Tranny swap problem: help anyone!

[mobes]

So last weekend I finally had the ambition to do the tranny swap I've been planning since April. Everything went well except for an axle issue, but Zoni clarified that (thanks) so no real problem there. I got everything swapped, car back together, I pressed the clutch, started it up, put it in gear, released the clutch, and ---- nothing. The car wouldn't try to move in any gear. A friend helped me verify the operation of the slave cylinder and everything seemed to operate correctly, it just didn't go. The clutch pedal felt a little lighter than I expected too.

So it sat all week, and this weekend we tore it all apart again. We can't find a damn thing wrong, we even made a trip to the Toyota shop but nobody was around but the parts guy. The clutch disc splines match up perfectly with the input shaft on the tranny, and there doesn't seem to be anything keeping the clutch from engaging.

This one has stumped everyone I've run it by. So, does anybody have any ideas? I really wish I could be driving my poor car right now

Here's a pic of the installed clutch (with Fidanza flywheel). I seem to remember the fingers sticking out farther on the last clutch I did, but that was like 4 years ago so I could be wrong. I looked on Ratko's page and his looks about the same so I'm not sure.



Anyone??

[AdamS]

Not to insult your intelligence but did you ensure that there is zero air in the hydraulic lines? Is the slave pushing the engagement fork when you depress the clutch pedal (assuming so)? There could be sufficient air in the lines to allow the slave to move "enough" so that it appears its operation is true, but not enough travel to disengage the clutch! Hate to be so presumptive, but this is at least my $.02

For your sake I hope that it is so simple...


-Adam

[yota]

Originally posted by AdamS
Not to insult your intelligence but did you ensure that there is zero air in the hydraulic lines? Is the slave pushing the engagement fork when you depress the clutch pedal (assuming so)? There could be sufficient air in the lines to allow the slave to move "enough" so that it appears its operation is true, but not enough travel to disengage the clutch! Hate to be so presumptive, but this is at least my $.02

For your sake I hope that it is so simple...


-Adam

If it was that then he wouldnt be able to get it in gear. Does it go into gear when the clutch isnt pushed in? Does it feel as though it is in gear? Have you tired anyother gear than first?

[zoni]

you can change gears without the clutch... its just horrible for the tranny

i agree with asking the question of wether it is in gear or not... its possible that it is just in neutral and stuck there... either that or the shift fork might be broken (almost impossible). or the clutch is installed improperly, mainly the release bearing... did you follow the haynes manual or some other manual while installing the clutch?

also, do you have the clutch disc facing the right way? its possible that its in backwards and it wont grip the flywheel.

[mobes]

Thanks for the ideas.

The clutch lines were bled properly, and proper slave cylinder action was verified. The clutch disc being backwards was my first guess but that wasn't the case. Yes it is in gear, I tried it out on the floor with the axles installed, and all gears operate as they should. It seems to be working, the car just wouldn't move. I'm totally stumped on this one. I think it has to be something with the clutch fork/slave cylinder/throwout bearing, but I just can't figure out what, everything is in perfect shape.

Thanks again and more ideas welcome.

[Your Uncle Moe]

Hey, lemme get in here and ask a question too. I wanna feel important! Have you tried shifting without depressing the clutch? And what happens?

[mobes]

I think I'll just put it back together tomorrow since I couldn't find anything wrong, then play with the hydraulic system a bit. The master cylinder and clutch line are brand new, but the slave cylinder is the one from the tranny (2000 with 50K miles). I'll try replacing the slave cylinder just to make sure. I'll keep you 'posted'.

And I didn't try shifting with the clutch up with the engine running. Without it running it is much harder to shift with the clutch up then with it down. I'll be sure to try that tomorrow.

[zoni]

i cant beleive the car doesnt move......

i'd try turning the car on and putting it into gear while on jackstands... of course put the e-brake on, and be facing outward from the garage just in case.... but see if the wheels spin at all.... ya know, see if the clutch is connecting at all to the flywheel.

worst case, it could be a bad tranny, it could be missing something or have something broken inside.

[ArmyofOne]

long shot here, did you put dowles in the Diff gears to make sure they didnt fall into the casing?? im not sure if this happens on toyotas, but it does on fords, whenever you remove an axle, you have to put a dowle through one side (a broobstick or somnething of similar diameter) to keep the diff gears from falling into the bottom of the case...just a thought, and again, a long shot at that.

[zoni]

nope, not in toyotas

you can take the axles out and bounce the tranny on a bungee jumping cord and it will be fine.

thats why its a toyota and not a ford...... FixOrRepairDaily

[mobes]

ArmyofOne: The diff gears are intact. The Haynes manual mentioned something about that but it doesn't apply to this particulair transmission.

I've also tried putting the axles in the tranny with it sitting on the floor and shifting through the gears to verify proper operation. I'm 100% certain it's a clutch problem of some sort, but I just couldn't figure out what.

[mobes]

Reading Zoni's reply reminded me: it was the Haynes manual for my old Taurus.

Camry >>>>>>>>>>>>>>>>>>>>>>>> Taurus.
I gave the Taurus to my sister when I bought the Cam.

[zoni]

where did you get the clutch from? what kind is it?

[mobes]

The clutch is a Bryco reman off eBay. The TOB and pressure plate are new OEM. The clutch disc splines mesh perfectly with the input shaft on the tranny, I also measured the offset from the bellhousing to block joint to make sure everything is where it should be, and found no issues there.

[zoni]

thats so wierd bro... i would definitely just say to take it to a mechanic at this point... you've been through everything that you can think of.