Outer Limits 4x4 Board

Hey guys,

After doing the 5-speed swap in my Patrol my clutch never worked properly. In fact it never worked at all! We ascertained that the clutch selector fork wasn't sitting on the input shaft properly so it wasn't pushing against the thrust bearing. This was mainly because when we were putting the box back in it was late, and we were getting tired.

So my question is... when I pull the box out, is it a simple case of sitting the release fork back in place? Or is there some sort of circlip that's likely broken and needs replacing. I ask this because the car is 50km away from where I live now, at my old place (now my mates) and without other wheels I want to minimise the train trips back and forth to look at the damn thing.

My FSM doesn't show anything about any circlips, only that a small amount of grease should be put on the two pivot points of the fork. It's just that I've been told something about circlips. Can anyone shed any light on this?

Thanks!

I may be mistaken but I was of the opinion that the push rod coming out of the slave cylinder is also of a different length!!!
Somebody my wish to confirm this.

Yes you could be right, the other thing could be the little clip that sits in the back of the fork that helps hold it in position, if this isnt on correctly it could come off. Id check both things but the slave sounds like a good bet and easy to check also.

Ok so my pushrod might need swapping over then? Doesn't seem to hard, I could knock something up out of an old screwdriver with a grinder or something. Just want to get this thing back on the road.

Forgot to say, the fork actually came away and is now sitting inside my bellhousing somewhere... but when it was half on it was at a really weird angle to the slave cylinder so I am assuming it wasn't sitting on correctly in the first place.

on the 4 speed the fork clips onto a pivot ball in the bellhousing, its held on by a strange wire clip that sits in the fork, there is also a u shape clip that holds the fork to the thrust bearing

when the forks get old they are very prown to falling off the ball.
but should be fine if you can get the box back in without it falling off

we used the old shaft from me dads yabby pump as the new piston extension as the original was brass and same dia

I had the same problem and what it is is the throwout bearing holder needs to be modified. It has nothing to do with all the above suggestions. Your symptoms are that the clutch is engaged all the time even to the point you can nearly change gears with the engine running without putting your foot on the clutch (Right??) you need to remove the gearbox again and modify the bearing carrier (needs to be shortened) all you need is a straight edge and tape measure and work out the distance the bearing sits inside the bell housing and how far the spring fingers sit out from the same mounting point on the engine block. You can shorten the mount trust me just have a good look at it.
Hope this all makes sense

um i'n not sure it's what you describe dr. basically at the beginning what was happening was you couldn't disengage the clutch. i actually drove it a 850km round trip with no clutch (needed to get to a funeral and had no other option) so it's not that i could change gears easy. pretty much the opposite.

my boss came around and had a look and wiggled the throw-out leaver i was describing and said it wasn't sitting on properly. which makes sense because it wasn't even lining up with the pushrod/slave... was about 2cm below and to the left of it on a weird angle.

thanks for the suggestions please keep em coming gotta get the shitbox running in time for bushranger clubkhana and tuff truck!

I think if your fork isnt lining up with the pin on the slave cylinder the only thing to do is take the box off again and put the fork back in place again, there is no other way around it and from what you describe this is exactly what the problem is.

thanks MQ and everyone who's replied. yeah that's what I'm gonna do, just bite the bullet, trudge out there on the train and go for it...

yea sorry I missread your thread. I just assumed you went from a 4 spd to a 5 spd. I reccon bushmq is correct

no no doc I did go from the 4spd to the 5spd and i will keep an eye for what you are saying

thanks again for the help