[Samurai81]

Had the rear main seal and clutch replaced today. The mechanic had a few difficulties getting it bled and adjusted. It drove okay on the way home but I couldn't get it in to first or reverse when I tried to park it in the garage. After an hour it had cooled down and the clutch was working fine again. I took it for a 15 minute run and the clutch started to pack up again. There is no fluid loss from the hydraulic system. I have to brave the early morning traffic and take it back to the workshop but do any of you SV420 gurus have an opinion about what's going on?
Steve.

[steak_knife]

First make sure none of the steel line's for the slave cylinder are touching the exhaust
second, bleed it again...

[Samurai81]

Right now its pitch black, raining and cold outside but it'll be the first thing that gets checked in the morning. We did fit extractors a couple of weeks ago and they seemed to have moved so that getting the slave cylinder off required the down tube to be massaged with a ball pene. Nothing seemed to be touching the exhaust when it was finished but it was close.

[steak_knife]

Samurai81 wrote:

Right now its pitch black, raining and cold outside but it'll be the first thing that gets checked in the morning. We did fit extractors a couple of weeks ago and they seemed to have moved so that getting the slave cylinder off required the down tube to be massaged with a ball pene. Nothing seemed to be touching the exhaust when it was finished but it was close.

Could be now.....

Kina sound's like your boiling the fluid in the line....... or slave.

[Samurai81]

[steak_knife]

Samurai81 wrote:

Cheer up Emo!!!!

[Samurai81]

Yep I can cheer. The clutch was supposed to be the easy part of the week though. I still got to sort out a miss that I've heard for a year and two sparkys cant, and fit new rotors and pads and feel happy with the Vitara before heading off for the long weekend. I seem to have the reverse Midas touch with this SV420 and the missus wont travel in the Samurai.

[steak_knife]

Samurai81 wrote:

Yep I can cheer. The clutch was supposed to be the easy part of the week though. I still got to sort out a miss that I've heard for a year and two sparkys cant, and fit new rotors and pads and feel happy with the Vitara before heading off for the long weekend. I seem to have the reverse Midas touch with this SV420 and the missus wont travel in the Samurai.

Coil's Ok???

[Samurai81]

Three of them were replaced 2 weeks ago. Got wet and had a massive fail.

[Samurai81]

Well we made sure no part of of the slave cylinder or pipe work was close to the exhaust, extended the push rod on the master 5 mm, bled the system 3 times including pulling the master and finding it slightly leaking and have now replaced the master cylinder. All to no real improvement. The mechanic called Repco (who supplied the clutch kit) and it turns out there is an option with the thrust bearing. The optional one is about 2 mm thicker and this may make all the difference. It also looks like the clutch pedal is bent but its been like that for over a year and caused no problem.
Original problem - new clutch works fine until after a half hour drive then doesn't completely disengage so that reverse and first graunch badly.

Next step is remove the gearbox again and check tolerances on the moving bits. Its getting hard to love this truck!

[steak_knife]

Samurai81 wrote:

Well we made sure no part of of the slave cylinder or pipe work was close to the exhaust, extended the push rod on the master 5 mm, bled the system 3 times including pulling the master and finding it slightly leaking and have now replaced the master cylinder. All to no real improvement. The mechanic called Repco (who supplied the clutch kit) and it turns out there is an option with the thrust bearing. The optional one is about 2 mm thicker and this may make all the difference. It also looks like the clutch pedal is bent but its been like that for over a year and caused no problem.
Original problem - new clutch works fine until after a half hour drive then doesn't completely disengage so that reverse and first graunch badly.

Next step is remove the gearbox again and check tolerances on the moving bits. Its getting hard to love this truck!

Can't see that waiting till it's hot to be a problem, if that was the problem it would do it all the time... could be wrong tho, has happened before....

[Samurai81]

It'll be a few days before I can do anything more about it but I'll post up progress.