Clutch issue on cdi

[smangle]

Help lol

I have a 10 plate cdi that will not engage gear with the engine running though it does go into gear with the engine switched off tried everything to get it working I think the clutch may be seized as it has been standing for about 6 months 1 thing I did note was that when I removed the actuator to clean and service it the clutch fork seems to just be flopping around is this normal it makes me think the bearing is jammed.

Thanks for any help

[10:45PM]

You could try manually pushing the fork with a suitable object (i.e. emulate the actuator), it's just a lever ... you should be able to feel the 'spring' of the pressure plate pushing back at you and you should be able to operate it (i.e. disengage the clutch) manually in this manner.

[smangle]

I have tried to push it with a large screwdriver I will try in the morning with a crow bar the actuator doesn't seem to move forward very far maybe only 3-5 mm it's driving me mad think I may have to pull the box.

[tolsen]

There should only be less than a mm lateral play in fork.
To test grab actuator rod and move its fork end laterally. Lateral play can be felt but is minimal.

[10:45PM]

There should only be less than a mm lateral play in fork.
To test grab actuator rod and move its fork end laterally. Lateral play can be felt but is minimal.

I think you must have still been dreaming when you woke up at 5am lol........

Re-read the original statements, he's not talking about the actuator, he's talking the clutch fork within the bellhousing.

[smangle]

There is no way to push the clutch fork it is sitting about 15mm inside the hole the only way it appears to move I back towards the actuator but there is no spring back if you know what I mean when I done clutches on other cars the clutch fork has always been fixed into position until pressure is applied this just seems to be hanging there with no tension against the bearing at all

[10:45PM]

'box out then

[tolsen]

I think you must have still been dreaming when you woke up at 5am lol........

Re-read the original statements, he's not talking about the actuator, he's talking the clutch fork within the bellhousing.

Actuator rod has ball socket actuator side hence its fork end is free to move laterally unless restrained by fork. Not dreaming, brain clear as a bell even that early.

[10:45PM]

It was ME that hadn'tread your reply correctly,I was up too early lol

[smangle]

Right I have put the car into 2nd gear with the engine off removed the actuator the only way I can move the clutch fork is with a crowbar and dam near all my strength it will move back about 20mm whilst being levered and the wheels are still rotating

[smangle]

How do I upload a video ??

[10:45PM]

You don't ,you'll have to upload to youtube etc and then link to that

[tolsen]

20 mm axial movement is about right. Considerable force required and not easily done with a crowbar.

Provided fork springs back evenly I think you can conclude clutch is fine. Would be better if you could cobble together some bolt on lever arrangment to operate clutch more controlled. You can then tell be feel if clutch is fine.

The fact you report clutch actuator rod only moves a few mm, I conclude that is faulty.

Shop around if buying a new one. Expensive part.

[tolsen]

It is quite possible the 451 cdi fork has more lateral play than the 450 cdi which I am familiar with. Clutch is different and fork is different too.

[smangle]

Finally got it sorted the actuator had chewed the bits off the cog inside itself I swapped it for another one from the breakers kept my motor just swapped the mechanism so it works good now it extends a good 30mm when changing gear but I do have a rattle sound on idle and when pulling away any ideas ?