Gearbox problem, advice needed

[zajo]

Hello, I've got a 1990 964, I need urgent advice since I'm in the middle of a road trip. Any help greatly appreciated!

I believe the problem got worse gradually, in recent months it was sort of tricky to engage first gear when stopped. I *think* pressing on the clutch a bit more solved the problem. I've been planning a transmission oil change for a while so I was ignoring he problem until that's done.

Today, after some driving in traffic, the situation got so bad that if the car is stopped and the engine running I can't shift into any gear. Turning the engine off lets me shift fine. During driving, shifting is tricky, and requires good RPM matching on the way up or down.

Driving while in gear is as good as ever, no noises, no nothing.

The most important question: could this be causing further damage to the car? Like I said, I'm in the middle of a road trip, probably 1000 more miles to get home, and while I *can* tolerate the inconvenience, I don't want to cause further damage.

Secondly, what could be causing this? Clutch not disengaging fully? Synchros not working well?

Thanks a lot for any information!

Z

[Flat6pac]

There is a wear bushing at the bottom of the shifter on the 964, might be the problem
No. 928.424.005.01
Bruce

[Jeff Burger]

clutch

[wesleyc]

My 993 had the same shift link setup and problem. Drove it 500 miles home after purchase barely able to shift into reverse and 3rd. Took the tunnel and shiftboot off under the car when I got home. Bushing ring and broken plastic fell out of shift box ! Shift rod to shifter was hanging on ok. It's a pressed on unit. So when it goes your stuck. A rubber shift box bushing was gone causing most of my immediate problems I used some wire and some rubber material for a week while waiting on new bushings. With 1000miles to go I would pull into a auto parts store borrow/buy tools to get tunnel cover/shift box boot off. If shift box bushings are bad you can rig it up to get back home. Good luck Replaced it all with ssk/golden rod from FDmotorsport.

[RedCoupe]

If it shifts okay with the engine stopped, I don't think it's a shifter problem, I believe that it's the clutch. The clutch problem can be either mechanical or hydraulic. First, I would check the fluid level and look for any possible leak that might let air into the system. Access to the slave cylinder is tight, but it can and probably should be bled to push new fluid through and air bubbles out. Once the fluid part has been all checked out, you can have someone push the pedal and see how much motion is happening at the slave cylinder. If the hydraulics check out okay, then the problem could be anything from worn pedal bushings to bad cross shaft bushings, bad clutch fork, or badly worn cross shaft. I have even heard of a broken ear in the transmission housing because of a seized needle bearing on the cross shaft. But I would start with the hydraulic system.

[zajo]

Based on symptoms and what I read here, I begin to think it's the clutch.

If that's the case, is it OK to drive the car in this condition?

Once again, thank you all very much!

[964TargaC2]

Sounds like clutch hydraulics, as mentioned check and make sure the brake fluid reservoir is full (clutch and brakes share same reservoir)
If it gets worse with heat its likely the flexible line to the slave cylinder, you are at the time where it should be replaced as it starts to get soft and instead of pressure to the shift fork the pressure puffs up the flexible line instead making shifting difficult

Dont sweat driving it since you are avoiding grinding the gears away and remember Occams Razor or "The fastest solution to a problem is usually the simplest"

[TMc993]

[QUOTE=964TargaC2;8081317]Dont sweat driving it since you are avoiding grinding the gears away....QUOTE]

I disagree. If you are having to match revs and are struggling to get the transmission from one gear to another, you are stressing the hell out of the sychronizers and probably grinding more gears than you think. If it were my car, I'd have it flatbedded to a qualified shop and have it repaired properly.

[zajo]

I'm pretty sure it's the clutch, but the car was driving fine today so I'm good to get home. It's all highway anyway, so I keep it in 5th pretty much all the time.

Thanks everyone!

[rsscotty]

I have seen the roll pin break on the clutch shaft at the pedal assembly. Something to look at before pulling the clutch out, but you can get a sense of this by how the pedal feels. Not to mention that the clutch slave and master cylinder must be functioning properly.

[Schwarzeritter]

Zajo,

Honestly, you should get to your destination and have whatever's up inspected and repaired to be absolutely sure.

But!

It really depends, I would at the very least inspect and ensure you have enough fluid in the clutch master reservoir.

Check to see if it's leaking extremely low. Add if so. This is not a fix but temporary aid " if this in fact is the issue ., "

It could be a bad clutch master / slave. It could be that the clutch is not engaging correctly because of a low pressure and thus not operating correctly.

As some here have stated it's possible that clutch and assembly are past due and need to be replaced. It could be that you've linkage issues or worn bushings but all in all it sounds like you'll need to have a shake down.

Hope you get to wherever safely.

[bazar01]

Originally Posted by zajo

I'm pretty sure it's the clutch, but the car was driving fine today so I'm good to get home. It's all highway anyway, so I keep it in 5th pretty much all the time.

Thanks everyone!

It is a clutch hydraulic issue.
Try double clutching or even triple clutching meaning pumping the clutch pedal 2x or 3x before shifting. It will help pressurize the line and help disengage the clutch before shifting.
Replace both master and slave when you get home.