Hilux gear selection problems

Submitted: Monday, Nov 03, 2003 at 15:33
ThreadID: 8280 Views:4278 Replies:3 FollowUps:0
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I have a 98 3 l diesel Hilux dualcab with 130k on the clock. On the weekend it started to develop gear selection problems. Wouldn't go into reverse without slamming it in, doing it normally resulted in gear crunch, much like you would expect when not using the clutch. Similar problem when going into and out of hi and low range. Also when going up and down the gears it needed a rev in neutral to make the shifts smoothly. There is no evidence of clutch slip ie would stall easily in gear, and held on in 1 st low on extra steep hill. There is plenty of clutch fluid and no evidence of fluid leaks.

It does feel like the clutch isn't disengaging properly, anyone have any ideas on how to check what might be wrong.


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Reply By: BHarrison - Monday, Nov 03, 2003 at 18:43

Monday, Nov 03, 2003 at 18:43
Quickly check that no floor mats etc bunched under the pedal youll be suprised

if not then clutch is not disengaging fully

Bleed system for airlock (water vapor) may as well give it some fresh fluid while your there

check back of Master for a slow leak stick your head under the dash ,and dont forget a torch
or remove boot from slave and check for leaks

These are the cheap simple options

if none of the above

expensive /lotsa swearing and barked knuckles options

strip down clutch

worn/bent fork or fingers on pressure plate
sticky spigot

new clutch plates

try the simple ones first

AnswerID: 36099

Reply By: Mickl - Monday, Nov 03, 2003 at 18:46

Monday, Nov 03, 2003 at 18:46
First thing to do here is check you gearbox oil level. Next check the action of the hydraulics (get someone to push the pedal while you take a look and see that the slave cylinder moves the clutch fork ok) Has the fluid level dropped (even a little?) Has the pedal "feel" changed? even the smallest of leaks will let air into the system. Also check clutch pedal free play, make sure it's within specs.
Have you done any dusty trips lately? dirt building up on the input shaft and holding up the clutch has caused me drama's before.
AnswerID: 36100

Reply By: howesy - Monday, Nov 03, 2003 at 19:37

Monday, Nov 03, 2003 at 19:37
All of the above. And while you are checking the clutch fork take a look inside and check the pivot to see that the mushroom head of the pivot ball is still there they have been known to snap. Also were you in water, check the fluid in box and transfer case for contamination and if you refill it go for a lighter grade of gearbox oil such as an 80 grade. Gear changes are a lot smoother with the lighter oil.
AnswerID: 36103

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