clutch release arm movement issue?

[chrisrigby]

Chaps I need some help understanding a problem.

I have taken an mgtf 1.6 in for rescue the inital fault was the AA diagnosed as slave cylinder failure. Well from what I initially found was correct the folk was off the slave and the piston was pushed out with the clutch pedal held to the floor due to the lack of hydraulic pressure.

Turning the engine over there was a mass of noise from the gearbox something was definitely broken inside. I stripped the gearbox and found the arms of the pressure plate all over the place and the thrust bearing all smashed up.

I removed everything cleared all the metal, removed the flywheel and ensured there were no bits left, cleaned it all up, checked over the parts the gearbox shaft was fine. I found the hole on the end of the clutch release arm was excessively worn as was the retaining pin also.

I have changed the arm and pin, I had a very good used 1.6 clutch and presure plate that I took off an old 1.6 a few years ago when that car died, the clutch was only 300miles used so kept it in the shed just in case. I bought a new clutch release bearing too.

So heres the issue.... reassembled as ive done before a few times, the clutch plate is deffo the correct one, for example a 1.8 has six springs (cant remember the accutual name) where as the 1.6 has four. I double check on the rimmers site and the pictures are correct. It can only fit one way as its sits flush with the flywheel, as fitting it the opposite way fouls against the flywheel mounting bolts and therefore would never sit flush against the fly... thus no drive transfer from the fly to clutch.

The gearbox fitted back onto the engine, I can only assume that it is alligned correctly or would not fit right???

It was all bolted up and back where it should be.

To ensure the system was going to work ok I bleed the master first and them onto the slave kept going till I could get clear fluid.

My problem is that the arm does not seem to move the full distance forward, ie for the release bearing to apply pressure to the pressure plate and break away from the flywheel. Moving the arm by hand and even with a bar on the arm. It moves forward but I can hear it tapping against the fins of the pressure plate but with all my force I cannot move it further forward. I very much doubt that the slave cylinder would produce more pressure or force to move it. Even when blead it pushes, appear to hit and then flex back on its mounting bracket.

The drive shafts are not fitted, I wanted to ensure the clutch was blead and released before rebolting everything else. The car starts with the clutch engaged and yes it is in neutral checked both the lever and the selector on the box. I can cycle through the gears but I was informed that ok as its through the sincomesh?

So any advice or direction would be great.... I'm stuck and my only option is to call a mobile specialist. Cheers

[talkingcars]

Was the original 1.6 a MGF or a front engined car?

The 1.6 F/TF is the only MG/Rover to use the PG1 box.
However I'm not sure if the ratios or just the final drive is different.

[chrisrigby]

Was the original 1.6 a MGF or a front engined car?

The 1.6 F/TF is the only MG/Rover to use the PG1 box.
However I'm not sure if the ratios or just the final drive is different.

Yer same mgtf 1.6. The release bearings are all the same, the clutch plate ect are different part numbers.

[RobboMC]

Could the release bearing have come out of the fork as you fitted the gearbox?

This about the only explanation I can think of. It could be the fork hitting the clutch fingers and without a release bearing in the right place
I don't think it would have enough travel to open the clutch.

Or could your new pin have fallen out? Unlikely but I'm clutching at straws.

Seems to me a quick removal of the gearbox is needed to see what's going on, at least you didn't refit the drive shafts.

[frenchdave]

Chris did you solve the problem?
I have a sick 1.6tf here, which it appears the release arm is working, and the slave is ok, but you can run the engine and change gear without the clutch, but not get any drive. Last owner said it stopped suddenly at some lights? Could the release bearing have fallen out?
What did you find
Thanks
Dave

[Rob Bell]

There is a fork at the end of the end of the release arm (its a lever and a rod, which bears onto a fork that releases the clutch). If everything you see is functioning as it should and yet the clutch is disengaged, then I suspect that the fork has come off and wedged the clutch. Seems rather unusual though?