Cars been off the road a few years, in that time i’ve fitted a reyland hydraulic clutch conversion, helix 6 paddle clutch kit ect. Put it all back together with my new engine but having issues getting into any gear, tried adjusting pedal height ect and fitted another master cylinder but still the same. Definitely bled properly aswell.

Clutch pedal feels good, issue is gear selection in every gear, box was fine before taking off the road. Oil is atf dextron 4. Gearbox is a standard T5

Anyone else had similar problems before I take the box out?

 

Is it a side push conversion with bracket welded on to the bell housing for the slave cylinder? I originally had the same one fitted on my 2wd Saff. The length of the pushrod has to be spot on or you will either get clutch slip or clutch drag.I think with mine the length had to be shortened.I have the same same Helix 6 paddle clutch.I found it was better than the original cable operation but still not without some problems.I have recently had a new centre push hydraulic clutch system fitted by Julian Godfery in West Sussex and it is a big improvement over the original side push Reyland one.

 

Yes side push with the welded bracket, reyland template was used for position.

Thats interesting that you’r slave rod was too long, i’ll unbolt it and pack it back with washers to see if that helps.

Cheers

 

If your T5 gearbox was operating properly before you took your car off the road there is no reason for it to now have a major fault stopping you selecting the gears. Try as you say adjusting the push rod as it sounds to me like at the moment it has clutch drag preventing gear selection. Good luck with it.

 

Cheers mate, just to be clear was it the rod on your slave cylinder that needed shortened or the threaded rod on the master cylinder?

 

The slave cylinder rod, from memory mine was made from hard plastic and it was put in a lathe and shortened. Tremona Garage in Southampton fitted mine and hey have a fully equipped engineering workshop as well.

 

Surprised plastic was strong enough to be fair, what made you change to concentric in the end?

 

its only a matter of adjustment. i used a willwood pull and push slave cylinder i made my own kit and bit of assing around

 

It was never really very good and I opted for the centre push option after hearing how pleased a couple of other Saff owners were who had had the conversion done at Julien Godfrey in West Sussex. I am very pleased with it and wish I had gone for the centre push job in the first place.

 

Update

After messing about with different length rods, i found making it longer made it slightly better but was still having issues coming down the gears ect and in general gear selection was fucking shite.

Removed box and it selected fine off the car

Bought a concentric hydraulic bearing setup from Brands hatch performance and fitted that, gear selection is now perfect.

Raging with the amount of time spent pissing about trying to make the external slave setup work

 

You have done the sensible thing going for the centre push option, so much better. I wish I had gone for that in the first place!

 

I wished you had contacted me rather than condemning the product, this kit was designed by me years ago and has been copied by many and I've literally sold hundreds of these over the years and also ran them on my own vehicles without any issues whatsoever.

It sounds like the pedal was not moving enough fluid for the clutch to disengage, this is normally because the hole that needs drilling in the pedal is too high, or the boss was welded on the fork in the wrong place but even if that was the case the next size up master cylinder fixes it. If it wasn't either of those there is another common mistake that causes this, got a picture of the slave installed?

Moving to a centre push only fixed the issue because it required less fluid than the side push to move far enough to properly disengage the clutch, if you didn't give a centre push the amount it needed you would have had the same issue.

 

Incorrect, a properly installed side push does exactly the same job as a centre push but is better as you can replace parts without removing the gearbox, with a single plate clutch its a better option.

 

I did Martin, you told me it sounds like an install error, so i removed the pedal box and measured where i drilled the hole which was spot on, i slotted the hole so it can be adjusted in-situ, spent ages adjusting where the master bolts onto the pedal and also the height the pedal sits at thinking that would sort it.

 

I don't recall the conversation, I absolutely stand by the install error comment though. If the pedal end was correct then you either welded the boss onto the arm in the wrong position or you fitted the slave upside down. This isn't rocket science, the clutch cover doesn't care whether the actuating hydraulics are in the centre or external, all its looking for is the correct amount of push on the fingers to release the clutch. Your initial post is only a few weeks ago, are you saying you spoke to me this year?

 

No, i phoned around April 2021, your wife answered and then put you on.

I’ll post pics up in a bit, slave was mounted with the bleed pointing downwards.

 

Then you must have welded the boss onto the arm too far out, the next master cylinder size up would have fixed that.

 

Boss was welded so that the rod of the slave was straight, what would the next size up be? I changed to a 0.750

 

Pic with hose is remote bleed line, not pressure line. Rod is sagging down in that pic due to it not being supported by the input shaft.

 

Modified tunnel to give appropriate clearance and allow for slave removal in-situ

 

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Nice bit of fabrication.