TD 27, WD 21 pathfinder, manual gearbox conversion

[Roy]

Have successfully installed 2004 navara 5 spd manual into '92 pathfinder. Now have no clutch, as in clutch will not disengage, system is fully bled, seems as if fork is travelling about 25 mm, but not even sliding, let alone releasing. Are the input shafts longer, or does anyone have any other ideas.

[slide]

Has it got normal pedal feel?
If not I suspect fork pivot point is different. Or could be fork or release bearing thickness different. Take it you've tried a longer slave cylinder rod to stop piston popping out?
If clutch plate is bent it won't disengage, but will still have normal pedal feel.
(it may well partially disengage, but won't let you shift into gear from neutral)

[Crash bandicoot]

Worst case scenario

Clutch plate around the wrong way.

being nissan the spline in the center of the clutch plate is offset and probably bound on either the thrust bearing inner race or the spigot bearing.

Best case Scenario

as aforementioned the salve push rod needs preloading.

OR

IF you used an earlier master cylinder (assuming you are doing a manual conversion from auto)(or replacing a weak D21 box) the master does not flow as much volume as the later D22 master cylinder.