I've recently had the engine out of my fzj80, and fitted a new clutch kit while it was out.
Old clutch still had some life in it, but pedal feel was deteriorating, and I'd had some slipping offroad.
I'd previously adjusted the pedal position, and pushrod adjustment etc as per the FSM. Push rod was engaged by about 1 thread only on the clevis adjusting nut which was clearly not right.
Old pressure plate and fly wheel had some minor hot spotting, but both were in pretty good shape considering they have 250k km on them.
I fitted a new OEM master cylinder, and new OEM slave cylinder, and had fly wheel ground too. Fitted a new exedy HD clutch (can't remember which version)
Bled everything thoroughly. Adjusted the clutch pedal position, and push rod adjustment. The new push rod clevis also only has about 1 full thread engaged on the rod! Odd!!
After reinstalling the engine, the clutch would not disengage at all.
Could not select a gear at all. And there was no resistance at the clutch pedal at all.
After some digging, I find that two different throw out bearings where used with the 1FZ / H151 combo in 80 series. One being ¼ to ⅜" longer than the other. I still don't know why, or which models used the different bearings.
Seeing as I would have to pull the gearbox out in my garage, I
decided to replace the throw out bearing with the longer one, and replace the clutch fork and pivot ball.
I hate throwing parts at a problem, but didn't want to repeat pulling the gearbox on my back, under the car in the garage.
The bearing supplied with my clutch kit was the shorter one, and appears correct when searching part numbers using my VIN.
The old clutch fork and pivot seemed to be fine when compared to the new ones. New parts were fitted.
bolted gearbox back in. And can now feel some resistance at the pedal, so clutch is engaging/disengaging. I still can't quite engage a gear with the engine running. So the engine, and engage first, i can due the engine up, and the vehicle wants to creep forward. So clutch is not quite disengaging fully!! Grrrrr!
I re-bled the clutch. Re-checked pedal adjustment, and no change!
I've read elsewhere that the push rod clevis can sometimes be pinned in the wrong hole in the clutch pedal. My pedal only has one hole.
I've looked at the over centre spring loaded lever arrangement on the clutch pedal, and have come to the conclusion that it is there to assist with depressing the clutch pedal to make the clutch feel lighter.
I played with this with the master cylinder out, it clearly pulls the pedal to the floor once you get past about ¼ pedal travel.
My HDJ81 had a boosted church, and didn't not have the over centre lever arrangement on the pedal.
I'm thinking I'll take the over centre assist thingamajig off, see if that makes a difference. My big foot don't need help with depressing a clutch!
I'll also bleed everything AGAIN!
At this point, I'm kind of at a loss as to what the issue is.
I've ordered new pins and bushes for the clutch pedal assembly.
I think its odd that both the old and new master cylinder push rod clevis only gets 1 thread engagement on the rod when pedal position is adjusted.
It's like the leverage ratio on the pedal is wrong.
The only thing I can think of at this point is that the bushings in the pedal pivot are worn and affecting the throw on the pedal. Or the clutch pedal bracket on the fire wall is bent?
I'd love someone to tell me I've missed something simple, right now I'm clutching at straws (pardon the punny).
Old clutch still had some life in it, but pedal feel was deteriorating, and I'd had some slipping offroad.
I'd previously adjusted the pedal position, and pushrod adjustment etc as per the FSM. Push rod was engaged by about 1 thread only on the clevis adjusting nut which was clearly not right.
Old pressure plate and fly wheel had some minor hot spotting, but both were in pretty good shape considering they have 250k km on them.
I fitted a new OEM master cylinder, and new OEM slave cylinder, and had fly wheel ground too. Fitted a new exedy HD clutch (can't remember which version)
Bled everything thoroughly. Adjusted the clutch pedal position, and push rod adjustment. The new push rod clevis also only has about 1 full thread engaged on the rod! Odd!!
After reinstalling the engine, the clutch would not disengage at all.
Could not select a gear at all. And there was no resistance at the clutch pedal at all.
After some digging, I find that two different throw out bearings where used with the 1FZ / H151 combo in 80 series. One being ¼ to ⅜" longer than the other. I still don't know why, or which models used the different bearings.
Seeing as I would have to pull the gearbox out in my garage, I
decided to replace the throw out bearing with the longer one, and replace the clutch fork and pivot ball.
I hate throwing parts at a problem, but didn't want to repeat pulling the gearbox on my back, under the car in the garage.
The bearing supplied with my clutch kit was the shorter one, and appears correct when searching part numbers using my VIN.
The old clutch fork and pivot seemed to be fine when compared to the new ones. New parts were fitted.
bolted gearbox back in. And can now feel some resistance at the pedal, so clutch is engaging/disengaging. I still can't quite engage a gear with the engine running. So the engine, and engage first, i can due the engine up, and the vehicle wants to creep forward. So clutch is not quite disengaging fully!! Grrrrr!
I re-bled the clutch. Re-checked pedal adjustment, and no change!
I've read elsewhere that the push rod clevis can sometimes be pinned in the wrong hole in the clutch pedal. My pedal only has one hole.
I've looked at the over centre spring loaded lever arrangement on the clutch pedal, and have come to the conclusion that it is there to assist with depressing the clutch pedal to make the clutch feel lighter.
I played with this with the master cylinder out, it clearly pulls the pedal to the floor once you get past about ¼ pedal travel.
My HDJ81 had a boosted church, and didn't not have the over centre lever arrangement on the pedal.
I'm thinking I'll take the over centre assist thingamajig off, see if that makes a difference. My big foot don't need help with depressing a clutch!
I'll also bleed everything AGAIN!
At this point, I'm kind of at a loss as to what the issue is.
I've ordered new pins and bushes for the clutch pedal assembly.
I think its odd that both the old and new master cylinder push rod clevis only gets 1 thread engagement on the rod when pedal position is adjusted.
It's like the leverage ratio on the pedal is wrong.
The only thing I can think of at this point is that the bushings in the pedal pivot are worn and affecting the throw on the pedal. Or the clutch pedal bracket on the fire wall is bent?
I'd love someone to tell me I've missed something simple, right now I'm clutching at straws (pardon the punny).
