Clutch / Gearbox issue - Won't go into gear.

[l1ttle_d3vil]

Hey guys, had a weird problem come up with the KE25 the other day.

On the way to work after about 10km with no issues the clutch just stopped working, pushed it to the floor and graunched my way into gear. Pumped it, still nothing. Pulled over to check it out, couldn't see anything amiss so I put it into 2nd and cranked it over until it started and drove home in 2nd gear.

Can't think of what it would be, and hoping I can get some ideas before I resort to pulling the box off and physically checking the clutch / thrust bearing setup etc.

Clutch - work fine, ie when its driving there's no slipping or anything. Worked perfectly fine previously, no sign of wearing or anything.

Synchros - Every gear is the same, so not likely to be worn synchros. Plus they wouldn't go from perfectly fine to completely stuffed in 2 minutes!

Master / Slave Cylinders - they're working exactly as expected. Clutch fork is sliding back and forth, have bled the M/C just incase, no change. Not losing any fluid anywhere. Pumping the pedal does absolutely nothing.

A bit of googling seems to point to the clutch fork / pivot point / thrust bearing being a common issue, and given everything else seems to be working fine this is what I'm leaning towards. Gearbox is a W55, whole setup has been in the car for a number of years without issues.

Any ideas??

Thanks
-Matt

[gt4dude]

Any more adjustment on the pedal?

[l1ttle_d3vil]

Haven't tried adjusting the pedal but did clamp the flexi hose from chassis > slave cylinder incase it wasn't getting enough travel / flow for some reason.

Pumped it once and the slave pushed the fork out like normal and held it there, pumped again and it gave even more movement (probably about as far as the slave can travel) but still no change in the gearbox.

[Lloyd]

Best pop the box out and have a look. Fork and pivot ball do give trouble, or it may have dropped a spring and be jamming things up

[Flannelman]

I agree with Lloyd. It has happened to me twice. The center spring fell out and jammed the pressure plate. Only fix was new clutch and pressure plate

[matt dunn]

My guess would be a pressure plate problem too.

[l1ttle_d3vil]

Dammit. I came here hoping for an answer which DIDN'T involve pulling the gearbox off in my garage... without a pit... or hoist... fun times!

What would cause the springs to fall out? Too much abuse? Clutch not grunty enough for the engine?

[Lloyd]

Abuse/bad shifting habits/bad luck

It just happens sometimes. More often with 4WDs taking a bit more abuse than a light little car though.

[allencr]

My .02 WAG, Seized pilot bearing.

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Why? Lotta age, kilometers, city driving on it, or recent clutch kicks?

[RS13]

What would cause the springs to fall out? Too much abuse? Clutch not grunty enough for the engine?

All of the above. Sounds like you've dropped a dampener spring or torn the centre of the clutch plate out. I've done it before as well.

[l1ttle_d3vil]

Hmmm actually come to think of it, I did give it a slight clutch kick a couple of shifts before it first started feeling odd.

As for abuse... its in a 750kg / 190kw rwd car with a gearbox and diff that will never break

Bad shifting habits... flat shifting / launch control probably isn't the most ideal habit to have?

Also do a fair bit of around town driving on it. Just checked and the clutch has actually been in since 2008 too, much longer than I thought... so not a bad run I guess

[Lloyd]

In that case, I'd pick the springs or centre are in places that they shouldn't be.

[l1ttle_d3vil]

Finally managed to get the gearbox off - pretty bang on with the diagnosis guys!

Fair bit of play in the other 2 larger springs too. Now to get the car ready for night drags...

[Rick]

lol join the club