RN Hilux gearbox issues.

[jezz]

Folks,

I'm looking for some input to an issue that started this evening in my RN106 hilux (2.4L 22R petrol, manual 5 speed W56 ? I think)

Got in the car to go pick-up the kids warmed it up for a few minutes and then went on my way - nothing out of the ordinary.

About 7mins in changing gears becomes much harder like the clutch is not engaging but i still have spring in the pedal and exactly the same amount of resistance as before.

I get to the top of the hill and the cars sticks in 3rd gear i stick the clutch in and try and pull it out for a minute while coasting down the hill.

Eventually get it out of 3rd but it refuses to go into any gear.

I coast all the way to the school carpark (or at least the bus stop out the front) and kill the engine. I still can't get it to go into gear.

Jump out and check my master and slave as best I can both look fine no fluid leaks and it all appears to be operating normally.

There is no burning clutch smell and there wasn't any slippage.

I call the wife to come get the kids and call a mate to come have a look.

20 minutes later my mate shows up, I chuck him the keys and tell him i can't get it in gear.

He has a couple of soft goes and then manages to jam it into first.

Now i can put it into any gear with the car off.

We turn the car on and try selecting a couple of gears - yep its all working but now there is a new grinding noise coming from the gearbox.

Great i say that sounds like a throw out bearing.

We wait around another 20min's for my wife to show up and take the kids.

With my mate following I attempt to drive it home.

Going very softly - mainly in third - and its seems to be shifting fine.

All the gears work and nothing feels bad.

The question is... what the fuck went wrong and will it do it again ?

I would love some solid reasoning before having to take the gearbox out.

I'm planning on taking tomorrow off work to check everything including the gearbox oil which could be low/old as shit.

So thoughts ?? Google was turning up mostly clutch plate symptoms...

[madmont]

Spigot bearing ?

[jezz]

Could be.

To be on the safe side I’ve started removing the gearbox and I’ve ordered a clutch kit.

[bmxer54]

i wonder whether you need my brass shifter rebuild bush, and whether it will fit in your g52

[jezz]

Well the shifter was ok after disassembling the car yesterday.
I drain the fluid and there was plenty of it so that's good.

but here is the kicker.

I can't get the box to come out.

Managed to get a two finger gap all the way round the bellhousing to engine but it won't go any further.

It seems like the throw out bearing / clutch plate has seized onto the input shaft.

Not sure what to do at this point...

[Grega]

you're not fouling on the firewall with the bellhousing?
nothing fouling anywhere else?

can you get a crowbar/prybar either side and walk (a little at a time) each side to help persuade it out.

i had difficulty getting the bw35 box out of my 66 ford as the torque converter had rusted into the spigot in the back of the crank.
i wonder if your spigot bush has come out of the back of your crank and is fouling on teh clutch plate perhaps?

you may want to replace the spigot bush as well.
check your fork as well as they are soft as shit, and, the clutch fork pivot bolt, as, they are notoriously bad.

[madmont]

Maybe cut a hole in the bell housing to get at the bolts holding on the pressure plate?

[Grega]

you could get to them only just thru the starter motor hole? would be painful and hard, but reckon you could if you're keen?
they are 10mm if memory serves.

[jezz]

Thanks guys I’ll have a look at how much room I’ve got to try and get to the pressure plate bolts.

Bmxer has sorted me on all the new parts I need. So I should be fine after I’ve got the damn box out.

[bmxer54]

If you haven't succeeded yet, I'll give you a hand next weekend , and the pressure plate bolts are m8 so they will have a 12mm or 13mm head, either way ill bring my prybars

Cheers, Peter

[Hen]

Hopefully you're not as stupid as me, but I had a similar problem of the box being loose, but not coming all the way off.

Turns out that after removing the starter we screwed the bolts back in a few turns to stop them getting lost. They were invisible under the intake and stopped the bellhousing, about an inch off the block.

[cresslux]

sounds like the spigot bearing to me, it will shift fine at first but as the bearing heats up and siezes again, its like your not pressing the clutch at all.

if you put it in gear and start it with your foot on the clutch, does the car creep forward?

had a similar thing happen with a 1jz/r150 hiluc box combo. spigot siezed and when i went to pull the box out, the spigot pulled out with box, had to undo the clutch from the bellhousing inspection holes (lucky those bellhousings have big inspection openings) and remove the clutch plates with the box. needed a bearing puller juts to get the spigot off the shaft!

i really hope thats not your issue otherwise you are in for a fun time, or a new bellhousing when you destroy the old one to gain access to the clutch bolts.

other posibility is the throwout bearing but they and to screm and still be drivable or simply stall the car when you put your foot on the clutch, as it doesnt actually touch the input shaft or clutch disc.

[ToyTA22]

sounds like the spigot bearing to me, it will shift fine at first but as the bearing heats up and siezes again, its like your not pressing the clutch at all.

if you put it in gear and start it with your foot on the clutch, does the car creep forward?

had a similar thing happen with a 1jz/r150 hiluc box combo. spigot siezed and when i went to pull the box out, the spigot pulled out with box, had to undo the clutch from the bellhousing inspection holes (lucky those bellhousings have big inspection openings) and remove the clutch plates with the box. needed a bearing puller juts to get the spigot off the shaft!

i really hope thats not your issue otherwise you are in for a fun time, or a new bellhousing when you destroy the old one to gain access to the clutch bolts.

other posibility is the throwout bearing but they and to screm and still be drivable or simply stall the car when you put your foot on the clutch, as it doesnt actually touch the input shaft or clutch disc.

My opinion is the same as cresslux, spigot bush in end of crank is seized or seizing as heats up. Unluckily can be a bugger to get gearbox
out.

[jezz]

Yep you guys are no doubt right.

I'm going to give it another go this weekend.

[petergoudie]

We had a Peugeot some years ago and a common fault was the clutch bearing throwout arm fatigues on the pivot point. You need to look closely because with no load they look OK but on closer examination they will be cracked and bend on the crack hence limiting the force transmitted to the bearing.