Stiff clutch

[syncropete]

Hi,
Just taken gearbox out (2.1DJ 16" Syncro) for 3rd time to inspect clutch. It is fairly stiff to operate, drags and bangs into gear. The friction plate and pressure plate appear to be in good order. The release arm and bearing are free, as is the friction plate on the input splines. There is no air in the system and the travel distance looks fine. Spigot bearing is good. This vehicle has been stood in the bush for a year with no gearbox and at first i presumed that termites had taken sand up into the pressure plate, but i have banged it and nothing to speak of comes out. release fingers are normal, but it all looked a bit dry. have put small amount of penetrating oil on release fulcrums and belville/clip. A clutch is not something available off the shelf here and I am reluctant to import one when the other looks fine. Any Ideas would be welcomed.
Pete

[California Dreamin]

That's a dificult one when everything looks fine. The only thing I can suggest is a thorough strip/clean and re-lube of all the pivotting/sliding and touching surfaces ie:
Remove the release arm through the box, clean and lube the arm and the insides of the bushes.
Lube the rod end of the slave cylinder to release arm.
Thoroughly clean and re-lube the input shaft splines (using special spline grease..also apply internally to the centre plate splines)
Have a squirt around the pivots on the clutch pedal (engine oil) WD40 is too thin.
Thoroughly examine the spigot shaft end for wear and the support bearing in the end of the crankshaft (these collapse: common fault)....given that you have had repeated problems I would be tempted just to change it anyway....apply grease after fitting.
Bleed the clutch to ensure fresh clean brake fluid is lubricating the master and slave pistons.
Apply a small amount of grease to the release arm fingers/back of release bearing.
Clean and re-apply grease to the bearing sleave (over the input shaft)

The normal cause for stiff operation would be dry splines/bearing sleave AND worn diaphram spring fingers (where the face of the release bearing touch) worn spigot bearing.
Check that nothing has worn flat or grooved.

Martin

[Aidan]

spigot bearing ? rather than clutch, causes drag and selection issues as described

[Ian Hulley]

spigot bearing ? rather than clutch, causes drag and selection issues as described

Yep, been there done that. Eventually you'll not be able to select gears with the engine running

Ian