Offroad-Express

Hi guys

I just got a 91 surf with a 1uz + 5 spd conversion, Engine goes great but its having serious trouble selecting every gear. Even with the clutch engaged it crunches into reverse. With the engines on its a real struggle to get into gear however if i turn the engine off it glides into gear fine.

What are the things i should be investigating? master/slave cyclinder, gearbox syncros, clutch itself, all of the above. anything i'm missing?

Thanks

I'd check the length of the piston? bit that goes on the fork to slave that actually pushs the clutch in.. I had one that wasnt the right length and swapped it and worked great.. just a thought ALso check fluid and there are no air locks in the system.. that will play havoc ..

I had a similar issue when I swapped the 5L into my Hilux the clutch master cylinder was worn and as I had used a HD clutch, there was not enough pressure to engage disengage the clutch. A cheapo replacement master cylinder from Repco sorted it. It had been fine on the old clutch.

yep as above sounds like clutch linkage/adjustment/pushrod/master cylinder/slave cylinder etc sort of problem

Sadam_Husain wrote:yep as above sounds like clutch linkage/adjustment/pushrod/master cylinder/slave cylinder etc sort of problem

Sharp as a tack..

Big wrote:

Sadam_Husain wrote:yep as above sounds like clutch linkage/adjustment/pushrod/master cylinder/slave cylinder etc sort of problem

Sharp as a tack..

ya got to cover all the bases you you come accross sounding pretty clever

could also be that your clutch fork has broken where it pivots on the ball stud - had that same problem recently at work replaced master cylinder / slave etc but still wont go into gear so pulled the box out to find the clutch fork had broken

do you know if its always been a problem for the previous owner? is it a custom bellhousing or an adaptor plate between the bellhousing and the gearbox?

first thing i would do though would be to check the clutch master and slave cylinder for leaks etc you can pull back the rubber boot on the slave cylinder and see if there is any fuild in there if there is you need to replace it , same with the master cylinder if you get up under the dash board and have a look around where the push rod from the clutch pedal goes through the firewall into the master cylinder - if there is any sign of leakage its no good , if not then i would try bleeding the clutch system and see if that makes any difference and or possibly adjusting the push rod , however when the clutch wears the pressure plate fingers move closer to the release bearing so this shouldnt theoretically be something you need to adjust.

if after all that there is still a problem you'd be looking at the clutch fork / box out scenario. Hope this helps , Cheers.

could just be a seized spigot bearing.

tweake wrote:could just be a seized spigot bearing.

Could be but you'd want to check the rest first - not just jump into pulling the box out to find nothing conclusive.

nztimr33 wrote:

tweake wrote:could just be a seized spigot bearing.

Could be but you'd want to check the rest first - not just jump into pulling the box out to find nothing conclusive.

i agree..

Thanks heaps for the flow of info guys, talked to the seller yesterday and he said he replaced the slave the day before it was picked up so he reckons he may not have bleed it properly, also reckons that if it's not that then the master has probably had it as its done alot of kms.

All the advice i was given in this thread i passed to my mech dude.
I still dropped it in to be checked ova this morning BUT when i jumped in (ready for a war) to take it down it was fine??!?!?! Everything seemed to work fine, every gear slide into place??? It's like nothing was wrong in the 1st place I'm totally blown away/f@#$n stoked by it.

It was parked outside in the frost this mourning, could the cold have had an effect? That's the only difference i can think of.

id say needs a bleed. same thing happened to gfs car. drive along was all good then would slowly get worse and hard to shift. next day same thing. turnned out needed a bleed

KotangKort wrote:Thanks heaps for the flow of info guys, talked to the seller yesterday and he said he replaced the slave the day before it was picked up so he reckons he may not have bleed it properly, also reckons that if it's not that then the master has probably had it as its done alot of kms.

All the advice i was given in this thread i passed to my mech dude.
I still dropped it in to be checked ova this morning BUT when i jumped in (ready for a war) to take it down it was fine??!?!?! Everything seemed to work fine, every gear slide into place??? It's like nothing was wrong in the 1st place I'm totally blown away/f@#$n stoked by it.

It was parked outside in the frost this mourning, could the cold have had an effect? That's the only difference i can think of.

Check how close your exhaust is to the slave cylinder, maybe heating fluid. Had this problem, was a bitch to get into gear.

Try replacing the gearbox oil. had this problem with our hiab truck at work, would be a bitch to get into any gear, changed oil and all was sweet.

I heard through the grape vine its all sorted now yea? Sounds like whoever mounted the slave cylinder put it on the wrong angle and also the pipe into the slave cylinder was leaking everytime you put your foot on the clutch.

ClassicCruiserSpares wrote:I heard through the grape vine its all sorted now yea? Sounds like whoever mounted the slave cylinder put it on the wrong angle and also the pipe into the slave cylinder was leaking everytime you put your foot on the clutch.

Yep thanks heaps Jason!!! The clutch goes mint now, not to mention the truck Thanks to all the other members for your help aswell, was good ta have everyones input.

Cheers