Clutch not fully disengaging, difficulty changing gear .

Sep 20th, 2004, 19:19

Hi All

I have a 1987 740 with a M46 gearbox (4sp + OD). Gear changes are getting more difficult, they are particularly bad in stop/start traffic, after say 20 mins the situation can arise where first gear can not be selected, in fact I managed to bend the gear stick the other day trying to force the issue in a mild panic.

Reverse is also difficult to select and usually grinds.

When the engine is off the gears change fine so I think the box is not the problem.

I'd hoped that I could adjust the push rod that goes into the clutch master cyclinder but it is non adjustable.

I have thought that replacing the master or slave cylinders, or refurbishing them with a kit could help.

There is also a small amount of play in the plastic clutch pedal where a steel (clevis?) pin has ovalised it's holes. A replacement pedal or a repair job could reduce the play there and allow some more compression of the master cylinder.

Any comments or suggestions of where to start? I'm not in a position to do any major work myself (like removing gearbox). If I have to fork out for this to be done so be it, but if it could be someting simple/inexpensive I'd obviously like to try that first.

Regards,
Ian

Sep 21st, 2004, 08:40

have you tried adjusting the clutch cable? could just be that the pedal is reaching the end of its travel but the clutch isnt?

Sep 21st, 2004, 10:07

No cable to adjust, mine has hydraulic line between pedal and clutch fork rather than a cable. I'm not sure which is more common.

Sep 21st, 2004, 11:20

http://pic7.picturetrail.com/VOL188/...8/23744414.jpg

You can try measuring the travel of the clutch fork when cold and again when the problem occurs.
If there is less travel when hot it could just be a hydraulic problem.

It does sound though, as if there is an internal fault causing clutch drag.

If the box has to come out to replace the clutch, make sure that the spigot bearing is also replaced (it does not come with a clutch kit).

Also carefully check the release fork pivot and the fork itself for wear, the pivot bolt can wear through the pressed steel fork.

Colin.

1990 740SE B200E/M47, remote C/Locking.

Sep 20th, 2004, 19:19	#1
ianp Guest Location:	Clutch not fully disengaging, difficulty changing gear . Hi All I have a 1987 740 with a M46 gearbox (4sp + OD). Gear changes are getting more difficult, they are particularly bad in stop/start traffic, after say 20 mins the situation can arise where first gear can not be selected, in fact I managed to bend the gear stick the other day trying to force the issue in a mild panic. Reverse is also difficult to select and usually grinds. When the engine is off the gears change fine so I think the box is not the problem. I'd hoped that I could adjust the push rod that goes into the clutch master cyclinder but it is non adjustable. I have thought that replacing the master or slave cylinders, or refurbishing them with a kit could help. There is also a small amount of play in the plastic clutch pedal where a steel (clevis?) pin has ovalised it's holes. A replacement pedal or a repair job could reduce the play there and allow some more compression of the master cylinder. Any comments or suggestions of where to start? I'm not in a position to do any major work myself (like removing gearbox). If I have to fork out for this to be done so be it, but if it could be someting simple/inexpensive I'd obviously like to try that first. Regards, Ian

Sep 21st, 2004, 08:40	#2
5lab Guest Location:	RE: Clutch not fully disengaging, difficulty changing gear . have you tried adjusting the clutch cable? could just be that the pedal is reaching the end of its travel but the clutch isnt?

Sep 21st, 2004, 10:07	#3
ianp Guest Location:	RE: Clutch not fully disengaging, difficulty changing gear . No cable to adjust, mine has hydraulic line between pedal and clutch fork rather than a cable. I'm not sure which is more common.

Sep 21st, 2004, 11:20	#4
Colin Shepherd Guest Location:	RE: Clutch not fully disengaging, difficulty changing gear . http://pic7.picturetrail.com/VOL188/...8/23744414.jpg You can try measuring the travel of the clutch fork when cold and again when the problem occurs. If there is less travel when hot it could just be a hydraulic problem. It does sound though, as if there is an internal fault causing clutch drag. If the box has to come out to replace the clutch, make sure that the spigot bearing is also replaced (it does not come with a clutch kit). Also carefully check the release fork pivot and the fork itself for wear, the pivot bolt can wear through the pressed steel fork. Colin. 1990 740SE B200E/M47, remote C/Locking.

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