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206 1.6 16V XS 2004 gearbox/clutch issue
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wac38

Posted: Tue Sep 19, 2017 8:42 am

Joined: Dec 06, 2014
Posts: 2
Trade Rating: 0

Morning, hope you can help me out with this one please.

Clutch (3 piece sachs) is 2500km old and replaced the original (237kkm) as was slipping at 3000 rpm in all gears, with whine in neutral and less with clutch depressed but no whine at all with clutch depressed and in 1st. Driveshaft seals changed. GB oil changed since twice (driveshaft change, intermediate bearing shagged, oil appeared clean and no leak).

Just went on a long trip (25hrs motorway driving) and old problems reoccur.
Generally, slipping at 2900-3100 rpm with engine overrun at 110 km/h in 5th, followed by judder (like driving over the textured lane markers at the edge of the road), loss of speed and recovery with bite. However, will happily sit start at 130km/h and pull up a long steep hill with 250kg of stuff in the back (yes) - it did eventually start going backwards but held bite. In gear sounds OK in 4th and 5th with low gears pretty rough but better than in neutral.

At second last stop had serious clunky slowly rotating noise in neutral, with clutch (not same noise but still bad) and in 1-2-3 pretty bad, mechanical, rotating, rather than dull whine - no whine or noise apparent in 4th and 5th when listening for noise driving thru tunnels.

Now, after arriving back, the most appalling noise at start-up (very mechanical, clunky, slowly rotating and grating and something sounding very broken - don't dare drive it far/at all).

Gear selection always no problem, clutch still feels OK and gear selection is solid. Acceleration clearly affected all weekend even with good bite. Fuel econ identical to normal (690km/45l motorway on E10; 100 less on ethanol). No oil on road after parking overnight.

Early symptoms appeared to me to be pretty similar to previous before clutch change but now in a much more advanced state of failure.

Can all this be clutch? or can I always have had a gb issue that appears like or caused over revving like a slipping clutch?

Anything to do before I take it apart/spend on gearbox too just to check?

thanks

w.

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