Ok, here's the scenario: Buy brand new clutch, drop gearbox, install new clutch as per instuctions, re-fit gearbox, fit clutch cable, test.

 

At the point of "test" I discover that I needed to adjust the clutch cable out as far as it would go just to (only just) be able to engage forward gears, can't get reverse at all, I've double checked everything and nothing seems to be wrong at all, but there are a few things I need to know,

 

1: Should there be any play in the clutch fork on the cable side of the gearbox? I can pull the thing forwards a bit by hand and that seems a bit weird to me because it hasn't happened before........

 

2: I'm quite certain that the cable isn't streched, as I was using it in the same car only days ago, but now there seems to be too much cable, wtf?

 

3: Has anyone else encountered this before?

 

I've managed to replicate this problem twice on 2 different cars and I have no idea what to do to fix it, if anyone can shed some light on this I appreciate the input.......

 

Ta, Yoda.

Did you put the throwout/thrust bearing in properly?

Yes, I had a complete and untouched matching gearbox sitting beside the one I was working on for comparison, everything matched and there were no missing/leftover parts, it went back in in the same condition that it came out, which is why I'm confuddled. Everything is exactly as it should be and yet it doesn't co-operate....... :fuzz:

Hey ben, think you'll find it is simply a streched cable. Seen this happen a few times. The new clutch has a diffeent take up point.

There is a place on howick street, just up round the corner from me, called rope and chain, go round there and get them to shorten in for you. :fuzz:

 

Work case scenario I'll lend you the one out of the wagon for the weekend.

If you want a brand new one.....

 

http://cgi.ebay.com.au/TOYOTA-COROLLA-KE30...1QQcmdZViewItem

 

:P

Edited July 22, 200818 yr by Taz_Rx

While a good idea, it doesn't explain why there is play with the clutch fork where there wasn't with the old clutch, I'll try spacing it out with some washers first just to make sure though.......

 

Had a chat with some Toyota technicians today, and they said (I expected this) "streched cable or incorrect clutch, try a genuine one", thing is, I've had the same problem with a genuine clutch, after that they decided that they could only tell me what the problem was if they looked at the car, not helpfull........

 

I'm gonna have a play around, see if I can figure out some dodged up way of making this bastard work........

i think if you take it apart you will find differnt finger height on the pressure plate causing your problem, i take it was a aftermarket clutch?

your options are shorten your cable as mentioned above, put a spacer on the release bearing or fit a different brand pressure plate, only other thing that will affect this is if you have a lightened flywheel where it sits at a different positon from excess machining.

cable sounds easist/cheapist

Yeah as the clutch plate wears the pressure plate get less pre-tention on it, causing the fingers to poke out the back of the pressure plate more.

 

Its an exedy clutch Boost+k. :fuzz:

You could always put a spacer on the firewall where the adjustment clip goes for the clutch cable. A rubber shock bushing with big washer might do the trick, allowing you to take up the excess play.

Chucked a pair of sizeable washers in to space things out, and behold! It worked(just), so I do in fact need a new cable, time to start fishing I guess.......