacing the clutch?

CSU

I helped a mechanic friend of mine replace it (a god bless you job, so I can't exactly keep hassling him about it), although no mechanic myself I've 'helped' out with dozens at this stage.

Yep, pressure plate, disc & release bearing changed. flywheel didn't catch our attention either...

I've come across this billiten on the web:

Field Remedy: 1653
Subject:
F23 transmission - Bad cold shifting behaviour in 1st and 2nd gear
Models:
Astra-G 1998 ... 2004,Zafira
1999 2004,Speedster 2001 ... 2004,VX220
2001 2004,Vectra-B 1998 2004,Vectra-C
2002 2004,Signum 2003 2004
Engines:
AII,AII,AII,AII,AII,AII ,All
Option:
F23 Transmission
Complaint:
Some customer complain about bad cold shifting behaviour in 1 st and 2nd gear. The gearshift mechanism is correctly adjusted and clutch system is bleeded.
Cause:
Tolerances of toothing of the sliding gear.
Production:
Introduction of transmission with modified siding gear as of transmission number Gxx03240969 in calendar week 41 /2003.
Remedy:
In case of customer complaint the sliding gear has to be replaced by using the Repair Kit, Partno.: 9201451 / Catalogno.: 16 07 013. There is no need to replace the entire transmission.
FunctionalGroup:
K - Clutch/Transmission
Complaint Group:
08 - Hard to operate
Trouble Code:
None

which leads to this part number

...It's just odd as it wasn't sticking before we changed it (reverse & first when cold).

The first 10% of travel on the clutch feels like it's doin F-all...and after bleeding it got marginally better for a day as I've said, so, only thing now I'm thinking is either a. the new pressure-plate is shallower than the old leaving too much of a gap that the release-bearing has to travel before it bites properly (could this happen?), or b. I've heard of one-way valves on the clutch fluid line...could this be nackered...

Unless by some miracle it is this "Synchronizer Ring"...what would changing that entail do you know?...

Greyfoot

Grinding gears would indicate worn syncro indeed, especially if clutch changed recently and correctly.
As the bulletin mentions gearshift mechanism correctly adjusted, someone else might know if there is a specific Opel/Vauxhall issue there. If I recall correctly on those boxes there is a bowden cable with a nut and holder on top before the clutch cylinder where you can adjust the mechanism, try that first.

Point a. is highly unlikely, a brand new genuine clutch will be the same as per manufacturers state.
Point b. I have no clue about tbh.

Changing the syncro would be a costly job indeed, not something you should try without experience. The F23 is a widely used box, I guess getting one 2nd hand would be same price as getting the synco done.(in that case at least you know its been fixed, so no future issues.)

HellFireClub

CSU wrote: »

Have had the clutch replaced on my 03 Vectra and as above, when cold it's very hard to select reverse & 1st... everything is fine when she's warmed up though

I've bled the clutch and everything looked normal with good pressure etc and the clutch did improve for a day but then returned to horrible sticky selection (I do have to swing out of the stick to select reverse in the mornins')

Anyone any idea of whats goin on please?

Difficulty selecting 1st gear and/or reverse is a clutch clearance problem. Your clutch pressure plate assembly is not lifting sufficiently, in order to let the clutch disc disengage fully.

First two questions I'll ask you:

(1) What brand was the replacement clutch kit, (I'm assuming you used a 3 piece replacement clutch kit).

(2) If you can provide your vehicle reg number, I can run a check here on TecDoc to see if the parts you have there are correct (if you can provide brand & part number on the box that you bought the kit in).

I'm a mechanic who specialises in clutch & transmission work.

Lucifer

Also if you pm me your reg or chassis ill tell you if that bulletin relates to your car. That only applies to certain gearbox types.

Also there is no one way valve in the system, it would not be able to function with fluid only travelling in one direction.

As said above first and reverse is a sign of clutch clearance so you need to check you have the correct parts and check your hydraulic circuit.

Another thing to check, does it select gear ok with the engine off? If not then it could be the selector/cables. Is this a petrol engine? I have seen a few vectras come in after a clutch change that are hard to get gear, and the person who changed the clutch has damaged the plastic coolant pipe that runs across the top of the box. You need to move the pipe to get the box in and out. I have seen a bracket off the pipe broken and this acts as a spacer for the selector cables, without it there it cam be hard to get gear.