[Santos]

Gearbox is stuck in gear, brute force doesnt get it out.


Did an engine swap recently so i could get the lwb on the road. The engine with gearbox was dropped by wellmeaning friends at about chest height. Sent friends home and replaced bent enginemounts. Installed engine it apears to run fine.
Gearbox was jammeed in gear .

Tried driving a few meter and wouldnt un-jam . Had someonelse round yesterday, dropped gearbox, put in second gearbox after swaping over the new thrust bearing i had installed. Putting it back together today and went to put the gearbox in neutral. STUCK in gear
So i am thinking maybe there was nothing wrong with the gearbox and i have done some wrong.. twce. but can't think what it is?

[Santos]

Footnote: I have swapped out a gearbox a couple of times before this. I didn't put a retainer clip for the thrust bearing so i going to track one down. I can't imagine that would cause the gears to jamn. Also i tested the gear shifts outside the car on the 2nd gearbox

[shandy92]

How does the clutch feel? Good smooth travel?

[Santos]

was on the 1st box, had the clutch in to start & test engine etc.

current one could do with some adjustment on the lever, i stuck it on a less agressive angle with the intent of using the cabe to adjust the slack, needs to be somewhere between where the other one was and where it is now on current box.

[fordem]

First a question - can you shift gears with the engine off?

No - gearbox or shift lever related issue.
Yes - clutch related issue.

[AckerDackerly]

Santos wrote:

was on the 1st box, had the clutch in to start & test engine etc.

current one could do with some adjustment on the lever, i stuck it on a less agressive angle with the intent of using the cabe to adjust the slack, needs to be somewhere between where the other one was and where it is now on current box.

Unless Suzuki took us USAens for complete idgits and only marked our clutch lever and the shaft it mount on for perfect fitment, you should also see a dot stamped into the face of the clutch arm at the splined hole and another dot stamped on the end of the splined shaft the clutch arm attaches to. These dots, when aligned together, mark the correct attachment of the clutch arm to the throwout shaft.

As for the clutch and cable itself, I cannot comment with any sureity other than to say that there are at least two clutch cables of different lengths available - or possibly a clutch cable not manufactured to specification.

We have many forum posts "up over" that complain about clutch adjustment with a wrong length cable that will not properly adjust to working condition even though the factory service manual's instructions were followed.

Finally, did the clutch arm get damaged when the gearbox was dropped?

I hope that this helps!

[Santos]

Hi Ack, never noticed the dots, would make sense i will check on some of my gearboxes.

2nd gearbox was not dropped so i dont think the damage was there,
clutch cable is aftermarket, have the same one in my SWB daily driver with no problem (also swapped the gearbox out 3 times on that one with not problem )

[Zook_Fan]

You're not installing the shifter in the wrong gate are you? Like putting the box in gear before installing and then dropping the shifter in behind the gear when reinstalling it?

[Santos]

Both times i have taken the shifter out and re-installed it, i will get a maglite and check it again. Also must remember t put it in neutral f i do drop the box again