Clutch Problem???

[ilikemotorbikessoverymuch]

Got a 2000 dual cab 3.0TD Hilux. Clutch is an exedy HD with about 50,000 on it, feels and worked great. Has new clutch fork and throwout bearing.

Few weeks ago i was driving and all of a sudden struggled to go into gear. I adjusted the pedal for more throw and it was all good again. Now its completely gone. I replaced master and slave and bled two whole bottles through! Still no go. When I first got the problem i remember driving at about 100ks and hearing a loud snapping sort of sound from what sounded like the front right, but thinking maybe the bell housing. (something snapped and flying around inside?) it sometimes happens pulling away in gear and even got it to do it one time by revving in neutral.

It seems like the clutch fork has moved back towards the slave cyl over the past few weeks if that helps.

Any ideas!?

Cheers

 

[low_rb]

Can you drive it fine without using the clutch?

 

[my67xr]

Is there a boot or something around the fork you can pull back to look in there ?
Sound's like the clips that hold's the thrust bearing carrier to the fork have come off, or broken ?
You need one of these- 3 5 2 1 5M 5 5mm Android Endoscope Waterproof Borescope Inspection Camera 6LED D | eBay

 

[ilikemotorbikessoverymuch]

I can drive it relatively well without the clutch so its not a gearbox issue. I extended the slave rod as an experiment and it made the clutch work however it preloaded the pressure plate which made the clutch slip. Maybe this rules out a broken pressute plate? I actually thought of using one of those cameras. Might try that

 

[low_rb]

So you have no feel at the pedal at all or is it solid and you can push the pedal down?

 

[ilikemotorbikessoverymuch]

It feels a bit softer than usual. Springs back without pedal spring attached. Slave seems to be getting a normal amount of travel. Its just that the fork has moved back towards the slave too much so normal throw isnt enough to disengage clutch i think

 

[low_rb]

Going to have to get your eyes in there somehow.
Might be able to see through the fork hole but its going to be a box out job by the looks.

If you have the space and a engine crane makes the job alot easier.

 

[my67xr]

The spring on the back of the fork that hook's over the ball pivot might have broken, or come out of the top or bottom hole ?
If that's happened it would allow the hook's/spring clip's on the thrust bearing carrier to slip off the end of the fork too

 

[ilikemotorbikessoverymuch]

Pivot and clips and springs seem fine.gearbox is off. I don't know what's wrong

 

[ilikemotorbikessoverymuch]

Every component looks fine. Pivot. Fork. Clutch. I dont understand what could have worn over matter of weeks for the throwout to slowly move further and further from the pressure plate.

 

[ilikemotorbikessoverymuch]

Why is fork so close to slave???

 

[my67xr]

You might need to take the clutch plate and pressure plate to a clutch specialist and get them to check the spring's etc
Or is there and Exedy help line ?

 

[ilikemotorbikessoverymuch]

Maybe the dowel i found flying around in bell housing has damaged pressure plate. Or the missing dowell is in the clutch somewhere

 

[ilikemotorbikessoverymuch]

turned out to be pressure plate. Finger height was about 3mm out toward gearbox more than a new one. Obviously enough to make a diff unless it was the spring pivot or something. Thanks for the help fellas.