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Clutch/Gear shifting problem on EF after T5 conversion 

 

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 Post subject: Clutch/Gear shifting problem on EF after T5 conversion
Posted: Sat Feb 05, 2011 11:16 am 
Oompa Loompa
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Ride: '95 EF II (Interceptor)

Location: Melbourne
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Gday all,

After finishing my T5 conversion in my 95 EF, I'm finding I cant shift into gear :?
Motor off I can shift fine. In neutral she starts and runs smoothly.
But with the motor on, clutch down, I cant shift...like there's some resistance.
The Airbag light is on too...not sure if that's changing anything?
I've hooked up the clutch cable to the clutch pedal and down underneath to the clutch fork. The cable nuts are tightened and the pedal is off the ground around 140mm.

Any help would be great!!!
Cheers guys!
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 Post subject: Re: Clutch/Gear shifting problem on EF after T5 conversion
Posted: Sat Feb 05, 2011 11:25 am 
Getting Side Ways
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i dont know anything about fixing gear boxs but my mate had a similar problem in a suzuki x90 and thrust bearing was in wrong way or somthing i think he said? dont take my word for it

 

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 Post subject: Re: Clutch/Gear shifting problem on EF after T5 conversion
Posted: Sat Feb 05, 2011 11:49 am 
Oompa Loompa
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Interesting bry40l i'll keep that in mind.

UPDATE: Just tightened the clutch cable bolts and took her for a spin in 1st. Pedal is right up to the dash though and can't engage 2nd onwards, or reverse! :shock:
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 Post subject: Re: Clutch/Gear shifting problem on EF after T5 conversion
Posted: Sat Feb 05, 2011 2:33 pm 
Getting Side Ways
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Did you use a 2nd hand clutch or a new one ???
How is the insulator bush in the fork???
Did you fit the clutch plate in the correct way???
How are the clutch pedal bushes???
Did you do up the pressure plate bolts evenly.....1/2 to 3/4 of a turn each till tight.....???
How is the fork pivot plate for wear & adjacent face on fork???
How is the "Shoulder bolt" for wear????
Do you have the correct oil in the gearbox???

 

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 Post subject: Re: Clutch/Gear shifting problem on EF after T5 conversion
Posted: Sat Feb 05, 2011 3:26 pm 
Oompa Loompa
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Ride: '95 EF II (Interceptor)

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I appreciate the in-depth questions cjh
Gearbox was reconditioned and all other parts are new (clutch, cable etc) except for flywheel.

Did you use a 2nd hand clutch or a new one ??? Brand New
How is the insulator bush in the fork??? Is this on clutch cable. Clutch cable brand new.
Did you fit the clutch plate in the correct way??? I hope so. Will quiz mechanic.
How are the clutch pedal bushes??? Brand New
Did you do up the pressure plate bolts evenly.....1/2 to 3/4 of a turn each till tight.....??? Will as mechanic
How is the fork pivot plate for wear & adjacent face on fork??? Not sure where this is
How is the "Shoulder bolt" for wear???? Not sure where this is
Do you have the correct oil in the gearbox??? Dexron III was added. One bottle was "automatic" but this shouldn't matter
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 Post subject: Re: Clutch/Gear shifting problem on EF after T5 conversion
Posted: Sat Feb 05, 2011 7:06 pm 
Getting Side Ways
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clutch plate the correct way around?

 

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 Post subject: Re: Clutch/Gear shifting problem on EF after T5 conversion
Posted: Sat Feb 05, 2011 9:43 pm 
Getting Side Ways
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The shoulder bolt holds the wear plate and fork in place. If you can pull the fork out, without undoing the shoulder bolt, then the bolt & or fork are worn.
The insulator bush is on the fork.....has the claw on it for the clutch cable end to hook into.
The guts of them can pull out till it bottoms out on the pins. The pins stops the guts coming out altogether.

 

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 Post subject: Re: Clutch/Gear shifting problem on EF after T5 conversion
Posted: Sat Feb 05, 2011 9:48 pm 
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twase wrote:
clutch plate the correct way around?


Beat me to it..

 

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 Post subject: Re: Clutch/Gear shifting problem on EF after T5 conversion
Posted: Sun Feb 06, 2011 12:56 pm 
Oompa Loompa
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Ride: '95 EF II (Interceptor)

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I bet you guys are right and the clutch was put in the wrong way. Stupid idiot mechanic!
I'll let you guys know the result in a few days.
Maaaan I'm itching to drive her badly!!!!!!!!!
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 Post subject: Re: Clutch/Gear shifting problem on EF after T5 conversion
Posted: Wed Feb 09, 2011 7:26 pm 
Oompa Loompa
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Ride: '95 EF II (Interceptor)

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PROBLEM SOLVED!

A simple solution thank goodness! My mechanic failed to tell me to really hammer it into each gear to burn the clutch in. Here I am trying to be careful and not damage the thing.
But with a tight reconditioned gearbox and short shifter some real push is needed on the first proper run.

Thanks heaps guys for the help and suggestions! Much appreciated.
I was told too that it's physically impossible to put the clutch on the wrong way.

...by the way, the EF drives like an absolute dream!!! Wished I'd done this to her 6 years ago! Sounds better, feels a bit little, goes waaay better, and has more guts. You beuwty!!!
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 Post subject: Re: Clutch/Gear shifting problem on EF after T5 conversion
Posted: Wed Feb 09, 2011 7:36 pm 
Getting Side Ways
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FATT EF wrote:
PROBLEM SOLVED!

A simple solution thank goodness! My mechanic failed to tell me to really hammer it into each gear to burn the clutch in. Here I am trying to be careful and not damage the thing.
But with a tight reconditioned gearbox and short shifter some real push is needed on the first proper run.

Thanks heaps guys for the help and suggestions! Much appreciated.
I was told too that it's physically impossible to put the clutch on the wrong way.

...by the way, the EF drives like an absolute dream!!! Wished I'd done this to her 6 years ago! Sounds better, feels a bit little, goes waaay better, and has more guts. You beuwty!!!


roflmfao.... pretty sure the clutch plate is marked 'flywheel' for a reason.... i had the box out of my ea a few times and not sure about later models, but the ea (3 bolt) had washers between the pressure plate and flywheel and leaving these out meant a pretty much full time engaged clutch due to increased pressure from the pressure plate equalling hard gear changes and eventually worn syncros.

 

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Last edited by low_ryda on Wed Feb 09, 2011 8:34 pm, edited 1 time in total.

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 Post subject: Re: Clutch/Gear shifting problem on EF after T5 conversion
Posted: Wed Feb 09, 2011 8:16 pm 
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you certainly can put a clutch plate in the wrong way, the splines go straight through the bastard, meaning is can be be reversed just as easy, If I had an input shaft I would post pics to demonstrate.

 

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 Post subject: Re: Clutch/Gear shifting problem on EF after T5 conversion
Posted: Wed Feb 09, 2011 8:29 pm 
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i think your mechanic is a d**k!!
since when do you need to flog the clutch to burn it in??
you find clutch manufacturers wont give warranty if the cluch is abused in first 1000km..

and if the clutch plate is put in back to front the protruding side will rub on the flywheel bolts causing drag...
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