clutch problem

[girlycar]

we have put a new clutch in our Hyundai H100 2.5TD van. Now the gears won't engage properly, especially reverse. When they do the van wants to pull without any bite on the clutch. Have bled it twice, now am at a loss. Any help please?

[cazzz1975]

is it lined up properly? you may have to strip it down to check it

[girlycar]

Himself reckons it is lined up properly, but he thinks it may be a case of stripping it down again, just looking for some pointers or a miracle answer please..!

[cazzz1975]

if the piston moves immediately when you put your foot on the pedal (right to the floor) there is enough travel so it more likely the clutch is out of line somewhere (inside)

[girlycar]

will strip it down again 2 moro and check it (dam!) bloody heavy gearbox! thanx and will take any advice

[david1702198]

its impossible for the clutch not to be lined up properly or wou would never be able to refit the gearbox

[BigB]

david1702198 is right The clutch is lined up properly.
The issue is not enough lift on the clutch cover which prevents the driven plate to be freed during disengagement. There are various causes:
1. Wear to the slave cylinder push rod
2. Wear to the release arm at the point the push rod contacts.
3.Wear to the release arm at the point the release bearing contacts it
4. Any combination of the above
5. A faulty clutch.

The first 4 are the common problems but if they are all ok then have a look at the clutch. There are 3 flat metal "straps" around ther outside edge of the clutch cover. These should all be the same shape. If one is a slightly different shape then thats the problem.

Also if the gearbox has been allowed to hang unsupported during fitting the weight of the box can distort the driven plate.

[dougielogan]

Are you sure you have put the friction plate on the correct way? it should be printed on it "gearbox side" I have seen them fitted the wrong way round.

[girlycar]

Thanks to you all for your help, it is invaluable, stripped it down and refitted it, couldn't see anything wrong. Tried engine on and gears b4 fitting propshaft and all was ok. Finished putting all back together and took it out. Just the dam same. Gears very difficult to get and reverse gear has to have engine off to get it.
The plate is the rightway round. Talking to a mechanic today who says he thinks air in system or slave cylinder.
Not worked on it today, foul weather and no garage.