Clutch won't disengage; Main reservoir ok

[paulo999]

RAC called about 2 hours ago, but in the meantime I've been reading the wiki.

Situation pretty much as per thread title. The main reservoir is full to the max line. Pedal still has fairly normal resistance.

I'm guessing any further diagnostics means crawling under the van?

(If so, I'll leave it to the RAC. Busy road. If I got shunted whilst under the van I'd be toast.)

Assuming the RAC man/woman can't sort it, I guess I'll then have to wait for a flatbed. Had to happen one day!

[paulo999]

So, no roadside repair - not that I was expecting it.

Helpfully towed me the 300m or so to where I can legally park near where I live - avoiding having to go straight for the recovery truck and even more waiting. Luckily the van specialist I use is within 10 miles, so I can get a free recovery tomorrow from home to bus hospital.

Once I know the verdict, I'll post back just in case it might help anyone else in future.

[billy739]

well if it looks ike the clutch arm moves ok when you press the pedal and the slave / master cylinders are dry then looks like a box out job to check the clutch

[paulo999]

well if it looks ike the clutch arm moves ok when you press the pedal and the slave / master cylinders are dry then looks like a box out job to check the clutch

I've not checked the cylinders yet, but the main reservoir is full to the 'max' line, so I'm assuming that suggests no downstream fluid leak?

(To add insult to injury, the RAC have sent another van when they were meant to be sending a truck. So now the recovery process starts over again.)

[ermie571]

Paul,

check the spigot bearing.....when mine went clutch was fine, gears wouldn't (dis)engage at all with engine running. Engine off, and we got it into 2nd gear, just. Started with a kangaroo leap and got her home with all hazzards going and the AA right behind. Only a mile or so....and only one junction at which I didn't have to stop (lucky!)

Em
xx

[paulo999]

Hi Em,

Van is now at bus hospital. Not inspected yet, but initial guess was a failed bearing. He did explain where (between engine and clutch, I think). Is that the spigot bearing?

Anyway, he says if it's that it can be a pig to get off. Might need new clutch. Might even need new gearbox depending on what he finds.

Not looking forward to this bill.

e2a: I've since bumped into a mate who has a bay. His needed a new spigot bearing when he first bought it. Jack's in Notting Hill said he needed a new gearbox. So he went elsewhere and got the bearing done by mechanic who knows his vans and did it for about £150... I'm now thinking if I can mine fixed for less than £200 I'll be happy.

[billy739]

gearbox out - 1 hour , spigot bearing change - 20mins if difficult - box refit -1hour

all generous times unless there are probs - but usually simple.

so no probs and should not be a big bill.

[paulo999]

gearbox out - 1 hour , spigot bearing change - 20mins if difficult - box refit -1hour

all generous times unless there are probs - but usually simple.

so no probs and should not be a big bill.

That's encouraging - thanks billy

[ermie571]

Paul,

so you know...

a long cylinder of metal sticks out the front of the gearbox....this goes into the engine and is known as the Input shaft. This shaft needs support in the engine, so between the engine block and the shaft is a needle bearing, called the spigot bearing. if this fails, you will know as when you pull the box, you will feel the needles loose in the enclosure - or may even come out with the box.

Yes, they can be a pig to get out IF you don't have a puller. A decent garage should have a puller. My clutch was absolutely fine.

However, if the spigot is fine (and it costs a tenner to buy, may be worth changing while box is out if a puller is available), the clutch springs may have come through the fingers...that could be the reason he reckons it could be a new clutch. Worst case is the gearbox....has it been difficult lately? (my spigot collapsed in rush hour!!, but had been fine the day before...it just went!)....but before you panic, get the drain tool, loosen the filler (to make sure you can refill!), then drain the gearbox oil. Gonna cost you around £25 in gear oil to refill, but as the box is out it will be a darn site easier to do, you will see what carp is on the magnet (small filings = normal, big bits of metal = Oh dear....) and what is in the oil. If you can, get some pictures up - those more knowledgable than I will be able to diagnose! new oil in the gear box isn't a bad thing to have

Can you go and look at it during the work? Do you trust this place? Not been ripped off before. Make sure you ask for the old parts back....I always do this (they are mine) but I can then see the condition, and am less likely to pay for parts that haven't been changed!

Hope it goes ok - keep us updated.

Em
xx

ps - my "chap" did switched a gearbox for me in less than an hour....I was going on holiday at 10 am...bus was at garage (packed, ready to go!), the car that was on the ramp cam off, the van was going on as I walked out of the garage -went next door to get a tin of quality street for the lads in the garage, read my book for a bit, and 50 mins later the van was on a test drive. Cost = £50. BUT....this is a chap who has been fixing my vans on a scheduled and emergency basis for several years. AND, he had all four of his lads on it for half hour, holding, suppporting and wiggling to get me away on my holidays (and get the bloody van out of the garage!! lol) So, it can be done.

[kevtherev]

might even be a failed slave cylinder

[paulo999]

Well, here's the outcome:

Spigot bearing replaced.

The spindle coming out of the gearbox had apparently been damaged by the failed bearing, and need remachining (he said that spares aren't available any more). He did show me the failed bearing, but couldn't show me the spindle as it was all reassambled.

He also fitted a new clutch whilst the box was out.

Six hours labour @ £50 per hour plus VAT, so the total bill including parts came to £480. Which was a bit of an ouch.

There's no way I could be doing this kind of work myself - I don't even have a drive. But I might try a different garage next time, just to compare. This guy certainly knows his vans, that's pretty much all he does, but I never feel like I've got a bargain. If anyone has any recommendations for London area mechanics, let me know!

[California Dreamin]

Re-machined as in, add new metal and lathe to original size? or re-dress with a file which will mean it's too small and will slop about.

Martin

[ermie571]

Paul....we have done 3 clutches on the side of the road.....with 2 people its not impossible. My spigot was done on the roadside too....as you, we don't have the luxury of any off road repair space!

can't help with garages unless the outskirts of Kent are not tooo far to travel.

regards

Em
xx

[paulo999]

Re-machined as in, add new metal and lathe to original size? or re-dress with a file which will mean it's too small and will slop about.

Martin

No new metal. The only other thing I know is that emery paper was involved.

The change into first is now very lumpy. 2nd is okay-ish. 3rd and 4th are fine. He's said I can take it back for him to tweak the eccentric adjustment, if it stays like that.

[paulo999]

Paul....we have done 3 clutches on the side of the road.....with 2 people its not impossible. My spigot was done on the roadside too....as you, we don't have the luxury of any off road repair space!

can't help with garages unless the outskirts of Kent are not tooo far to travel.

regards

Em
xx

There's only me - just the one pair of hands (and my parking is on a road where traffic passes within about a foot of the van )

Yes, Kent could well be doable - please send me details of your garage, they sound like good people. It doesn't help that my man is a one man outfit, so that likely limits the speed he can get stuff done.