Hi everyone,

Spent the weekend changing the clutch on my dads 2009 sport 2wd manual trans. Now it wont shift into gear when running.

We changed:
clutch
Flywheel
Pressure plate (made sure springs were zeroed)
slave cylinder
Pilot bearing
Throw out bearing
master cyl

everything went tog well. And bled the clutch, has a solid pedal. You can even see the clutch engaging through the inspection hole. But it still wont shift into gear.

Anyone have any ideas ?

 

Did the pressure plate look like this?

See the yellow springs? They need to be compressed completely before install. Basically, you use a press or similar device to compress the fingers of the pressure plate, then rotate the metal ring that runs around the plate (visible through the slots) next to the springs in a counter-clockwise direction until the springs compress. Hold the ring in place and release the pressure on the fingers and the springs will stay compressed until you install it and press the fingers with the slave cylinder. This is the "self adjusting" mechanism.

Second possibility, did you have the shifter in neutral when you removed it? If it wasn't in neutral there is a good chance it's not aligned and is locking the shift fork. Pull the shifter, use a flathead screwdriver to align the shift forks into their neutral positions and reinstall. Of course you can ignore this if you know for a fact that it came out and went back in neutral.

 

The springs were set fully compressed and the trans in neutral.

I'm totally stumped.

 

So you can shift easily into every gear with the engine off correct?
Did you bleed the master while it was out of the vehicle? Bench bleed? I had a hard time getting it bled is why I ask. It is notoriously hard to bleed in the truck due to the angle of the master cylinder. I know you said it's got plenty of travel when you press the clutch but I had to ask.

You can shift it into first while the engine is off, then start it, but beware. If you aren't getting enough clutch travel to disengage the transmission its gonna lurch forward and/or stall and you could possibly damage something.

If it were me I'd double check the clutch assembly again, it sounds like a disengagement issue.

 

Can you move the shifter at all?

When you pull out the shifter arm, to drop the transmission out, it MUST BE IN NEUTRAL
If not then when you put shifter back in you won't be able to shift transmission at all

Oops, nevermind, lol

 

The shifter moves fine when the truck is off.

I've had the trans off twice and it's still not working. Thinking maybe the new master cyl is faulty.

 

Your clutch travel is pretty easy to test. Have someone get underneath and hold a small wood ruler or piece of cardboard flush with the throwout bearing. Now depress the clutch pedal completely and mark the throwout bearings travel distance on the ruler. It should travel 10mm. If you aren't getting 10mm of travel then yes, most likely there is still air in the master. If its moving 10mm then your problem isn't hydraulic.

 

^^ thanks for that. Ill measure the travel.

 

The travel seems to be around 1 cm for sure.

 

Well the good news is that your master and slave are bled properly, so that's checked off.

If it shifts with the engine off but not with it running, then the clutch isn't disengaging.

Here's a couple things to check if you aren't 100% sure.
1: Check the housing to engine seal all the way around and make sure its good. Sometimes the wiring harness that runs behind the engine can get pinched between the top of the bell housing and engine.
2: Is the shim installed? The plate that goes between the engine and trans.
3:Is the shifter and its components installed correctly?
4:When you bolted up the transmission, did the input shaft find the pilot bearing easily? If you struggled with it or pulled them together with the bolts you could have crushed the pilot bearing or possibly damaged the input shaft bearings. This is a longshot, I can't imagine being able to bolt the trans in incorrectly and not feel it while it's happening. It would be tough as hell.

 

Updating the thread.

Used a vacuum bleeder and managed to suck more air out of the clutch line. Truck is shifting smoothly!

Thanks everyone!

 

Good stuff

Thanks for the update