Clutch gone, then back, then gone - any ideas?

[Fraz-ktf]

Hi.

Parked up my 2005 Galaxy tdi on Friday, no issues.  Went to it today and it wouldn't go into gear with the engine running.  Turn off and it goes in and you can start the engine ok but the biting point was very low down.  Drives in 1st ok but won't come out of gear to get 2nd (Unless you switch off the engine!)

Tried the brake fluid but that was topped up ok.  No leaks under the car, clutch pedal feels "Normal".  No rumbling noises and depressing the clutch doesn't make or diminish any noises.  Jumped up and down on the clutch pedal with the engine running about a million times . . . . . but no difference!

I spoke to two local "Clutch companies" who both said that the DMF had gone and it was a Ã,£700 to Ã,£800 + VAT touch.

About an hour later, just for my own amusement, I tried it again and all was normal!  Working as it should (Self healing DMF me thinks  )

Then later this evening, it's gone back to not working again, though it's only been standing on the drive all day.


Any suggestions out there?

Thanks

[SilverBeast]

Wouldn't it go into any gears, or did you just try 1st/2nd.

You can adjust the cable selection mechanism at the gearbox end.  Also the shafts on the gearbox have been known to seize, but can be freed up.  Have a look in this thread http://www.fordgalaxy.org.uk/ford/index.php/topic/5156-help-needed-gear-cable/#entry35431 and also read the linked threads as there can be a number of different issues (that have become mixed up in my head not having actually experienced any of them!)

From memory:-
(i) Cables can pop off balljoint at gearbox end - probably not your problem.
(ii) Selector shaft sticks in gearbox and won't go up and down - loses the ability to select lower gears - maybe your issue.  Can be fixed with judicious use of WD40 and "working" the mechanism under.
(iii) Cables need adjusting. There is a method to do this on TIS CD also youtube video and descriptions on the Galaxy Sites you frequent. This again can be the cause of selection problems.  Seems unlikely for you as it is coming and going.  Maybe cables need lubricating?
(iv) Bolt comes out/shears on selector mechanism. Most serious.  Can be lucky and it drops to bottom of gearbox with no damage or unlucky and it gets caught in gears (I think someone recently had it make a hole in the gearbox casing.  The selector mechanism can be removed from the gearbox and worked on for this.  Key thing seems to be retrieving the bolt before damage is done.  Again could possibly be yours as bolt may be coming out and catching on something.

[Fraz-ktf]

My issue is as described, with the engine off, it will select any gear but is stuck in that gear until you switch off again.  I can drive / set off in any gear and when I start up, the car doesn't lurch forwards in the gear, the clutch works but with a very low biting point, so I can ride the clutch to get moving.

there are no rattles or noises

[Chrispb]

Sounds like start of hydraulic problems, master cylinder probably if you have no leaks.

[Mirez]

I would also suggest a hyro problem, start by bleeding the clutch...