After having my Getrag 5 speed rebuilt (and everything fighting me along the way), I finally got everything pieced back together today. Got a new driver's side axle installed, filled the trans with fluid, torqued my wheels, axle nuts etc, and put it on the ground. Started her up, put her in gear, and slowly let the clutch out... NOTHING! No movement, nada. Now I should say I also installed a new clutch and pressure plate, and made sure the "gearbox side" of the clutch plate was toward the gearbox, all pressure plate bolts torqued appropriately.

Infuriated and confused, I turned the car off and got out to ponder. Then I heard dripping, and found ALL of my brand new trans fluid on the ground, having *poured* out of my drivers side axle seal.

The axle is new. I *thought* I felt the circlip pop into place when I put the axle in, so I didn't push any further. I suppose it's possible that I didn't push it in far enough? I didn't want to break anything... how can I be sure I got the axle in far enough, and is it possible to push it in TOO far?

And if the axle is just pressed in, what keeps it from popping out while driving?

And even if the axle WEREN'T in all the way, shouldn't the other wheel be turning when the car is put into gear and the clutch released?

At this point (about a month into this project, and having had enough of this bull***) I'm simply infuriated and absolutely loathing the possibility of having to take the trans BACK out to inspect the clutch etc.

Can anyone help?

I've never posted so many (probably stupid) questions on a forum without adding many times that in advice etc. However, this car has been a PITA since I bought it. I wish I didn't love it so much, and could just get rid of it, but I'm in too deep now to do that.

Any help would be tremendously appreciated.

 

It sounds like you don't have the axle in all the way.

You can't have it in too far either, just push until it doesn't go in anymore . And the clip keeps it from popping out again.

You might be able to do it without taking anything apart. Not positive but at most all you have to do is pop the ball joints again. I would pull it out, check the clip, and then push it back in again to make sure you got it in all the way.

If you still have no gears then you need to check your shifter linkage and also make sure the fork/slave cylinder is working correctly.

 

That is exactly what I wanted to hear, I desperately hope you're right. I would have just TRIED this, but didn't want to **** anything up. Shift linkages/cables seem to be working just fine, and the selector feels just like it always have. The trans was rebuilt by a gentleman who specifically rebuilds older Mini 5 speeds, so I would like to think it's all done correctly, and nothing internal is awry.

I'll give this a go on Friday (had to order another $40 worth of trans fluid, 'DOH!) and post results.

Thanks again, and any other advice is still appreciated!

 

No problem, hopefully you don't have to pull the transmission out.

You can't really install the clutch the wrong way. You said you made sure it was facing the right way, and the pressure plate only goes on one way. The clutch can not be centered but that just makes it really hard to put the tranny on. Nothing else to screw up except for not tightening the bolts correctly but that shouldn't prevent the wheels from turning.

The output shaft seal could be leaking but you said it was pouring out so I would think you would have noticed if that seal was that messed up.

 

All of the oil dumped out in one go, which made me assume I didn't push the axle in enough. The seal is also brand new obviously, so it damn sure shouldn't be the seal!

 

I can't for the life of me get the axle to go in any further. The clip looks fine to me (although I'm not sure what I'm really looking for. It goes in most of the way then stops. Is there a trick?

 

Looking at it again, I think the axle may be going all the way in, but the clip isn't keeping it in? It "pops" into place, but only takes a light pull to yank it out. It's a brand new axle, although it was cheap, a temporary replacement until I could get my OEM part back from the rebuilder (will be over a month until he can get it back to me)

 

Sounds like you found your problem. It just takes a good solid shove to get it in there.

 

Not really, I can't get it in any further than it was before... It takes very little force to pop it in, and very little force to pop it out.

Now it looks like the clip isn't holding it tight enough. Is that a common problem with aftermarket axles?

 

Personally haven't used an aftermarket for quite a while. Lucky enough to have a good axle builder close by.

Youre probably going to have to try a different clip.Or if you got it from your local parts store maybe exchange it for a different one?

 

It's from Rock Auto, who I've always had good luck with, this being my first incident. Reading stuff now, it looks like they're supposedly not terribly good quality, but this seems ridiculous.

Where would I even try to source a new clip?

 

You could try changing the size of the clip too. Just make it a little bigger

 

I think I'd rather buy a new axle if that's really the problem. If it popped out while driving and destroyed things I'd be beside myself. Also, I have no way of knowing what size clip to use, where to find one etc, and have no reference as to what is "tight enough" vs not, as when I sent the trans in to be rebuilt I left that portion of the axle installed, not knowing it would just pop out. Trying to get a hold of The Driveshaft Shop to see what they can tell me.

I'm so ****ing done with this job, I hope I can get it tidied up without any other big setbacks. If I run into another major problem with this car, I'll likely cut my losses and sell it, as much as it would pain me to do that. What should have been a 1 day dis-assembly and 1 day reassembly has turned into a 6 week headache.

 

Emailed Driveshaft Shop (after hearing others praise them) and they said they do not carry the 05-06 5 speed shaft.

Looking like I'll have to try a used ebay axle for now...

 

Well, I feel like an idiot, but must post here in case someone else commits the same folly.

My differential was turned 90 degrees in my transmission housing. The axles would go in, and feel fairly solid because of the interference between the axle and the seal.

Derp.

Either way, I'm returning the Rock Auto axle because of the things I've read, and am going with a used axle from eBay until I can get back my known good parts from my trans rebuilder in a month or 2.