problem transmission stuck after clutch replacement

My throw out bearing died, I put on a new clutch kit plus output and crankshaft seals, and changed transmission fluid. Put back everithing together everything fitted well, but after i adjusted the shift linkage with 2x 5mm pins, It will only go in 3-4-5 speeds wich i've found weird. I've decided to put fluid back anyway and driveshafts to test it when running. I've started the motor, clutch works well but motor will stuck when i release clutch in gear. The differential works, when i turn one wheel the other turn the other way around. Both weels will only turn in the same direction when on neutral and clutch pedal pressed. It won't move if neutral and clutch not pressed neighter in 3-4-5 and clutch pressed, 1-2 won't get in. Motor turn free if neutral and clutch not pressed thus. Seems like something is stuck in the transmission but i did'nt touch anything in there and i've been pretty carfull to keep it clean aroundthe open gears. Anyone's got any idea what's wrong? Transmission was working properly before i changed the clutch, i did only remove pan to drain oil, visible gears seemed fine, oil was dark but particle free. It's an 07 aveo sedan with d16 transmission.

Please help.

Edit: Reverse won't go in too, wife told me that 1st and second gear were hard to shift in the hour before the bearing gave out completly. Transmission is out again, i guess i'll open it tomorrow...

Before you removed the transmission for the second time, did the wheels move when you had the clutch depressed and the trans in gear (clutch not fully disengaging)?

Before diagnosing it as an internal transmission problem, I would try replacing the slave cylinder. The slave may not be working fully and is not allowing the clutch to fully disengage. It can also be putting slight pressure on the throw-out bearing, which could have caused it to go bad.

Also, how old is the brake fluid in the reservoir/clutch lines? Again, mositure and air could have gotten into the fluid and could prevent the slave cylinder from working properly.

Is the clutch fork bent at all?

My money is on a bad slave cylinder.

Wheels did not move if in gear, weels did not move in neutral if clutch was not pressed. Slave cylinder seems works well, i asked my wife to press the clutch pedal while i look and i saw the cylinder did it's job. With engine running, i pressed the clutch pedal and put in 3rd or 4th or 5th gear with clutch pedal down, while i release the pedal i feel the clutch working but the weels would'nt move and if i realease the pedal fully the motor dies. It would not engage in 3rd, 4th or 5th if i did not press the clutch. Nothing is is bent outside, i did not had to force anything when removing, replacing and removing again transmission, did not had accident, I carefully inspected transmission, shift link, slave cilynder, everything seems fine, everything move like it should, there is no leak brake oil is clean.
With transmission removed the throwout bearing and finger to slave cilynder moves properly but transmission won't shift in reverse 1st and second gear, it will only engage in 3rd, 4th and 5th speed. The problem seems around there, I believe that nothing should pervent the transmission to engage in gears while transmission is on my bench.
I've found is a little dent on the inside of the clutch componnent and another one on a balancing weight on the new pressure plate that was protuding too far maybe 1/32, i hammered the weight carfully and it should not touch anymore, that explain the few tick that i heard during the first few seconds after starting the motor but not the transmission not turning...

I've found the problem, don't understand how it happened tho... i opened the shift cover and gear cover and played with things trying to figure how it works, after a bit of playing I've found a rod than should move to put the reverse on, it looks like it was stuck on reverse position it, the part that moves it from the shift fork kind of disengaged from the place it should have been so it tried to go front and reverse at the same time, it also prevented the parts to move down enough to engage the 1st, 2nd and reverse gears. I'll try and post a few pics later on. I just feel like i'm becoming a master of the manual transmission.

Interesting find. I hope it all works out!

Car is back up and running. Here is a few pictures with description. I'm not sure what could have caused that, except, well after a bit of thinking it must have been a gremlin.

Attachment 10212
The long finger on the left goes in the hollow part pointed by the screwdriver.

Attachment 10213
On the left is the rod that moves to put to reverse. It is now in front position when i opened the case it was not protuding.

Attachment 10214
Here we see the what move to change the gears. The small finger on the first piocture goes in the slot.

Did you take off your intake for this, or do you have a used intake gasket set? I need a set for research.

I watched a YouTube video on a Hyundai manual transmission . Your transmission looks similar .

Any idea if your transmission is related to the Hyundai manual transmission ?

God bless
Wyr

Sorry, no idea.

https://www.youtube.com/watch?v=-yfICJKkLhE

https://www.youtube.com/watch?v=9GjP2tMLVbQ

The Hyundai is Korean , as was the original AVEO . So , the transmissions may share some common heritage ?

God bless
Wyr

Hey I recently replaced a clutch in a 08 Aveo when I put it all back together it was stuck in reverse where neutral should be I opened it where the shift fork is at and freed it up from reverse but now it’s not wanting to shift into any gear I don’t know if I have a bad transmission or the shift fork just isn’t sitting in there rite

If it was working before you took it apart, the transmission is surely not broken, I would take it apart again and look, think and understand how it works, then you should be able to find what's wrong, it looks like something is not where it should. You should be able to shift and rotate it a little by hand to see it if works when it's off.

I would agree, usually if stuff is not in the right position when you put pressure on it, it's not going to work right. I often have to take things apart as I did not understand it the first time.

Remember if you have to try and try again, maybe sky diving is not for you.

Sorry for posting on an old thread, but this exact thing happened to me upon changing the clutch on my '08 Aveo hatchback. I managed to get it going again with the transmission still on the car by taking off the top cover and using my finger to push the rod back into the far rear position.

Buttoned it back up and now she's shifting great. Thank you to drynk who saved my bacon with this post.

Quote:

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Originally Posted by eristocratic

Sorry for posting on an old thread, but this exact thing happened to me upon changing the clutch on my '08 Aveo hatchback. I managed to get it going again with the transmission still on the car by taking off the top cover and using my finger to push the rod back into the far rear position.

Buttoned it back up and now she's shifting great. Thank you to drynk who saved my bacon with this post.

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Thanks for all contributions on this thread. I had the same issue after installing a new clutch. Couldn't get into 1sr, 2nd, and reverse, and stalled when I let go of clutch in any other gear.

As pointed out by the TS drynk, the reverse idler connecting rod inside the transmission shifted over to engage reverse, while the transmission was out. In my case I was hammering in new cv axle seals which could have dislodged the rod.

When you remove the top shift linkage cover, you may not be able to see the rod - it's about 4-5" past the cover, and you can feel it with your hand if you poke around. Just slide it over to the right until the detent on the rod aligns with the shift linkage handle part. Thanks all and good luck

We’re there and pilot bearings or anything when replacing the clutch. Part stores says there’s pilot bearings and dealer says no. Replaced spring plate and throw out bearing and have a small chatter. I’m replacing the fly wheel tomorrow any info would be great


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