You need to expand on what you mean by the thrust bearing going "hay wire" because that description means nothing. Is the slave cylinder actuating with no driver input causing the clutch to slip!
snoopy221,
Jun 18, 12:49am
Reading between the lines here it sounds like the thrust bearing is complete with a carrier which is a diferrent length to the old thrust bearing carrier.
ceebee2,
Jun 18, 12:59am
You may need to take the kit AND flywheel to clutch specialist to check heights. The flywheel height may be incorrect. Also they slave cylinder may be the wrong one also if its "pushing out" do you mean beyond its travel or simply working OK!
tonyrockyhorror,
Jun 18, 1:18am
Did you match the new clutch kit to the old or just assume it was the right one!
supernova2,
Jun 18, 1:29am
How can a hydro clutch slave cylinder self energise!Is it a case of the push rod is shaking loose and falling out rather than the piston pushing it out!If thats the case the throw out bearing/carrier is possessed!Maybe the gearbox nose piece is too short and thrust bearing dropping off and jambing the clutch.By the way "clutch is stuffed" is not a very good description of the damage that has occurred.
skin1235,
Jun 18, 3:00am
you have failed to locate the fork on the pivot, or you have broken the pivot off altogether
that is the only way to cylinder can push the rod right out ( cos it is pivoting on the edge of the slot instead of further in) if the pivot was actually engaged the thrust bearing would have made contact with the clutch plate ( inside the pressure plate ie impossible) long before the carrier could jam on the slide
joe-996,
Jun 18, 3:21am
i agree with above, old mate that adjusted the pedal may have adjusted it too much and the slave cylinder seals dont allow the bypass to work therefor keeping pressure on the clutch allowing it to slip, seen it all befor
andrewph,
Jun 18, 3:23am
Just a thought.Did your mate adjust the pushrod adjustment, taking away the freeplay from the master cylinder! Thus the fluid cant return to the master cylinder reservoir because te edge of the seal is ahead of the return hole. There should be 2 or 3 mm freeplay at the bottom of the pedal and approximately level with the height of the brake pedal.
ceebee2,
Jun 18, 1:50pm
If as you describe when you pump the clutch the slave cylinder push rod eventually pops out then the problem is crap in the master cylinder as there is no residual valve in the master cylinder or shouldn't be. Each time you pump the clutch the push rod should travel exactly the same distance AND return the same. If not the master cylinder has crap in it or possibly even the wrong one.
steve312,
Jun 18, 4:44pm
A lot of these light trucks actually have an adjustable clutch fork pivot bolt.When you replace the clutch kit, the clutch cover fingers are at there most extreme amount of travel.When you push your clutch pedal down the slave piston travels as far as it will ever have to travel.If you haven't set the clutch pivot point up correctly, it means the piston can actually protrude from the end of the slave cylinder and jam.Sounds like this may be what is happening.
elect70,
Jun 18, 10:11pm
Did youturnslave adjusting rod back when new clutch went in . Sounds like too much travel& pushing rod out of the slave cylinder .!
modie61,
Jun 18, 10:34pm
Does it have a vac assisted clutch master,like some Patrols ! Maybe try it standing still,engine off and see what goes.
sas777,
Jun 18, 11:02pm
As above. My money on that. I had same problem on my Mercedes truck (2232) when replacing clutch. Bled system out but disturbed all the crap build-up in the master + slave cylinders. I guess they only have a few mm's movement for years and years until you bleed them, and then they operate at full stroke. On mine the pistons were jamming and preventing proper clutch bearing release. Lucky I spotted it but the only realistic repair was to replace both cylinders. Ouch!
supernova2,
Jun 19, 4:56am
From whats been said the new clutch is the same as the old and the old worked.The new gearbox may have the fork pivot in a different position to the old or as said above its adjustable and needs to be reset.The only other variable would appear to be the adjustment made by the "mate".If the pushrod is pumping out of the cylinder then clearly the cylinder piston is not trerurning as it should.Should there be a return spring on the fork which is now missing.Maybe a pic of the cylinder,pushrod arrea might help.
hijacka,
Jun 19, 5:06am
Agree! Good possibility this has happened. How come this theory seems to go un-noticed!
supernova2,
Jun 19, 5:10am
Agree but dont agree.In my old EK holden we managed to pump the pushrod out when trying to bleed the clutch system.The bleed was full of muck and the pressure wsa such that it just pushed the pressure plate further and further until the rod and piston came out.I think that the EH had a carbon thrust so it was prob worn to the max and allowed just too much movement.
So really nothing is imposible it just a case of eliminating probables one by one until you find the actual.
hijacka,
Jun 19, 5:24am
OP says:by time used clutch 10 to 20 times throw out bearing jaming up. IMO the only thing that can jam up the release bearing is the clutch fork and if the clutch fork is not pivoting on the ball then it may very well jam up the release bearing and cause the slave cylinder to pop out after afew presses. A worn out slave or master cylinder would not cause this issue. I Found cases of leaking slaves and masters after new clutch installed but that would not cause the release bearing to jam or the slave to pop out .
elect70,
Jun 19, 10:12pm
take slave cylinder off , shouldnt be any pressure on itwith clutch engaged .& make sure the release bearingpivots &turnsfreely .didnt instal it back to front !
sr2,
Jun 19, 10:29pm
My 10 cents worth: The only way it could be a hydraulic problem would be if the compensating port on the master cyl was either blocked by rubbish or covered by a seal as a result of previous incorrect pedal/pushrod adjustment. Assuming the correct parts have been fitted I would be looking at the clutch fork pivot point.
supernova2,
Jun 20, 4:18am
Back the pedal adjustment off so its got a bit of freeplay and see if slave behaves properly.(If a slave misbehaves is it OK to beat him/her! - sorry couldn't resist)
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