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Old 11-11-2020, 03:15 AM   #1
Carter Thomas
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Join Date: Nov 2019
Location: Missouri
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Default 96 5spd At a loss

Needing some help with this one.

Stopped for gas one afternoon after school and found the car would not go into gear anymore. Had to turn off car, put in gear then fire it up and give it gas to make it home......slowly.
Found the slave cylinder leaking and replaced it.
Still would not go into gear. Inspected the master and found a tear in the rubber boot, so replaced for good measure. Still would not go into gear.
Bled the system several different times and ways. No joy.
Only option after that is to drop the transmission and see if there is an issue with clutch.
Just finished that over the weekend. New Sachs clutch kit installed! Inspected transmission while out of the car for any obvious issues. Nothing prevented it from shifting into any gear. No odd grinding or noises. Changed fluid to boot.

With transmission back in, my dad and I re-bled the system. Even emptied out reservoir and bled from the slave cylinder up. Pushing any and all air bubbles out the top.

Peddle feels great. Shifts fine while car is off.

Still refuses to go into gear when the car is on.

What in the world am I missing?
How would you approach troubleshooting this? Is there a specification for how far the slave plunger should move when engaged?

Thanks for any input and insight you can provide. This has been quite the adventure.
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Old 11-13-2020, 10:13 PM   #2
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If it shifts fine engine off that should eliminate the trans / shifter bits. If the clutch is not fully disengaged, you would expect some noise when trying to engage a gear engine running. Did you compare the slave cylinder pushtod length new to old? Anything that limits disengagement travel comes to mind as a potential problem. Even throw out bearing height/ fork pivot pin wear.

Good luck.
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