GTI conversion done... but not getting a gear :(

[beaver700]

Gday,

I apologise for all the threads/questions, but this may be my last for a while...

I cant figure out why I couldnt get a gear and move the sierra now... it is always like its in neutral! The 4wd gearstick is in 2wd, so thats not the problem...

All driveshafts on.

I put it on the pit this afternoon, with the car in gear, parkbrake off, and pushed from underneath... I could hear a scraping noise in the front of the gearbox which I could recognise as a slipping clutch...


I used the sierra flywheel, clutch plate etc, but no go...


It is a real pain having to lift out the engine/gearbox just to check the clutch..., so if anyone can diagnose the problem before I have to do this....that would be tops


Thanks again,

Martin

[Cruzer!]

hey dude...few questions...

a. do you have any clutch pedal feel at all?or is nothing there...
b. is the clutch adjusted correctly (www.suzukiinfo.com for correct adjustment procedure )
c. did the clutch get dropped, or overly dirty during the engine swap
d. did the throwout bearing get put back in(dont laugh, seen apprentices at work forget to put it in) AND did the selector fork get put into the throw out bearing correctly?

Cheers,

Ben

[beaver700]

Gday Cruzer, thanks for the help,


here is my situation..


1. There is certainly clutch pedal feel there... Ive noticed that when I push it down, at about 3/4 to the floor it suddenly gives way... (if you know what I mean)
2.Will check suzukiinfo
3. I am pretty sure the clutch wasnt dropped
4.During the conversion I am pretty sure I left the gearbox alone, as well as the throwout bearing, pretty sure the selector fork is on the throwout bearing..


I will check suzukiinfo first.


Cheers mate

Martin

[Cruzer!]

no wuckers mate let us know how ya go

[beaver700]

Just an update...

1. I adjusted the clutch cable...same issue.
2. I took the gearbox out to check the clutch, release bearing/fork etc. Everything looked ok, then I realised I had the clutch plate in the wrong way

3. Spent another 3 hours trying to align the clutch by using a mirror
4. Put the starter etc everything back in and adjusted the clutch cable again...

5. Then put it back into gear, pqark brake off, pushed it... it was not different from when I started the job 6 hours before


So now I have no idea what the problem is

[noelb1]

Hi Mate , have you pulled transfer stick out and put it back in they can get stuck in neutral ( due to a worn bush the stick sits on )and it looks like they are in 2wd .

noel

[beaver700]

Gday Noel,

I havent checked the transfer lever, but I will do this afternoon after work.

The main reason I think it is a slipping clutch is because I can hear a scraping noise in the bellhousing when I push the car forward in gear..



One more question... if the sierra clutch cover different from the gti clutch cover? I used the gti clutch cover, because it was near new. They looked identical to me except for the amount of fingers.. (the gti had about 5 or 6, while the sierra one had twice as much.



Thanks

[noelb1]

did you use the gti clutch and pressure plate ?? if so the clutch should be engaged unless the gearbox shaft isn't long enough to meet the splines in the clutch plate ..... try puttin the transfer in neutral and the gbox in 1st try to spin the jack shaft in the back of the gear box if it spins it is a clutch or gearbox problem, if it don't spin and feels like it is in gear Id say try the xfer.

noel

[timthev8man]

if you turn the motor while in gear , does the jack shaft turn ( tailshaft from gbox to t case) if so then your t case is in neutral. You need to use the GTi pressure plate with the Gti flywheel , but use the sierra clutch plate. I cant remember if there the same i have always just used the gti pressure plate as they have more clamp, so if your using the sierra pressure , you will have heaps of problem with your clutch slipping anyway. Best thing to do is get NPC at acherfield to build you a new clutch , $250 for a 1600llbs clamp and never have a problem with it again. The standard clutch is 750 lbs !! and in a 4x4 you need a good clutch

[christover1]

I thought you had to use the gti flywheel, but I haven't done it, so not sure.
It clearly isn't making contact, via plate and/or splines.
Something is too long, or too short, at a wild guess.

christover

[beaver700]

Thanks for the help guys,

I put the sierra on the pit, shifted the transfer lever to neutral, put the gearbox in 1st gear, went underneath the car, turned the smallest driveshaft (from gearbox to transfer), and I could hear the scratching noise from the bellhousing again.

Christover - From memory, I think I tried to use the gti flywheel, but it wouldnt fit inside the bellhousing.

At the moment I am using a gti pressure plate, sierra flywheel, sierra clutch, all in good condition...

It clearly isn't making contact, via plate and/or splines.
Something is too long, or too short, at a wild guess.

That makes sense though... I just dont know where to go with it... the engine is all settled in with wiring, plumbing etc, and it would be a hassle/shame to rip it out again to check why this problem is with this clutch... but it may have to happen

Any suggestions welcome


Thanks

[nicbeer]

did u try a sierra pressure plate in there as the other bits are sierra?

Nic

[beaver700]

Gday Nicbeer, no I havent yet, but thats what I may have to do next...

Its a real job trying to undo the starter etc, and take the transmission out to get to the clutch, so if anyone can suggest something else to do before I drop it out for a second time... that would be tops

Cheers,
Martin

[mr green]

either way your gearbag has to come out again. your problem is going to be clutch or gearbox so rip your box back out and stop keeping us in suspence when you get your box back out you should be able to hold output shaft and turn input shaft by hand in gear if the problem is in the box. when i did this conversion i used the sierra flywheel, disc and pressure plate with no problems. and if you are getting no drive at all and you can turn your jack shaft by hand, the disc would have to be as loose as a goose in the pressure plate. but you said you spent 3 hours lining the clutch up so i assume the disc was not loose in the pressure plate when you tightened the pressure plate . i think i just said pressure plate too many times
jason

[christover1]

I have been told, but have never seen it, that some Sierras have a different spline on the clutch to most. Have no idea, but worth a look at.

I doubt clutch could slip on pressure plate or flywheel without this being obvious during assembly.

But if the spline don't engage, wrong type or length, this could explain it.

If you have engine running in gear, the small jack shaft should turn, if not its clutch or gearbox.

If it is turning, chances are its in the t-case.

make sure t-case is in neutral, in case it bites and drives off.

christover

[christover1]

ps gearbox should come out from underneath without removing engine.
depending on mods you may have.
christover

I should read with eyes open, you already know this

[beaver700]

Gday,


Thanks plenty guys will check everything today after work,


Cheers,

Martin

[noelb1]

let us know ...

[timthev8man]

i have said it once but i'll say it again, you have to run the gti flywheel, BUT you'll have to use the sierra flywheel bolts !!!! thats the trap ! and use a sierra clucth plate with the gti pressure plate, I have done this conversion and know .

[beaver700]

Gday everyone,

Update:


1. Pulled the gearbox out this afternoon.
2. Checked the clutch, exchanged to sierra pressure plate, torqued pressure plate bolts to 25Nm
3. Put the gearbox back in, filled it with oil, then one single spring washer fell down the shift lever column as I was re-installing the lever
4. Pulled the gearbox out a second time...
5. Cracked open the gearbox to fish out the washer...
6. Reinstalled gearbox...


In all it took about 6 hours!, and it was worth it too because the clutch is working now!

I cant explain why this was so...but just a suggestion to anyone who does this conversion, just buy a heavy duty sierra clutch kit and be done with it... dont try and economise with mixing bits and pieces of the gti clutch etc...




Thanks for all your help guys

Cheers,
Martin

[Cruzer!]

excellent, good on ya champ, get out there and enjoy it