Freshly rebuild 4AGZE now running great with added clutch problems!

[Hatta1978]

Hi worldwalker,
That straighten things a bit. Have you checked the injectors. They can make some clicking sound. Sorry but I like to find out the cheap repairs first before going to more complicated jobs. Regards.

[worldwalker]

Hi guys, after a holiday and being away with work for a few months I finally had a chance to try running the engine with some water in it.

After a few starts to get things warmed up, the clicking/tapping noise has slowly quietened down (factory Oil pressure gauge is towards the top end and steady) the final start (before I realised I'd left the radiator bleed tap open) the noise had ceased completely; before then I had the stethoscope to it and noted the noise was strongest on the intake side at the pulley end.

The rough running persisted through, until something literally clicked (sounded similar to the supercharger or A/C clutch engaging) the revs went from 1300-1500 smoothed right out and the engine ran perfectly, if slightly high: the factory water temp gauge was showing just under 1/4.

I hope this might shed some more light on the issue, hopefully it was something a bit sticky thats now sorted but I will check back soon once the engine has cooled and I can top the coolant back up.

[worldwalker]

So engine is consistently running great, starting first time, revs fine, sounds smooth and quiet but I can't drive it. I can't get the clutch the disengage!

I've run it on stands for 10km bringing the revs up to 3-4000 in 4th then holding the clutch brakes and accelerator until the clutch slips but still wont release.

I wasn't even able to get it into gear stationary, so I bit the bullet, jump started it and drove it around at about 50km/h. It didn't grind any gears but with the clutch in and racing the engine the clutch slipped easily and the car wouldn't accelerate further but the plate still wont release enough to engage the gears stationary.

Is there anything else I can do before pulling the engine out again?

Thanks,

Nick.

[dnegative]

Does the pedal feel like a normal clutch pedal? Have a look at the slave cylinder, give it a bleed and if it still wont engage then rip the box off.

[worldwalker]

Yeah good 30mm-ish movement on the fork (even if it weighs a fraction of the skylines) its definitely the plate stuck on the shaft. Best guess is the shaft has scale on it and holding the clutch in place. If it has to be done, any chance I could separate the box in situ and give the shaft a good bit of coating or CRC?

[dnegative]

Yeah its easily enough done in situ, I would wire brush the fuck out of the input shaft, get it spotless and make sure the clutch disk slides on and off without any effort. You can put a little grease on the input shaft splines but don't use anti seize or anything not really recommended for it. If its been slipping, maybe see about getting a new clutch disk? You will know when you get it off if its shagged anyway.

[worldwalker]

Thanks, just realised I'll be able to jiggle it free just by sliding the gearbox out, hopefully I can reach in and clean it like you said. From what I know the clutch is in good condition, otherwise I'd have changed it out. It's only slipping with the clutch in, just not free enough to release completely; with the clutch engaged its grabbing well. I think I've given it a good polish so far though!

Thanks again!

I'd plus rep you but you've been giving me too much advice and it won't let me. It's implied for now.

[Mr_Smith]

Hey Nick just read your thread! Dad told me about the clunk, sounds like my old yellow Corona when it spun that bearing haha! We have like 3 clutch plates and fly wheels here if you need one. Also if you need a hand with the gearbox I am free tomorrow. I need some seals and water pump for the other 4A we got I would post a pic of the progress but I don't now how! When are we going for a spin?

[worldwalker]

Noises are all gone Dave! Engine is running perfect (plenty of kick too)! The clutch is fine, plenty of meet from the little I can see, just need to free it up on the spline. Should be easy enough, just trying jiggling first then pull the box off if need be.

[Mr_Smith]

Ha bet you are stoked! Can't wait to see it on the road Where did you get your cam shaft seals from? I need a couple for this red top!

[worldwalker]

Vaels for the camshaft seals. Cover seals from repco.

[worldwalker]

Ok gearbox is out and the spline has been greased, any other ideas of what I should be looking for? Clutch hangs on fine under load it just won't release from the fly wheel even though the fork is pushing on the plate...

[dnegative]

Pull the clutch off and have a look?
Check the torsion and diaphragm springs along with the clutch disk hub spline

[allencr]

If you didn't see splines that are very rusty, with marks/scrapes from them being dragged outta the disk, then that ain't it.
I doubt that any disk frozen & locked onto the splines has ever caused a clutch to not dis-engage. Drag bad, sure, but it's flexible & springy enough to still slip.
Bad clutch/pressure plate or bent disk.

[worldwalker]

All off and it looks fine, but I don't have the facilities to test it so looks like I might just have to replace the whole lot.