Replacing a clutch in a 96 pajero and having problems

[googz]

hey, i have just recently blown up the clutch in my 96 mitsubishi pajero now im at the stage where i have unbolted all the bolts in the bell housing and have unbolted all the mounts, taken the knobs off both the gear levers and unplugged any wiring. I have seperated the gearbox and the engine about 3 - 4 cm but i cant get them to seperate. Any suggestions as to anything i should do or may have missed would be greatly appreciated. Thanks

[J Top]

Remove both driveshafts,remove both gearlevers,disconnect speedo cable,disconnect battery,remove starter.
Is the bellhousing fouling on the firewall,you may have to jack the front of the motor up to get clearance.
If you are positive you have disconnected everything,then it is possibly the spigot shaft has seized to the spigot bush/bearing and is trying to pull it through the clutch spline.
J Top

[Shadow]

Remove both driveshafts,remove both gearlevers,disconnect speedo cable,disconnect battery,remove starter.
Is the bellhousing fouling on the firewall,you may have to jack the front of the motor up to get clearance.
If you are positive you have disconnected everything,then it is possibly the spigot shaft has seized to the spigot bush/bearing and is trying to pull it through the clutch spline.
J Top

if the spigot shaft has siezed how would he fix it

just reef it, or could that do dammage?

[googz]

if thats the case then how the hell do i unjam it?

[googz]

http://www.clantnt.org/googz/arrgghhh.JPG
^exhibit A

[Shadow]

when the clutch lever is pushed it pulls the bellhousing and motor back together, could this mean the splines are not lined up properly, or could it be that the spigot bearing has siezed to the spigot shaft?

[googz]

anyone that has the workshop manual for a 96 pajero and a scanner it'd be a big help if you could maybe scan the pages relating to clutch removal/replacement and post them please...

[-Scott-]

when the clutch lever is pushed it pulls the bellhousing and motor back together, could this mean the splines are not lined up properly, or could it be that the spigot bearing has siezed to the spigot shaft?

Could it be that the clutch arm is still connected and that's causing the problem?

[4runna]

Nah it's not the clutch lever as that's connected to the release bearing which slides on the input shaft sleeve, so will come out with the box.

It definately could be the spigot bush, we sometimes had to get half the mechanics in the workshop together to remove boxes just because of the spigot bush (is it a bush or bearing in the Paj out of curiosity) And that was on the hoist when you have much better leverage.

assuming you have made sure there is nothing round the top of the bellhousing or above the gearbox that is holding it that you've missed, then a tyre lever between the block and bellhousing on each side, the 2 other guys, one shaking, one pulling the box and she'll come out.

just make sure u are positive there is nothing you have missed first.

Hopefully by this stage you have worked it out. I have a manual but my scanner is dead.

1 other thing, you didn't say you had actually removed the gearsticks, just the knobs? that will certainly stop it from coming out in most cars. Haven't done a box on a Paj tho.

Good luck, and let us know what it was.

Rob

[Rossco]

It may be a pull type clutch, where the throwout bearing is clipped if you like into the pressure plate. Pull the clutch fork boot back and have a look with a torch, if it is a pull clutch use a screwdriver to release the throwout bearing from the pressure plate. When putting it back together just hit the clutch fork gently with a hammer and that will locate the bearing in the pressure plate.

Good luck

[Rossco]

It may be a pull type clutch, where the throwout bearing is clipped if you like into the pressure plate. Pull the clutch fork boot back and have a look with a torch, if it is a pull clutch use a screwdriver to release the throwout bearing from the pressure plate. When putting it back together just hit the clutch fork gently with a hammer and that will locate the bearing in the pressure plate.

Good luck

[Rossco]

It may be a pull type clutch, where the throwout bearing is clipped if you like into the pressure plate. Pull the clutch fork boot back and have a look with a torch, if it is a pull clutch use a screwdriver to release the throwout bearing from the pressure plate. When putting it back together just hit the clutch fork gently with a hammer and that will locate the bearing in the pressure plate.

Good luck

[Rossco]

It may be a pull type clutch, were the throwout is clipped into the pressure plate. Pull the clutch fork boot back and use a screwdriver to release the bearing from the pressure plate. When putting it back together just hit the fork gently with a hammer to locate the throwout bearing

Good luck