Club 80-90 Forums

Went to take my new van on its first trip today, started fine, went to put it into first and the clutch pedal would only go down half way! Couldn't get it in gear!

Disconnecting the outlet of master cylinder means the pedal goes full travel so problem must be at the gearbox end.

Slave cylinder has a full travel too. So the lever on the gearbox for disengaging the clutch moves down but doesn't disengage the clutch. Am I right to assume that (given no problems until today) the clutch is fine and the mechanism for disengaging it has broken?

Any tips for mending it?

Thanks
Gary

If it is a problem with the release bearing then the gearbox needs to come out.

Deep joy !

Not as big a job as it sounds .... things can still go Orribly wrong though Driveshaft Bolts, clutch hydraulics,

Starter motor bush replacement time as well me thinks !!

Good luck, Ian.

Thanks for the replies,

I've got the gearbox off and the bearing had twisted round and fallen off the two sticks coming off the release bar, probably because the ends of the two sticks are worn. I've ordered a new one from JK. Clutch was in good condition, but I might as well put a new one in anyway now.

Luckily it has got a new starter motor on it, so I don't need to tamper with that.

I'll let you know how reassembly goes!

Thanks
Gary

My guess is the release bar will be of the same crappy quality I bought off them years ago... its still in my drawer... I reshaped the bits the touch the release bearing, nice and rounded with a file.. if they are badly worn... then weld a blob onto them and reshape...

Got the JK release bar on - seems exactly the same quality as the old one. So specialised they're probably all made in the same place. Took ages to get the lever off the end of the old one though - had to drill out the shaft.

Also had to buy a clutch alignment tool to get it all back together - very difficult to judge by eye.

But it is up and running again! Thanks for all the suggestions.

Gary